Wiring Diagram For 93 Ford Thunderbird 3.8 Litre Engine

Factory Workshop Manual Make Ford Model Thunderbird Engine and year V6-232 3.8L SC (1989) Please navigate through the PDF using the options provided by OnlyManuals.com on the sidebar. This manual was submitted by Anonymous Date 1st January 2018 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16 17 18 19 ) > System Information > System Diagnosis Code 11 - 20: Testing and Inspection 2 Digit KOER Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 11 - 20, ( 12 13 14 15 16 17 18 19 ) > System Information > System Diagnosis > Page 7 2 Digit Continuous Memory Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26 27 28 29 ) > System Information > System Diagnosis Code 21 - 30: Testing and Inspection 2 Digit KOER Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 21 - 30, ( 22 23 24 25 26 27 28 29 ) > System Information > System Diagnosis > Page 11 2 Digit Continuous Memory Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36 37 38 39 ) > System Information > System Diagnosis Code 31 - 40: Testing and Inspection 2 Digit KOER Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 31 - 40, ( 32 33 34 35 36 37 38 39 ) > System Information > System Diagnosis > Page 15 2 Digit Continuous Memory Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 41 - 50, ( 42 43 44 45 46 47 48 49 ) > System Information > System Diagnosis Code 41 - 50: Testing and Inspection 2 Digit KOER Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 41 - 50, ( 42 43 44 45 46 47 48 49 ) > System Information > System Diagnosis > Page 19 2 Digit Continuous Memory Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis Code 51 - 60: Testing and Inspection 2 Digit KOER Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 51 - 60, ( 52 53 54 55 56 57 58 59 ) > System Information > System Diagnosis > Page 23 2 Digit Continuous Memory Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis Code 61 - 70: Testing and Inspection 2 Digit KOER Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > Page 27 2 Digit Continuous Memory Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 61 - 70, ( 62 63 64 65 66 67 68 69 ) > System Information > System Diagnosis > Page 28 2 Digit Continuous Memory Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 71 - 80, ( 72 73 74 75 76 77 78 79 ) > System Information > System Diagnosis Code 71 - 80: Testing and Inspection 2 Digit KOER Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 71 - 80, ( 72 73 74 75 76 77 78 79 ) > System Information > System Diagnosis > Page 32 2 Digit KOER Codes 2 Digit Continuous Memory Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86 87 88 89 ) > System Information > System Diagnosis Code 81 - 90: Testing and Inspection 2 Digit KOER Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 81 - 90, ( 82 83 84 85 86 87 88 89 ) > System Information > System Diagnosis > Page 36 2 Digit Continuous Memory Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 91 - 100, ( 92 93 94 95 96 97 98 99 ) > System Information > System Diagnosis Code 91 - 100: Testing and Inspection 2 Digit KOER Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > A L L Diagnostic Trouble Codes ( DTC ) > Codes by Number > Code 91 - 100, ( 92 93 94 95 96 97 98 99 ) > System Information > System Diagnosis > Page 40 2 Digit Continuous Memory Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Horn Relay > Component Information > Locations Alarm Horn Relay: Locations Body & Chassis Components LH Side Of Trunk, Behind Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Locations Antitheft Relay: Locations Body & Chassis Components LH Side Of Trunk, Near Anti-Theft Module Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 63 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 64 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 65 Power Door Lock Relay: Electrical Diagrams Power Door Locks (Except Keyless Entry) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 66 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 67 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 68 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 69 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions Trunk / Liftgate Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 74 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 75 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 76 Luggage Compartment Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Antilock Power Relay <--> [ABS Main Relay] > Component Information > Locations Antilock Power Relay: Locations Engine Compartment Component Locations RH Front Of Dash, On Relay Bracket Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Locations Brake Fluid Pump Relay: Locations Engine Compartment Component Locations RH Side Of Dash, On Relay Bracket Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Body & Chassis Components Below Center Of Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 87 Electronic Brake Control Module: Description and Operation The electronic controller is located on a package tray in the upper portion of the luggage compartment of the vehicle, behind the righthand side of the rear seat. It is an on-board self test non-repairable unit, consisting of two microprocessors and the necessary circuitry for their operation. These microprocessors are programmed identically and operate on the principle of two channel redundant data processing and plausibility criteria monitoring. Most failures which occur to the system will be stored as a code in the controllers constant memory. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 88 Electronic Brake Control Module: Service and Repair Fig. 11 Electronic controller replacement Located, Lower RH panel in luggage compartment. 1. Disconnect battery ground cable. 2. Disconnect electrical connector from electronic controller, Fig. 11. 3. Remove electronic controller attaching screws and the controller. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Engine Compartment Component Locations RH Front Of Engine Compartment Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 95 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 96 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 97 Cooling Fan (Supercharged Engine) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Engine Compartment Component Locations On Relay Bracket Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description Compressor Clutch Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 104 X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 105 Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 106 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 107 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 108 Compressor Clutch Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 109 X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 - CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 110 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 111 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 112 Fig. 23 Integrated Controller Pinpoint Tests X13 & X14 (Part 4 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 113 Fig. 23 Integrated Controller Pinpoint Tests X15 (Part 5 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 114 Fig. 23 Integrated Controller Pinpoint Test X16 & X17 (Part 6 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 115 Fig. 23 Integrated Controller Pinpoint Tests X18, X19, X20 & X21 (Part 7 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 116 Fig. 23 Integrated Controller Pinpoint Test X22 (Part 8 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 117 Fig. 23 Integrated Controller Pinpoint Tests X23 & X25 (Part 9 Of 26) Fig. 23 Integrated Controller Pinpoint Tests X26, X27 & X30 (Part 10 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 118 Fig. 23 Integrated Controller Pinpoint Tests X31 & X32 (Part 11 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 119 Fig. 23 Integrated Controller Pinpoint Tests X33 & X35 (Part 12 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 120 Fig. 23 Integrated Controller Pinpoint Tests X36 & X37 (Part 13 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 121 Fig. 23 Integrated Controller Pinpoint Tests X40, X41, X42 & X43 (Part 14 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 122 Fig. 23 Integrated Controller Pinpoint Tests X44, X45 & X46 (Part 15 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 123 Fig. 23 Integrated Controller Pinpoint Tests X50, X51 & X52 (Part 16 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 124 Fig. 23 Integrated Controller Pinpoint Tests X53, X54 & X55 (Part 17 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 125 Fig. 23 Integrated Controller Pinpoint Tests X56, X57 & X58 (Part 18 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 126 Fig. 23 Integrated Controller Pinpoint Tests X59, X60 & X80 (Part 19 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 127 Fig. 23 Integrated Controller Pinpoint Tests X81, X82 & X83 (Part 20 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 128 Fig. 23 Integrated Controller Pinpoint Tests X84, X90 & X91 (Part 21 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 129 Fig. 23 Integrated Controller Pinpoint Tests X92, X93 & X94 (Part 22 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 130 Fig. 23 Integrated Controller Pinpoint Tests X95 & X96 (Part 23 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 131 Fig. 23 Integrated Controller Pinpoint Tests X100 & X101 (Part 24 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 132 Fig. 23 Integrated Controller Pinpoint Tests X102 & X103 (Part 25 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 133 Fig. 23 Integrated Controller Pinpoint Test X104 (Part 26 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair Control Module HVAC: Service and Repair Fig. 10 Control panel removal 1. Disconnect battery ground cable. 2. Position removal tool T87P-19061 into retaining clip access holes, Fig. 10, then disengage clips by applying pressure away from control panel. Fig. 11 Control panel assembly 3. Pull control assembly away from instrument panel, then disconnect electrical connectors, vacuum harness and temperature control cable from the assembly, Fig. 11. 4. Remove control assembly from instrument panel. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 91177 > Aug > 91 > Tape Player Hissing Noise Maintenance Reminder Control Module: Customer Interest Tape Player - Hissing Noise Article No. 91-17-7 08/21/91 ^ RADIO - TAPE PLAYER - MAKES HISSING NOISE - CARS WITH VEHICLE MAINTENANCE MONITOR (VMM) ^ NOISE - "HISS" FROM TAPE PLAYER DURING QUIET PASSAGES - VEHICLES WITH VMM FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hissing noise may be heard from the tape player during quiet passages. This occurs because of electromagnetic interference from the transformer being picked up by the head of the tape player. ACTION: Install a new vehicle maintenance monitor. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-38, for service details. NOTE: SUSPECT VEHICLE MAINTENANCE MONITORS MUST BE REPLACED ONLY BY A VMM WITH A DATE CODE OF MAY 1990 OR LATER. THE DATE CODE IS ON A LABEL LOCATED ON THE TOP OF THE MODULE IN MONTH/DAY/YEAR FORMAT. FOR EXAMPLE, 10/09/90 MEANS OCTOBER 9, 1990. THIS ISSUE DOES NOT AFFECT 1991 MODELS. PART NUMBER PART NAME CLASS F1SZ-10E850-A Vehicle Maintenance Monitor B WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911707A Install Vehicle Maintenance 0.3 Hr. Monitor DEALER CODING BASIC PART NO. CONDITION CODE 10E850 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91177 > Aug > 91 > Tape Player - Hissing Noise Maintenance Reminder Control Module: All Technical Service Bulletins Tape Player - Hissing Noise Article No. 91-17-7 08/21/91 ^ RADIO - TAPE PLAYER - MAKES HISSING NOISE - CARS WITH VEHICLE MAINTENANCE MONITOR (VMM) ^ NOISE - "HISS" FROM TAPE PLAYER DURING QUIET PASSAGES - VEHICLES WITH VMM FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hissing noise may be heard from the tape player during quiet passages. This occurs because of electromagnetic interference from the transformer being picked up by the head of the tape player. ACTION: Install a new vehicle maintenance monitor. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-38, for service details. NOTE: SUSPECT VEHICLE MAINTENANCE MONITORS MUST BE REPLACED ONLY BY A VMM WITH A DATE CODE OF MAY 1990 OR LATER. THE DATE CODE IS ON A LABEL LOCATED ON THE TOP OF THE MODULE IN MONTH/DAY/YEAR FORMAT. FOR EXAMPLE, 10/09/90 MEANS OCTOBER 9, 1990. THIS ISSUE DOES NOT AFFECT 1991 MODELS. PART NUMBER PART NAME CLASS F1SZ-10E850-A Vehicle Maintenance Monitor B WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911707A Install Vehicle Maintenance 0.3 Hr. Monitor DEALER CODING BASIC PART NO. CONDITION CODE 10E850 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9038 > Jan > 90 > VMM Oil Change Indicator - Reset Procedure Maintenance Reminder Control Module: All Technical Service Bulletins VMM Oil Change Indicator Reset Procedure VEHICLE MAINTENANCE MONITOR (VMM) - OIL CHANGE INDICATOR - RESET PROCEDURE Article No. 90-3-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The VMM oil change indicator must be reset every time that the vehicle's oil is changed. This means... ^ The oil change indicator must be reset even if the vehicle's oil is changed before the VMM has indicated an oil change is needed. ^ The reset procedure is necessary to keep the information in the oil change indicator updated whenever the oil is changed. ^ If the reset procedure is not done, the VMM will indicate an oil change prematurely. ACTION: After the oil is changed, manually reset the VMM oil change indicator by using the following procedure. 1. With the ignition key in the OFF position, turn the ignition key to the RUN position, but do not start the engine. Figure 1 2. Within 15 seconds of turning the ignition to RUN, reset the VMM by inserting a straightened paper clip or similar tool through the reset hole and press firmly. The module is located in the top center of the instrument panel directly above the radio, Figure 1. ^ You will not be able to feel the reset switch operating because it has no perceptible movement when it is pushed. ^ The oil change message window will begin to flash when the switch has been activated. NOTE: IF THE RESET PROCEDURE IS NOT DONE WITHIN 15 SECONDS, THE PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. IF "NOW" IS FLASHING, DO NOT WAIT FOR IT TO STOP BEFORE PUSHING THE RESET SWITCH TO INITIATE THE OIL CHANGE RESET. 3. Continue to depress the reset switch until the oil change display stops flashing, which will take about 4 seconds. NOTE: IF THE RESET SWITCH IS RELEASED BEFORE THE OIL CHANGE DISPLAY STOPS FLASHING, THE RESET PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Maintenance Reminder Control Module: > 902510 > Dec > 90 > Horn Button - High Operation Effort Horn Switch: All Technical Service Bulletins Horn Button - High Operation Effort HORN - HIGH EFFORTS TO DEPRESS PAD DURING LOW AMBIENT TEMPERATURES NON-SUPERCHARGED CARS Article No. 90-25-10 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: High effort may be required when depressing the horn pad to sound the horn. This is caused by a steering wheel horn pad that is too stiff in low ambient temperatures. The stiff horn pad may not allow the horn contacts to close. ACTION: Install a new horn pad made from urethane material. This improves low temperature flexibility and reduces the horn blowing effort. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 35-80, for service details. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902510A Install Horn Pad 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 13A805 99 OASIS CODES: 203000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > Page 165 Maintenance Reminder Control Module: Locations I/P Components Center Of Dash Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage Speedometer Module: Technical Service Bulletins Speedometer - Service Replacements With Pre-Set Mileage Article No. 93-12-9 06/09/93 SPEEDOMETER - ELECTRONIC INSTRUMENT CLUSTERS, PROGRAMMABLE SPEEDOMETER/ODOMETER MODULES - DIGITAL ELECTRONIC ODOMETERS - SERVICE REPLACEMENTS WITH PRE-SET VEHICLE MILEAGE FORD: 1985-92 THUNDERBIRD 1986-93 TAURUS 1989-92 PROBE 1992-93 CROWN VICTORIA LINCOLN-MERCURY: 1984-91 MARK VII 1984-93 CONTINENTAL 1985-92 COUGAR 1986-93 SABLE 1990-93 TOWN CAR 1992-93 GRAND MARQUIS LIGHT TRUCK: 1986-93 AEROSTAR 1992-93 ECONOLINE, F-150-350 SERIES 1993 VILLAGER ISSUE: Service replacement speedometer odometers, speedometer modules, electronic instrument clusters and PSOM (programmable speedometer/odometer module) clusters, with mileage preset to the mileage displayed on the removed cluster odometer, are now available. These components must be ordered through one of three Electronic Service Centers (Two (2) U.S.; One (1) Canadian). They will be provided on an exchange basis and will not be available through the parts depots. ACTION: If service is required, refer to the following ordering and shipping procedure. ORDERING PROCEDURE U.S. DEALERS The repair Form FPS 1878 must be filled out in sections 1A and 1B indicating the required vehicle information. A toll free phone call must be placed to the respective Electronic Service Center to relay the vehicle information: ^ Dealers who are normally serviced by the Detroit, New York and Atlanta Parts Distribution Centers should place their orders through the Eastern Electronic Service Center Call Line, 1-800-262-9606. ^ All other U.S. dealers should place their orders through the Western Electronic Service Center Call Line, 1-800-321-6969. CANADIAN DEALERS The repair Form 6125-2 must be filled out indicating the required vehicle information. To place an order through the Canadian Electronic Service Center, either fax the repair Form 6125-2 to FAX # 416-946-8975 or place a toll free phone call to 1-800-663-9974. ^ If the phone call or fax is placed to the Center before 4:00 p.m. on Monday through Thursday, the goal will be to provide the replacement cluster before close of business the following day. ^ If orders are placed on Friday or the day before a holiday, the cluster should be received on Monday or the day after the holiday. The clusters are shipped pre-paid freight. Assemblies shipped to Hawaii or Alaska should be received within forty-eight hours except on Fridays or the day before holidays. Saturday delivery is now available to dealers with Saturday operation hours. This service must be requested from the Service Center when placing the order. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 170 SHIPPING PROCEDURES FOR REMOVED CLUSTER Service replacement assemblies will be shipped pre-paid freight. The return freight charge will be collect. Follow the Return Shipping Instructions enclosed in the container in which the assembly was received. The removed assembly must be returned to the Electronic Service Center in the same container. ^ Ensure that the original shipping label is completely removed from the outside of the shipping container. ^ Simply affix the collect return shipping label that is supplied. ^ Place the removed assembly in the container with a copy of the memo billing from the Electronic Service Center, and the completed manufacturer's copy of Form FPS 1878 (U.S.) or FPS 6125-2 (Canada). This will ensure proper procedure so that the core charge of $300.00 will not be billed. ^ The removed assembly must be returned to the Electronic Service Center within thirty calendar days or the core charge will be billed against the dealer parts account. HANDLING PROCEDURES FOR DIGITAL SPEEDOMETERS WITH UNKNOWN MILEAGE ACCUMULATION To comply with regulations pertaining to the accuracy of odometers, cores will be read to determine accuracy of the reported mileage. In nearly all instances, the mileage continues to accumulate in the odometer memory chip even though the odometer is non-functional. This mileage can be verified even though it is not visible on the removed odometer. The dealer must verify the mileage accumulated on the odometer. ^ If the mileage cannot be determined accurately, the dealer must indicate to the Electronic Service Center that the mileage is unknown. ^ In cases where the mileage is unknown, the law requires that we supply a replacement part with the mileage pre-set to "O" miles and the service odometer (circle "S") segment illuminated. ^ A sticker must be attached to the door indicating the mileage at the time of the service repair. COST AND WARRANTY INFORMATION The service assemblies will be billed on the monthly Dealer Parts Statement. Application is provided by part number, dealer cost and core charge. Refer to Dealer Service Manuals and the FPSD Parts and Accessories Price Listing. Repair Form FPS 1878 can be ordered from the Parts Distribution Center. Follow the normal parts allowance plus labor charge as shown in the Service Labor Time Standards Manual when requesting warranty reimbursement. The core charge should not be entered on the warranty claim form as there will not be a charge for the core if the removed assembly is returned to the Electronic Service Center within the specified 30-day period following receipt of the replacement assembly. DIGITAL ELECTRONIC ODOMETER REPLACEMENTS FOR UNSOLD NEW VEHICLES IN DEALER STOCK You must use a new digital odometer for unsold new vehicles in dealer stock. Simply enter the word "Stock" for the owner name on Form FPS 1878 and identify the order as a new unsold vehicle when placing the order. Dealer handling procedures will be the same as previously outlined. DEALER PARTS COUNTER RETAIL SALE There will be an occasion when it will be necessary to sell digital assemblies over the parts counter. Dealers must complete Form FPS 1878 (U.S.) or 6125-2 (Canada) and provide the same information as required for a service department repair. As with warranty repairs, the dealer must verify the mileage on the removed assembly. If the core is not received from the customer, you should charge the customer the core charge. You will be charged for the core if it is not returned. Orders will be processed the same day as received. SPECIFIC PART NUMBER ORDERING INFORMATION For 1984 thru 1987 Continental and all Mark VIII vehicles with an odometer concern, you can order just the NVM Module from the Service Centers (E4LY-17C269-A). If the concern is with the display, you can remove the NVM module from the cluster and order just the display (-10D922-), then install the NVM module into the replacement cluster. NOTE: ODOMETER MEMORY CONTROL ASSEMBLIES (-17C269-) HAVE TO BE RETURNED TO THE SERVICE CENTERS USING THE PROCEDURES AS PREVIOUSLY OUTLINED. THERE WILL BE A $300.00 CORE CHARGE IF YOU DO NOT RETURN THIS MODULE WITHIN 30 CALENDAR DAYS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 171 If a cluster is needed for a vehicle prior to the 1984 model year, order it from your FPSD Parts Distribution Center. Analog PSOM components (tachometers and gauges) may now be ordered from your FPSD Distribution Center. You no longer have to order the entire cluster for those type of concerns. For any cluster with a speedometer/odometer concern, the entire cluster must be ordered from the Electronic Service Center. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 172 When ordering an Analog PSOM cluster or 1992-93 Aerostar EIC, refer to Figures 1 and 2. The Service Center will need additional information concerning the PSOM Conversion Constant. This constant is important for correct vehicle performance. Please refer to the following procedures in your 1993 Body/Chassis Service Manuals for determining or changing the PSOM conversion constant. These procedures apply to both 1992 and 1993 vehicles equipped with PSOM clusters. ^ 1993 Aerostar, Ranger, Explorer Body/Chassis Service Manual, Page 13-02B-7, Test Step C4 through Page 13-02B-9, Test Step C7. ^ 1993 Econoline, F-150,F-250, F350, Bronco, F-super Duty Body/Chassis Service Manual, Page 13-02A-7, Test Step C4 through Page 13-02A-8, Test Step C7. NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 173 IF A VEHICLE HAS EITHER HAD THE TIRE SIZE/TYPE CHANGED, OR HAS HAD MODIFICATIONS TO THE REAR AXLE, IT IS NECESSARY TO CHANGE THE PSOM CONVERSION CONSTANT. THIS CONVERSION CONSTANT CAN BE CHANGED AT THE DEALERSHIP SO IT IS NOT NECESSARY TO ORDER AN ENTIRE CLUSTER IN THESE CASES. TECHNICAL ASSISTANCE An Electronic Instrument Cluster Help Line is available at 1-800-461-6945 to assist with any technical concerns involving the digital electronic odometer or related wiring or hardware. A PSOM (Programmable Speedometer/Odometer Module) Cluster Help Line is available at 1-800-523-7763 to assist with any technical concerns involving the PSOM clusters or related wiring or hardware. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-14 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations LH Front Of Engine Compartment, On Radiator Support Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Control Unit: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 183 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 184 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 185 Daytime Running Lamp Control Unit: Electrical Diagrams Daytime Running Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 186 Daytime Running Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Headlamp Control Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 191 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 192 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 193 Headlamp Control Module: Electrical Diagrams Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 194 Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 195 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 196 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 197 Headlamps (Except Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay > Component Information > Locations Headlamp Dimmer Relay: Locations I/P Components RH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations High Beam Relay: Locations I/P Components RH Side Of Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall Engine Control Module: Customer Interest Engine - Detonation/Hard Start/Rough Idle/Stall Article No. 91-9-5 05/01/91 ^ DETONATION - 3.8L (N/A) - DURING WIDE OPEN THROTTLE AT NORMAL ENGINE OPERATING TEMPERATURE ^ HARD START - 3.8L (N/A) - LONG CRANK TIME DURING INITIAL COLD START ^ IDLE - ROUGH - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START ^ STALL - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard/slow start may occur at the initial cold start followed by a rough idle during the first 30 seconds. Spark knock may also occur during wide open throttle operation at normal engine operating temperature. These conditions occur because of the operating strategy of the EEC IV processor. ACTION: Use the following procedure to determine if a new EEC IV processor is required. 1. Perform the diagnostic procedures in the 1989/90 Engine/Emission Diagnosis Shop Manual. Service as required. 2. If the conditions still exist, install a new EEC IV processor with a revised operating strategy. 3. Refer to the following Parts Block for correct parts usage. Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS F0PZ-12A650-GA EEC IV Processor (49 State) B F0PZ-12A650-FA EEC IV Processor (California) W OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910905A Perform Engine/Emissions 0.5 Hr. Diagnosis. 910905B Replace EEC IV Processor 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall > Page 214 DRIVE J7 OASIS CODES: 602300, 607000, 608400, 615000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall Engine Control Module: All Technical Service Bulletins Engine - Detonation/Hard Start/Rough Idle/Stall Article No. 91-9-5 05/01/91 ^ DETONATION - 3.8L (N/A) - DURING WIDE OPEN THROTTLE AT NORMAL ENGINE OPERATING TEMPERATURE ^ HARD START - 3.8L (N/A) - LONG CRANK TIME DURING INITIAL COLD START ^ IDLE - ROUGH - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START ^ STALL - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard/slow start may occur at the initial cold start followed by a rough idle during the first 30 seconds. Spark knock may also occur during wide open throttle operation at normal engine operating temperature. These conditions occur because of the operating strategy of the EEC IV processor. ACTION: Use the following procedure to determine if a new EEC IV processor is required. 1. Perform the diagnostic procedures in the 1989/90 Engine/Emission Diagnosis Shop Manual. Service as required. 2. If the conditions still exist, install a new EEC IV processor with a revised operating strategy. 3. Refer to the following Parts Block for correct parts usage. Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS F0PZ-12A650-GA EEC IV Processor (49 State) B F0PZ-12A650-FA EEC IV Processor (California) W OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910905A Perform Engine/Emissions 0.5 Hr. Diagnosis. 910905B Replace EEC IV Processor 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall > Page 220 DRIVE J7 OASIS CODES: 602300, 607000, 608400, 615000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding Precautions Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding Precautions Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 230 Engine Control Module: Locations Body & Chassis Components Behind RH Shroud Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 233 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 234 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 235 Engine Control Module: Connector Views EEC-IV Module Connector Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 236 EEC-IV Module Connector Pin Usage Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Assembly (ECA) Engine Control Module: Description and Operation Electronic Control Assembly (ECA) Fig. 6 Electronic control assembly (ECA) The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration assembly, Fig. 6. The processor receives input signals from the various sensors. The information obtained is used by the processor to activate engine control systems to obtain optimum emission control and engine performance The calibration assembly is a permanent memory device that contains information. The processor applies the sensor inputs to the stored information to determine when and how long the various control systems should be applied. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Assembly (ECA) > Page 239 Engine Control Module: Description and Operation Failure Mode Effects Management FMEM is an alternate system strategy in the ECA designed to allow improved vehicle drive should one or more sensor inputs fail. When a sensor input is perceived to be out-of-limits by the ECA, an alternative strategy will be initiated. The ECA will substitute a fixed in-limit sensor value and will continue to monitor the faulty sensor input. If the faulty sensor operates within limits, the ECA will return to the normal Engine Running mode (strategy). Code 98 will be displayed when FMEM is in effect. The MIL ``Check Engine'' light will remain ON when the FMEM is in effect. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 240 Engine Control Module: Service and Repair The Electronic Control Assembly (ECA) is located behind the righthand kick panel. 1. Disconnect electrical connector from ECA. 2. Remove ECA lower leg-to-cowl side sheet metal attaching screw. 3. Remove ECA. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions Integrated Control Relay Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 245 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 246 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 247 Integrated Control Relay Module: Electrical Diagrams Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 248 Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Inside Power Distribution Box Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Page 266 Fuel Pump Relay: Locations FUEL INJECTORS: The fuel injectors are mounted in the lower intake manifold. FUEL PRESSURE REGULATOR: The fuel pressure regulator is attached to the fuel supply manifold. FUEL FILTER: The filter is located downstream of the electric electric fuel pump and is mounted on the underbody. FUEL PUMP: The fuel pump is mounted on the fuel sender assembly inside of the fuel tank. FUEL PUMP RELAY: LH side of trunk, behind wheelwell. INERTIA SWITCH: The inertia switch is located on the LH side of trunk, behind wheelwell. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 269 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 270 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description Fuel Pump Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 273 X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 - CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 274 Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 275 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 276 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 277 Fuel Pump Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 278 X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 - CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 279 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 280 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 281 Fig. 23 Integrated Controller Pinpoint Tests X13 & X14 (Part 4 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 282 Fig. 23 Integrated Controller Pinpoint Tests X15 (Part 5 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 283 Fig. 23 Integrated Controller Pinpoint Test X16 & X17 (Part 6 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 284 Fig. 23 Integrated Controller Pinpoint Tests X18, X19, X20 & X21 (Part 7 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 285 Fig. 23 Integrated Controller Pinpoint Test X22 (Part 8 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 286 Fig. 23 Integrated Controller Pinpoint Tests X23 & X25 (Part 9 Of 26) Fig. 23 Integrated Controller Pinpoint Tests X26, X27 & X30 (Part 10 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 287 Fig. 23 Integrated Controller Pinpoint Tests X31 & X32 (Part 11 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 288 Fig. 23 Integrated Controller Pinpoint Tests X33 & X35 (Part 12 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 289 Fig. 23 Integrated Controller Pinpoint Tests X36 & X37 (Part 13 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 290 Fig. 23 Integrated Controller Pinpoint Tests X40, X41, X42 & X43 (Part 14 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 291 Fig. 23 Integrated Controller Pinpoint Tests X44, X45 & X46 (Part 15 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 292 Fig. 23 Integrated Controller Pinpoint Tests X50, X51 & X52 (Part 16 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 293 Fig. 23 Integrated Controller Pinpoint Tests X53, X54 & X55 (Part 17 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 294 Fig. 23 Integrated Controller Pinpoint Tests X56, X57 & X58 (Part 18 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 295 Fig. 23 Integrated Controller Pinpoint Tests X59, X60 & X80 (Part 19 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 296 Fig. 23 Integrated Controller Pinpoint Tests X81, X82 & X83 (Part 20 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 297 Fig. 23 Integrated Controller Pinpoint Tests X84, X90 & X91 (Part 21 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 298 Fig. 23 Integrated Controller Pinpoint Tests X92, X93 & X94 (Part 22 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 299 Fig. 23 Integrated Controller Pinpoint Tests X95 & X96 (Part 23 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 300 Fig. 23 Integrated Controller Pinpoint Tests X100 & X101 (Part 24 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 301 Fig. 23 Integrated Controller Pinpoint Tests X102 & X103 (Part 25 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 302 Fig. 23 Integrated Controller Pinpoint Test X104 (Part 26 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions Integrated Control Relay Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 307 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 308 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 309 Integrated Control Relay Module: Electrical Diagrams Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 310 Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Inside Power Distribution Box Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations Component Location - Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations > Page 318 Ignition Control Module: Description and Operation Module And Pin-Out The main function of the DIS module is to switch between ignition coils and cause these coils to spark. The module receives the PIP and CID signals as well as the SPOUT signal from the ECA. During normal operation, PIP is sent to the ECA to provide base timing and engine RPM information. The CID signal provides the DIS ignition module with the information required to synchronize the ignition coils so that they are fired in the proper order. The SPOUT signal contains the optimum spark timing and dwell information. The spark angle is determined by the rising edge of the SPOUT signal. The falling edge controls the ON or dwell time of the coil current. The dwell time is controlled by varying the duty cycle of the SPOUT signal. With the proper inputs from PIP, CID, and SPOUT the DIS module turns the coils On and Off in the proper order for spark control. PIN 1 VBAT (BATTERY VOLTAGE) PIN 2 CID PIN 3 NOT USED PIN 4 PIP IN PIN 5 SPOUT PIN 6 NOT USED PIN 7 IGND (MODULE GROUND) PIN 8 COIL 1 PIN 9 COIL 3 PIN 10 NOT USED PIN 11 COIL 2 PIN 12 IDM (IGNITION DIAGNOSTIC MODULE) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Ignition System > Ignition Control Module > Component Information > Locations > Page 319 Ignition Control Module: Service and Repair Removal 1. Identify, then disconnect electrical connectors from DIS ignition module assembly by pushing down on the connector locking tabs. Tabs are marked PUSH. 2. Remove three retaining screws, then the ignition module from the lower intake manifold. Installation 1. Apply a 1/32 inch coat of silicone dielectric compound or equivalent to the mounting surface of the DIS module. 2. Mount the DIS module to the intake manifold. Torque bolts to 22-31 ft. lbs. 3. Connect electrical connectors to ignition module. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Locations Seat Belt Control Module: Locations Body & Chassis Components Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Locations > Page 324 Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Locations > Page 325 Seat Belt Control Module: Diagrams Connector View Harness Connector Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Locations > Page 326 Seat Belt Control Module: Service and Repair REMOVAL and INSTALLATION 1. Remove LH luggage compartment trim panel. 2. Disengage two cover retaining push pins and remove cover. 3. Remove processor assembly from bracket (snaps on bracket). 4. Disconnect electrical connectors and remove processor. 5. To install, reverse Steps 1 through 4. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Neutral Start Relay (Inhibitor Relay) > Component Information > Locations Neutral Start Relay (Inhibitor Relay): Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Engine Compartment Component Locations On Left Fender Apron Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information Steering Control Module: Technical Service Bulletins Rotunda EVO System Tester - Revised Information ^ SHOP MANUAL- 1989 - PAGE 13-52-7 - EVO SYSTEM TESTER REPLACES FABRICATED TEST LAMP ^ SHOP MANUAL - 1990 - PAGE 13-54-7 - EVO SYSTEM TESTER REPLACES FABRICATED TEST LAMP Article No. 90-18B-7 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The Rotunda EVO System Tester 105-00007 is to be used for system diagnosis on the Variable Assist Steering System in place of the fabricated test lamp referenced on Page 13-52-7 of the 1989 Thunderbird/Cougar Shop Manual and Page 13-54-7 of the 1990 Thunderbird/Cougar Shop Manual. ACTION: Refer to the pages following this TSB article for the revised information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 390000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 340 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 341 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 342 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 343 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 344 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 345 Steering Control Module: Locations Body & Chassis Components Under Center Of Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 346 Steering Control Module: Service and Repair With Anti-Lock Brakes 1. Turn ignition switch Off. 2. Locate module tray in luggage compartment, behind LH rear seat. 3. Disengage push-pin on LH side of tray, then swing tray down. 4. Release locking tabs retaining control module to tray, then remove control module. 5. Disconnect electrical connector from module. 6. Reverse procedure to install. Less Anti-Lock Brakes 1. Turn ignition switch Off. 2. Locate module tray in luggage compartment, behind LH rear seat under package tray. 3. Disconnect electrical connector from module. 4. Unscrew two plastic rivets on sides of module, then pull down rivet and head assembly from module. 5. Remove control module from mounting bracket. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations Body & Chassis Components Under Center Of Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Control Module > Component Information > Locations > Page 351 Suspension Control Module: Service and Repair 1. Turn ignition switch to OFF or LOCK position. 2. Working from inside of luggage compartment, remove attaching screws and carefully lower righthand panel located behind rear seat back. 3. Remove screws retaining control module or relay assembly from brackets. 4. Disconnect electrical connectors from control module or relays. 5. Remove control module or relays from mounting brackets. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Main Relay > Component Information > Locations > Hard Ride Relay Suspension Main Relay: Locations Hard Ride Relay Body & Chassis Components Under Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Main Relay > Component Information > Locations > Hard Ride Relay > Page 356 Suspension Main Relay: Locations Soft Ride Relay Body & Chassis Components Under Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Steering and Suspension > Relays and Modules Suspension > Suspension Main Relay > Component Information > Locations > Page 357 Suspension Main Relay: Service and Repair 1. Turn ignition switch to Off or LOCK position. 2. Working from inside luggage compartment, disconnect push pin at left side of package tray. 3. Swing tray downward. 4. Disconnect control module or relay electrical connectors, then remove control module or relays. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions Power Window Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 363 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 364 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 365 Power Windows Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 371 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 372 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 373 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations I/P Components LH Side Of Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 381 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 382 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 383 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Antenna Switch, Power > Component Information > Locations Antenna Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Antitheft Mode Switch > Component Information > Locations Antitheft Mode Switch: Locations Body & Chassis Components LH Side Of Trunk, Near Anti-Theft Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Fuel Door Switch > Component Information > Locations Fuel Door Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 401 OASIS CODES: 201000, 201200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 406 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 407 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 408 Power Door Lock Switch: Electrical Diagrams Power Door Locks (Except Keyless Entry) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 409 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 410 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 411 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 412 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Body & Chassis Components Lower Rear Of LH Door Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions Power Mirror Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 418 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 419 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 420 Power Mirrors Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Power Trunk / Liftgate Lock Switch: Locations In Center Rear Of Trunk Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions Power Trunk / Liftgate Lock Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 426 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 427 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 428 Luggage Compartment Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions Trunk / Liftgate Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 434 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 435 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 436 Luggage Compartment Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Engine Compartment Component Locations In Master Cylinder, Below Reservoir Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications > ABS Pressure Switch Brake Fluid Pressure Sensor/Switch: Specifications Pressure Switch 15-25 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications > ABS Pressure Switch > Page 445 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > ABS Pressure Switch Brake Fluid Pressure Sensor/Switch: Locations ABS Pressure Switch Engine Compartment Component Locations In Brake Control Unit Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > ABS Pressure Switch > Page 448 Brake Fluid Pressure Sensor/Switch: Locations Brake Pressure Warning Switch Engine Compartment Component Locations In Brake Line, Below Master Cylinder Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 449 Brake Fluid Pressure Sensor/Switch: Description and Operation Fig. 4 Pressure Differential Valve & Brake Warning Light Switch Fig. 5 Pressure Differential Valve & Brake Warning Light Switch Fig. 6 Pressure Differential Valve & Brake Warning Light Switch There are four basic types of brake warning light switches as shown in Figs. 4 through 6 and usually form a common electrical circuit with the brake warning light. When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 450 As shown in Fig. 4, movement of the differential valve forces the switch plunger upward over the tapered shoulder of the valve to close the switch contacts and light the dual brake warning lamp, signaling a brake system failure. In Fig. 5, the valve assembly consists of two valves in a common bore that are spring loaded toward the centered position. The spring-loaded switch contact plunger rests on top of the valves in the centered position (right view). When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. The spring-loaded switch plunger is triggered and the ground circuit for the warning light is completed, lighting the lamp (left view). In Fig. 6, as pressure falls in one system, the other system's normal pressure forces the piston to the inoperative side, contacting the switch terminal, causing the warning light on the instrument panel to glow. On front wheel drive models, a fluid level indicator replaces the pressure differential valve used in previous brake systems. It is contained inside the body of the master cylinder plastic reservoir and activates the brake warning light when fluid level is low. Fig. 7 Typical pressure valve and brake warning light switch Testing Warning Light System If the parking brake light is connected into the service brake warning light system, the brake warning light will flash only when the parking brake is applied with the ignition turned ON. The same light will also glow should one of the two service brake systems fail when the brake pedal is applied. To test the system, turn the ignition on and apply the parking brake. If the lamp fails to light, inspect for a burned out bulb, disconnected socket, a broken or disconnected wire at the switch. Fig. 7 is an exterior view of one of these switches. They are usually mounted on the left frame side rail or on the brake pedal bracket. To test the brake warning system, raise the car and open a wheel bleeder valve while a helper depresses the brake pedal and observes the warning light on the instrument panel. If the bulb fails to light, inspect for a burned out bulb, disconnected socket, or a broken or disconnected wire at the switch. If the bulb is not burned out, and the wire continuity is proven, replace the brake warning switch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 451 Brake Fluid Pressure Sensor/Switch: Service and Repair Fig. 12 Pressure switch replacement 1. Relieve system hydraulic pressure by turning ignition off and pumping brake pedal at least 20 times until an increase in pedal force is felt. 2. Disconnect battery ground cable. 3. Disconnect 7-pin electrical connector from solenoid valve body and 5-pin pressure warning switch connector if equipped, Fig. 12. It may be necessary to remove the lefthand front tie-rod at the steering knuckle to gain access to the switch. 4. Remove pressure switch using a suitable tool. 5. Reverse procedure to install. Torque pressure switch to 15---25 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Pad Wear Sensor > Component Information > Locations Brake Pad Wear Sensor: Locations At Respective Wheels, On Brake Housing Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Body & Chassis Components Top Of Parking Brake Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front/Rear Sensor Tightening Torque Front/Rear Sensor Tightening Torque Front Sensor Bracket Bolts 10-15 ft.lb Rear Sensor Bolts 14-20 ft.lb Sensor Bracket Post Bolts 40-60 in.lb Sensor Set Screws 21-26 in.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 461 Wheel Speed Sensor: Locations Body & Chassis Components In Respective Wheelhouse Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 462 Wheel Speed Sensor: Description and Operation Fig. 7 Wheel Sensor Assembly (righthand Side Shown, Lefthand Side Similar). 1989 Continental Fig. 8 Wheel Sensor Assembly. Cougar & Thunderbird Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 463 Fig. 9 Wheel Sensor Assembly. Mark VII This system, Figs. 7 thru 9, uses four sets of variable reluctance sensors and toothed speed indicator rings to determine the rotational speed of each wheel. The sensors operate on magnetic induction principle. For example, as the teeth on the speed indicator ring rotate past the stationary sensor, a signal proportional to the speed of the rotation is generated and transmitted to the electronic control unit (ECU) through a coaxial cable. The front sensors are attached to the suspension knuckles and the speed indicator rings are pressed onto the hubs. The rear sensors are attached to the axle housing and the speed indicator rings are pressed onto the inner CV joints. The sensors and the speed indicator rings are serviced individually. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Front Fig. 16 Front toothed sensor ring removal REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake caliper and rotor assemblies. 3. Position rotor assembly on an arbor press with studs facing up, then carefully press each stud individually until they contact sensor ring surface. 4. Press studs and sensor ring out of rotor simultaneously, Fig. 16. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 466 Fig. 17 Front toothed sensor ring installation INSTALLATION 1. Install studs into rotor one at a time. 2. Position sensor ring onto rotor, then press ring until fully seated, Fig. 17. 3. Install rotor and caliper assemblies, then the wheel and tire. Rear Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 467 Fig. 18 Rear toothed sensor ring removal Removal 1. Remove rear axle shaft, refer to Rear Axle Replacement Procedures. 2. Install pinion bearing cone remover tool, Fig. 18, between axle shaft flange and sensor ring. Ensure recessed portion of inner surface of tool is toward axle flange. 3. Position axle in an arbor press and press axle out of sensor ring. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 468 Fig. 19 Rear toothed sensor ring installation Installation 1. To install, position sensor on axle shaft with recessed side facing inboard. 2. Install pinion bearing cone remover tool, Fig. 19, on axle shaft. 3. Position a piece of bar stock on top of axle flange, then press sensor ring onto axle shaft until a 1.8 inch gap between face of sensor ring and flange is obtained. 4. Install axle shaft. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 469 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Front 1. Disconnect sensor electrical connector for RH or LH front sensor from underside of the vehicle (up near radiator support). 2. Remove routing clips along wiring harness. 3. Remove Torx head screw securing sensor to spindle. 4. Reverse procedure to install. Torque Torx head screw to 40-60 inch lbs. Rear 1. Disconnect battery ground cable. 2. Disconnect wheel sensor electrical connector, located behind wheelwell, under carpeting, inside luggage compartment. 3. Push sensor wire grommet through hole in luggage compartment floor. 4. Raise and support vehicle, then remove sensor wire from routing clips. 5. On Cougar and Thunderbird models, remove sensor retaining bolt with a 1/2 inch socket. 6. On Mark VII models, proceed as follows: a. Remove wheel and tire assembly, then caliper and rotor assemblies. b. Remove Torx head retaining bolt, then slip grommet out of rear brake splash shield and pull sensor out through the hole. 7. Reverse procedure to install, noting the following: a. On Cougar and Thunderbird models, align sensor location tab and bolt hole to axle, then push into position. b. Torque retaining bolt to 14-20 ft. lbs. c. On Mark VII models, loosen 5mm setscrew on sensor and ensure sensor slides freely on sensor bracket post. d. If sensor is to be reused or adjusted, ensure sensor face is clean and free of foreign material. Carefully scrape pole face with a dull knife. Glue a new front paper spacer on pole face (spacer is marked with a "R" and is .043 inch thick). Steel sleeve around post bolt must be rotated to provide a new surface for setscrew to indent and lock into. e. Torque Torx head screw to 40-60 inch lbs. f. Push sensor toward toothed ring, until new paper sensor contacts sensor ring. Hold sensor, then torque 5mm setscrew to 21-26 inch lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations Coolant Level Sensor: Locations Engine Compartment Component Locations RH Fender Apron, Top Of Coolant Reservoir Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Temperature Sensors 1.3L VAT: Measured between upper terminal (GN/BK wire) of airflow sensor and ground. 1.6L VAT: Measured between terminal 25 (upper terminal on airflow connector) and ground. 2.2L VAT: Measured between first (R wire) and fifth (LG/W wire) of airflow sensor. All others with EEC IV VAT: Measured between upper terminal (LG/P wire) of airflow sensor and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 479 Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 480 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Compartment. Top Front Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 481 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 4 Engine coolant temperature sensor The ECT, Fig. 8, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 490 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 491 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic Temperature Sensor (Gauge): All Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic > Page 497 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 502 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 503 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Sensor (Gauge): > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear Temperature Sensor (Gauge): All Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Sensor (Gauge): > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 509 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Page 510 Temperature Sensor (Gauge): Locations Engine Compartment. Top Front Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection > Pinpoint Tests Fig. 5 Temperature Indicating System Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection > Pinpoint Tests > Page 513 Temperature Sensor (Gauge): Component Tests and General Diagnostics Magnetic Type 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 73 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace gauge. Bimetal Type The instrument voltage regulator (IVR) supplies a common regulated voltage for temperature, oil pressure and fuel gauges. The IVR is malfunctioning only if all gauges show similar problems. Test temperature gauge with Rotunda Gauge Tester 021-00055 or equivalent or with a 10 ohm resistor for high calibration and a 75 ohm resistor for low calibration as follows: 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 75 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace IVR and retest. 6. If gauge is out of calibration, replace gauge. Refer to DIAGNOSTIC CHARTS for coolant temperature indicating system diagnosis. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Service and Repair Clutch Switch: Service and Repair Removal 1. Remove screw attaching switch to bracket. 2. Disconnect electrical connector. 3. Remove switch assembly. Installation 1. Install switch on bracket. 2. Connect electrical connector. 3. Install attaching switch to bracket. 4. Adjust clutch switch as described under ADJUSTMENT PROCEDURES. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision Technical Service Bulletin # 9025B6 Date: 901221 Horn/Speed Control Switch Assembly - Revision ^ CAR WIRING DIAGRAMS - HORN/SPEED CONTROL SWITCH ASSEMBLY SCHEMATICS REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - HORN/SPEED CONTROL SWITCH ASSEMBLY SCHEMATICS REVISED ^ SHOP MANUAL - SECTION 37-05 - HORN/SPEED CONTROL SWITCH ASSEMBLY SCHEMATICS REVISED Article No. 90-25B-6 FORD: 1986-90 TAURUS 1988-90 CROWN VICTORIA 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1986-90 SABLE 1988-90 CONTINENTAL, GRAND MARQUIS, MARK VII, TOWN CAR 1989-90 COUGAR ISSUE: The Horn/Speed Control Switch Assembly schematics shown in the publications listed below are incorrect. Speed switch wiring and circuit numbers have also been updated. ^ 1986 - 1990 Taurus/Sable Shop Manuals ^ 1986 -1989 Taurus/Sable EVTMs ^ 1988 -1990 Mark VII Shop Manuals ^ 1988 - 1989 Mark VII EVTMs ^ 1988 -1990 Continental Shop Manuals ^ 1988 -1989 Continental EVTMs ^ 1988 -1990 Lincoln Town Car/Crown Victoria/Grand Marquis Shop Manuals ^ 1988 - 1990 Lincoln Town Car EVTMs ^ 1988 - 1989 Crown Victoria/Grand Marquis EVTMs ^ 1989 - 1990 Thunderbird/Cougar Shop Manuals ACTION: Refer to the pages following this TSB article for the revised schematics and correct circuit numbers/color codes. OTHER APPLICABLE ARTICLES: 90-18B-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 522 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 523 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 524 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 525 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 526 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 527 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 528 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 529 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 530 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 531 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 532 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 533 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 534 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 535 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 536 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 537 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 538 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 539 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 540 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 541 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 542 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 543 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 544 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 545 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 546 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 547 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 548 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 549 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 550 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 551 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 552 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 553 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 554 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 555 Cruise Control Switch: Service and Repair 1. Pull upward on upper middle edge of the horn cover/pad assembly and separate it from the steering wheel. 2. Disconnect horn switch electrical connectors from horn cover/pad assembly, then set the assembly aside. 3. Disconnect electrical connector from the speed control/horn brush contact plate terminal. 4. On models with standard steering wheel, use your fingers to pry out the speed control switch. Remove switch and harness assembly from steering wheel. 5. On models with sport steering wheel, remove four speed control switch retaining screws. Remove switch and harness assembly from steering wheel. 6. On all models, reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Locations Oil Level Sensor: Locations Rear Of Engine RH Rear Corner Of Engine Below Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations Lower Right Hand Side, Front Of Engine, Below the Power Steering Bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Oil Temperature Sensor/Switch: Locations Engine Compartment Component Locations Lower RH Of Engine Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Blower Motor Switch: Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: Customer Interest A/C System - Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System Chemical/Refrigerator Type Odor > Page 578 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C System Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor > Page 584 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Pressure Cycling Switch Diagnostic Procedure AIR CONDITIONING-CLUTCH PRESSURE CYCLING SWITCH DIAGNOSTIC PROCEDURE Article No. 89-14-10 FORD: 1980-89 CROWN VICTORIA 1981-89 ESCORT 1982-88 EXP 1982-89 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-89 TEMPO 1986-89 TAURUS LINCOLN-MERCURY: 1980-89 GRAND MARQUIS, MARK VI, MARK VII, TOWN CAR 1981-87 LYNX 1982-86 CAPRI 1982-89 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-89 TOPAZ 1986-89 SABLE LIGHT TRUCK: 1980-89 BRONCO, F SERIES 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR 1988-89 ECONOLINE ISSUE: Poor air conditioning cooling caused by low or no refrigerant charge often results in unnecessary replacement of the clutch cycling pressure switch. The switch is designed to work on system pressure. It closes at about 46 psi and opens at about 24.5 psi. It has a normal cycle (on and off) rate of 2 to 5 cycles per minute. ACTION: If an inoperative or fast cycling pressure switch is found, use the following diagnostic charts before replacing the pressure switch. DIAGNOSTIC PROCEDURE: 1. Connect a manifold gauge set to the service ports and check the system pressures. They should be above the closing pressure of the switch (46 psi). 2. If the A/C system pressures are above 46 psi and the clutch will not engage, proceed as follows: ^ Check the pressure switch harness connector and harness wires for a continuous open condition. ^ Check for an intermittent open or a poor connection between the connector and the pressure switch terminals. a. If the harness connector and wires are OK, by-pass the pressure switch by jumping the two terminals of the connector. If the clutch still does not engage, THE PRESSURE SWITCH IS NOT DEFECTIVE. Refer to the respective EVTM for the clutch circuit schematic and circuit diagnosis. Repair as necessary. 3. Check the ambient temperature. If the ambient temperature is below 48~ F (9~ C), the system pressure will not be high enough to close the pressure switch (46 psi). 4. If the system does not contain refrigerant, the pressure will not be high enough to close the switch for compressor operation. Leak test, repair, evacuate and charge the system. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 589 Figure 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 590 Figure 2 5. If the pressures are above 46 psi and the clutch cycle rate is faster than the normal rate of 2 to 5 cycles per minute, the system is probably low on refrigerant. Check that the system contains the correct refrigerant charge by following the correct diagnostic chart (Figures 1 or 2). WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Pressure Cycling Switch Diagnostic Procedure AIR CONDITIONING-CLUTCH PRESSURE CYCLING SWITCH DIAGNOSTIC PROCEDURE Article No. 89-14-10 FORD: 1980-89 CROWN VICTORIA 1981-89 ESCORT 1982-88 EXP 1982-89 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-89 TEMPO 1986-89 TAURUS LINCOLN-MERCURY: 1980-89 GRAND MARQUIS, MARK VI, MARK VII, TOWN CAR 1981-87 LYNX 1982-86 CAPRI 1982-89 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-89 TOPAZ 1986-89 SABLE LIGHT TRUCK: 1980-89 BRONCO, F SERIES 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR 1988-89 ECONOLINE ISSUE: Poor air conditioning cooling caused by low or no refrigerant charge often results in unnecessary replacement of the clutch cycling pressure switch. The switch is designed to work on system pressure. It closes at about 46 psi and opens at about 24.5 psi. It has a normal cycle (on and off) rate of 2 to 5 cycles per minute. ACTION: If an inoperative or fast cycling pressure switch is found, use the following diagnostic charts before replacing the pressure switch. DIAGNOSTIC PROCEDURE: 1. Connect a manifold gauge set to the service ports and check the system pressures. They should be above the closing pressure of the switch (46 psi). 2. If the A/C system pressures are above 46 psi and the clutch will not engage, proceed as follows: ^ Check the pressure switch harness connector and harness wires for a continuous open condition. ^ Check for an intermittent open or a poor connection between the connector and the pressure switch terminals. a. If the harness connector and wires are OK, by-pass the pressure switch by jumping the two terminals of the connector. If the clutch still does not engage, THE PRESSURE SWITCH IS NOT DEFECTIVE. Refer to the respective EVTM for the clutch circuit schematic and circuit diagnosis. Repair as necessary. 3. Check the ambient temperature. If the ambient temperature is below 48~ F (9~ C), the system pressure will not be high enough to close the pressure switch (46 psi). 4. If the system does not contain refrigerant, the pressure will not be high enough to close the switch for compressor operation. Leak test, repair, evacuate and charge the system. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 596 Figure 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 597 Figure 2 5. If the pressures are above 46 psi and the clutch cycle rate is faster than the normal rate of 2 to 5 cycles per minute, the system is probably low on refrigerant. Check that the system contains the correct refrigerant charge by following the correct diagnostic chart (Figures 1 or 2). WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 598 Refrigerant Pressure Sensor / Switch: Locations Engine Compartment Component Locations On A/C Accumulator Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 599 Refrigerant Pressure Sensor / Switch: Service and Repair Fig. 6 Accumulator/dryer 1. Disconnect wire harness connector from the pressure switch, Fig. 6. 2. Unscrew pressure switch from top of accumulator dryer. 3. Reverse procedure to install. Lubricate O-ring on the accumulator nipple with refrigerant oil. 4. Check system for leaks and proper operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Brake Pad Wear Sensor > Component Information > Locations Brake Pad Wear Sensor: Locations At Respective Wheels, On Brake Housing Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations I/P Components LH Side Of Dash, Near Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Body & Chassis Components In Respective Door Latch Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 610 Door Switch: Service and Repair REMOVAL and INSTALLATION 1. Remove connector at switch. 2. Using an ohmmeter such as Rotunda Digital Volt Ohm Meter 007-00001, or an equivalent probe between switch terminal and ground (latch). 3. With door in latched (fully closed) position, switch should be open. 4. With door open, switch must be closed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level Fuel Gauge Sender: Customer Interest Fuel Gauge - Intermittently Shows Increase In Fuel Level Article No. 91-13-4 06/26/91 GAUGE - FUEL - ELECTRONIC - SHOWS FUEL INCREASES OR DISPLAYS "CO" INTERMITTENTLY - VEHICLES BUILT FROM 6/1/89 TO 1/15/90 FORD: 1989-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989-90 AEROSTAR This TSB article is being republished in its entirety to correct the fuel pump/sender part number listed for the 1989 Taurus/Sable. ISSUE: The electronic instrument cluster (EIC) fuel gauge may intermittently show an increase in the fuel level or display circuit open "CO". This happens when the fuel tank level is above 1/2 full. The condition is caused by either an intermittent high resistance contact or an open circuit internal to the fuel sender unit. ACTION: Perform the diagnostic procedures outlined in the appropriate Shop Manual, Sections 33-05 for Cars and 13-01A for the Aerostar to determine if a new fuel pump/sender is required. 1. Replace the fuel sender assembly. Refer to the appropriate Shop Manual, Sections 24-35 for cars and 13-03 for the Aerostar for service details. FUEL PUMP/SENDER APPLICATION CHART MODEL YEAR APPLICATION DESCRIPTION PART NUMBER 1989 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-C 1990 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-A 1989-90 Continental Fuel Pump/Sender E90Z-9H307-A 1989-90 Mark VII Fuel Pump/Sender E5LY-9275-A 1989 Town Car Fuel Pump/Sender E5VY-9275-A 1990 Town Car Fuel Pump/Sender F0VY-9H307-C 1989-90 Thunderbird/Cougar Fuel Pump/Sender F1SZ-9H307-B 1989-90 Aerostar Fuel Pump/Sender E99Z-9H307-A PART NUMBER PART NAME CLASS F0DZ-9H307-C Fuel Pump/Sender C E90Z-9H307-A Fuel Pump/Sender B F0DZ-9H307-A Fuel Pump/Sender B E5LY-9275-A Fuel Pump/Sender R E5VY-9275-A Fuel Pump/Sender BM F0VY-9H307-C Fuel Pump/Sender B F1SZ-9H307-B Fuel Pump/Sender B E99Z-9H307-A Fuel Pump/Sender B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-7-11 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level > Page 619 OPERATION DESCRIPTION TIME 911304A Replace Fuel Pump/Sender 1.5 Hrs. - 1990 Town Car, Thunderbird, Cougar 911304A Replace Fuel Pump/Sender 1.2 Hrs. - Aerostar 911304A Replace Fuel Pump/Sender 1.0 Hr. - Continental, 1989 Town Car 911304A Replace Fuel Pump/Sender 0.9 Hr. - Taurus, Sable, Mark VII DEALER CODING BASIC PART NO. CONDITION CODE 9H307 28 OASIS CODES: 204000, 204100, 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 891411 > Jul > 89 > Fuel Gauge Occasionally Sticks In FULL Position Fuel Gauge Sender: Customer Interest Fuel Gauge - Occasionally Sticks In FULL Position GAUGE-FUEL-OCCASIONALLY STICKS IN "FULL" POSITION Article No. 89-14-11 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A fuel gauge that ocassionally sticks in the "FULL" position may be caused by a binding fuel pump float assembly. The fuel pump float binds on the inner surface of the fuel tank and holds the float in the "FULL" position. This is most likely to occur when driving on unpaved or rough roads. ACTION: Modify the fuel pump float to prevent the binding condition. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 24-12 for removal and installation instructions. 1. Remove the fuel pump assembly. 2. Unscrew the nut from the end of the float rod assembly. 3. Remove the float from the rod. 4. Using a sharp knife, cut 3/8" to 1/2" (9.525 mm to 12.7 mm) off the end of the float. 5. Reinstall the shortened float on the float rod. 6. Install float retaining nut. NOTE: ALLOW CLEARANCE BETWEEN THE RETAINING NUT AND FLOAT SO THAT THE FLOAT SPINS FREELY. 7. Using diagonal cutters, trim the float rod so that it is flush with the retaining nut. 8. Reinstall the fuel sender. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891411A Modify Float 1.3 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 41 OASIS CODES: 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Intermittently Shows Increase In Fuel Level Article No. 91-13-4 06/26/91 GAUGE - FUEL - ELECTRONIC - SHOWS FUEL INCREASES OR DISPLAYS "CO" INTERMITTENTLY - VEHICLES BUILT FROM 6/1/89 TO 1/15/90 FORD: 1989-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989-90 AEROSTAR This TSB article is being republished in its entirety to correct the fuel pump/sender part number listed for the 1989 Taurus/Sable. ISSUE: The electronic instrument cluster (EIC) fuel gauge may intermittently show an increase in the fuel level or display circuit open "CO". This happens when the fuel tank level is above 1/2 full. The condition is caused by either an intermittent high resistance contact or an open circuit internal to the fuel sender unit. ACTION: Perform the diagnostic procedures outlined in the appropriate Shop Manual, Sections 33-05 for Cars and 13-01A for the Aerostar to determine if a new fuel pump/sender is required. 1. Replace the fuel sender assembly. Refer to the appropriate Shop Manual, Sections 24-35 for cars and 13-03 for the Aerostar for service details. FUEL PUMP/SENDER APPLICATION CHART MODEL YEAR APPLICATION DESCRIPTION PART NUMBER 1989 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-C 1990 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-A 1989-90 Continental Fuel Pump/Sender E90Z-9H307-A 1989-90 Mark VII Fuel Pump/Sender E5LY-9275-A 1989 Town Car Fuel Pump/Sender E5VY-9275-A 1990 Town Car Fuel Pump/Sender F0VY-9H307-C 1989-90 Thunderbird/Cougar Fuel Pump/Sender F1SZ-9H307-B 1989-90 Aerostar Fuel Pump/Sender E99Z-9H307-A PART NUMBER PART NAME CLASS F0DZ-9H307-C Fuel Pump/Sender C E90Z-9H307-A Fuel Pump/Sender B F0DZ-9H307-A Fuel Pump/Sender B E5LY-9275-A Fuel Pump/Sender R E5VY-9275-A Fuel Pump/Sender BM F0VY-9H307-C Fuel Pump/Sender B F1SZ-9H307-B Fuel Pump/Sender B E99Z-9H307-A Fuel Pump/Sender B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-7-11 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level > Page 629 OPERATION DESCRIPTION TIME 911304A Replace Fuel Pump/Sender 1.5 Hrs. - 1990 Town Car, Thunderbird, Cougar 911304A Replace Fuel Pump/Sender 1.2 Hrs. - Aerostar 911304A Replace Fuel Pump/Sender 1.0 Hr. - Continental, 1989 Town Car 911304A Replace Fuel Pump/Sender 0.9 Hr. - Taurus, Sable, Mark VII DEALER CODING BASIC PART NO. CONDITION CODE 9H307 28 OASIS CODES: 204000, 204100, 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return Technical Service Bulletin # RSB89170 Date: 891122 Remanufacturer Letter # 1 November 22, 1989 RSB # 89-170 To: All Ford Authorized Remanufacturers Subject: Sort and Return of Fuel & Send Assy. - E9DZ-9H307-C E5ZZ-9A407-A Gentlemen: Because certain fuel pump and sender assemblies may not meet Ford's high quality requirements, you are authorized to return unused parts for credit. Part Number Explanation E9DZ-9H307-C Action Required E5ZZ-9A407-A ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 - 1989; 0901 September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section, write "Returned per FPSD Purge 1079". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Returns restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Remanufacturer Letter # 2 November 22, 1989 RSB # 89-171 To: Ford Authorized Remanufacturers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1080". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 634 ^ Return parts to your Facing PDC using least expensive trarisportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 1 December 7, 1989 To: Ford and Lincoln Mercury, Dealers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date ccde of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section Write "Returned per FPSD Purge # 1080". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 3 December 7, 1989 To: Ford and Lincoln Mercury Dealers Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 635 Subject: Return of Fuel Pump & Sender Assy. - E9DZ-9H307-C and Fuel Pump & Bracket Assy. E5ZZ-9A407-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1079". ^ Return parts to your Facing PDC using-least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject part. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacemeut stock of the same part numbers is available for ordering immediately. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 640 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 891411 > Jul > 89 > Fuel Gauge - Occasionally Sticks In FULL Position Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Occasionally Sticks In FULL Position GAUGE-FUEL-OCCASIONALLY STICKS IN "FULL" POSITION Article No. 89-14-11 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A fuel gauge that ocassionally sticks in the "FULL" position may be caused by a binding fuel pump float assembly. The fuel pump float binds on the inner surface of the fuel tank and holds the float in the "FULL" position. This is most likely to occur when driving on unpaved or rough roads. ACTION: Modify the fuel pump float to prevent the binding condition. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 24-12 for removal and installation instructions. 1. Remove the fuel pump assembly. 2. Unscrew the nut from the end of the float rod assembly. 3. Remove the float from the rod. 4. Using a sharp knife, cut 3/8" to 1/2" (9.525 mm to 12.7 mm) off the end of the float. 5. Reinstall the shortened float on the float rod. 6. Install float retaining nut. NOTE: ALLOW CLEARANCE BETWEEN THE RETAINING NUT AND FLOAT SO THAT THE FLOAT SPINS FREELY. 7. Using diagonal cutters, trim the float rod so that it is flush with the retaining nut. 8. Reinstall the fuel sender. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891411A Modify Float 1.3 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 41 OASIS CODES: 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return Technical Service Bulletin # RSB89170 Date: 891122 Remanufacturer Letter # 1 November 22, 1989 RSB # 89-170 To: All Ford Authorized Remanufacturers Subject: Sort and Return of Fuel & Send Assy. - E9DZ-9H307-C E5ZZ-9A407-A Gentlemen: Because certain fuel pump and sender assemblies may not meet Ford's high quality requirements, you are authorized to return unused parts for credit. Part Number Explanation E9DZ-9H307-C Action Required E5ZZ-9A407-A ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 - 1989; 0901 September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section, write "Returned per FPSD Purge 1079". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Returns restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Remanufacturer Letter # 2 November 22, 1989 RSB # 89-171 To: Ford Authorized Remanufacturers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1080". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 650 ^ Return parts to your Facing PDC using least expensive trarisportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 1 December 7, 1989 To: Ford and Lincoln Mercury, Dealers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date ccde of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section Write "Returned per FPSD Purge # 1080". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 3 December 7, 1989 To: Ford and Lincoln Mercury Dealers Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 651 Subject: Return of Fuel Pump & Sender Assy. - E9DZ-9H307-C and Fuel Pump & Bracket Assy. E5ZZ-9A407-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1079". ^ Return parts to your Facing PDC using-least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject part. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacemeut stock of the same part numbers is available for ordering immediately. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 656 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 657 Fuel Gauge Sender: Locations On RH Frame Rail Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests Fuel Gauge Sender: Pinpoint Tests Fig. 1 Fuel Indicating System Diagnosis (Part 1 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 660 Fig. 1 Fuel Indicating System Diagnosis (Part 2 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 661 Fig. 1 Fuel Indicating System Diagnosis (Part 3 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 662 Fig. 1 Fuel Indicating System Diagnosis (Part 4 Of 5). Models w/Magnetic Gauge Fig. 1 Fuel Indicating System Diagnosis (Part 5 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 663 Fig. 2 Fuel Indicating System Diagnosis (Part 1 Of 2) Fig. 2 Fuel Indicating System Diagnosis (Part 2 Of 2) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 664 Fuel Gauge Sender: Component Tests and General Diagnostics Magnetic Type The required test equipment consists of a Rotunda Gauge Tester part No. 021-00055 or equivalent, a pair of 10 ohm and 75 ohm resistor or another fuel sender of known quality. 1. Perform test with resistors as follows: a. Disconnect wiring connector at sender unit, then connect resistor between gauge lead and a suitable ground. b. Turn ignition switch to On position. c. With 10 ohm resitor, the gauge pointer should contact the Full mark. d. With 75 ohm resistor, the gauge pointer should contact the Empty mark. 2. Perform test with fuel sender of known quality as follows: a. Turn ignition switch to Off position. b. Disconnect wiring connector from sender and connect it to test sender. c. Move float rod away from fuel filter against Full stop position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or above the Full mark. d. Move float rod toward fuel filter against Empty stop position. Turn ignition switch to Off position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or below the Empty mark. e. If gauge performs as indicated, perform fuel sender unit tests. Refer to DIAGNOSTIC CHARTS for fuel sender unit tests. f. If gauge is out of calibration at the Empty mark, or both the Empty and Full mark, replace gauge. Bimetal Type The required test equipment consists of a Rotunda Gauge Tester part No. 021-00055 or equivalent, a pair of 22 ohm and 145 ohm resistor or another fuel sender of known quality. 1. Perform test with resistors as follows: a. Disconnect wiring connector at sender unit, then connect resistor between gauge lead and a suitable ground. b. Turn ignition switch to On position. c. With 145 ohm resitor, the gauge pointer should contact the Full mark. d. With 22 ohm resistor, the gauge pointer should contact the Empty mark. 2. Perform test with fuel sender of known quality as follows: a. Turn ignition switch to Off position. b. Disconnect wiring connector from sender and connect it to test sender. c. Move float rod away from fuel filter against Full stop position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or above the Full mark. d. Move float rod toward fuel filter against Empty stop position. Turn ignition switch to Off position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or below the Empty mark. e. If gauge performs as indicated, perform fuel sender unit tests. Refer to DIAGNOSTIC CHARTS for fuel sender unit tests. f. If gauge is out of calibration at the Empty mark, or both the Empty and Full mark, replace gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Technical Service Bulletins > Ignition Key Warning Switch - Replacement Procedure Key Reminder Switch: Technical Service Bulletins Ignition Key Warning Switch - Replacement Procedure IGNITION SYSTEM-IGNITION KEY WARNING SWITCH-REPLACEMENT PROCEDURE SWITCH-IGNITION KEY WARNING-REPLACEMENT PROCEDURE Article No. 89-19-2 FORD: 1986-90 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1986-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR ISSUE: A new procedure for servicing the ignition key warning switch has been developed. The new procedure is not published in the shop manual. ACTION: Use the following service procedure to remove and install the ignition key warning switch. Figure 1 REMOVAL 1. Remove the ignition lock assembly from the steering column lock housing. Refer to the appropriate Car Shop Manual, Section 13-04 for service details. NOTE: LEAVE THE LOCK IN THE RUN POSITION. DO NOT TURN THE IGNITION KEY. 2. Remove the switch from the lock assembly using a screwdriver as shown in Figure 1. 3. Throw away the switch. Figure 2 INSTALLATION 1. Obtain a new key warning switch (11A127). 2. Place the switch halfway on the lock cylinder case. Note proper alignment as shown in Figure 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Technical Service Bulletins > Ignition Key Warning Switch - Replacement Procedure > Page 669 Figure 3 3. While pressing down on the switch with the thumb, slide the switch into place making sure all tabs are in place, Figure 3. 4. Install the lock cylinder assembly. Refer to the procedure in Section 13-04 of the appropriate Car Shop Manual. PART NUMBER PART NAME CLASS E7DZ-11A127-A Key Warning Switch C (Continental, Taurus, Sable) E6SZ-11A127-A Key Warning Switch (All Other C Car Lines) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2500, 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Technical Service Bulletins > Page 670 Key Reminder Switch: Locations I/P Components Part Of Ignition Switch Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Body & Chassis Components Top Of Parking Brake Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor: Locations On Rear View Mirror Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations LH Rear Side Of Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations I/P Components On Brake Pedal Support Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 684 Brake Light Switch: Service and Repair When servicing any component on a vehicle equipped with anti-lock brakes it is necessary to discharge the hydraulic pressure in the system. Refer to Brakes and Traction Control/Brakes/Antilock Brake System/Service and Repair for procedure for procedure. 1. Disconnect battery ground cable. 2. Disconnect electrical connector from brake sensor switch. 3. Remove sensor switch from brake control valve body. 4. Reverse procedure to install. Torque brake sensor switch to 8-10 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Body & Chassis Components In Respective Door Latch Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 688 Door Switch: Service and Repair REMOVAL and INSTALLATION 1. Remove connector at switch. 2. Using an ohmmeter such as Rotunda Digital Volt Ohm Meter 007-00001, or an equivalent probe between switch terminal and ground (latch). 3. With door in latched (fully closed) position, switch should be open. 4. With door open, switch must be closed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 693 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 694 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 695 Hazard Warning Switch: Electrical Diagrams Hazard, Horn And Memory Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 696 Hazard, Stop and Turn Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 702 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 703 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 704 Headlamp Dimmer Switch: Electrical Diagrams Headlamps (Except Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 705 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 706 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 707 Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 708 Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 709 Headlamp Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove lower LH finish panel retaining bolts and carefully pull to disengage retaining clips. 3. Remove lower LH reinforcement panel retaining bolts and remove panel. 4. Remove steering column lower shroud retaining screws and remove lower shroud. 5. Remove steering column retaining nuts, then remove column upper shroud. 6. Disconnect switch electrical connectors. 7. Remove switch retaining bolts, then remove switch. 8. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 715 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 716 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 717 Headlamp Switch: Electrical Diagrams Main Light Switch (Except Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 718 Main Light Switch (With Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 719 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove two cluster trim panel retaining screws. 3. Pull off headlamp switch knob and snap off cluster trim panel. 4. Disconnect electrical connector to headlamp dimmer sensor assembly. 5. With headlamp switch in full On position, using opening in instrument panel, depress shaft release button on switch and remove shaft. 6. Remove headlamp switch retaining nut and pull switch through opening to disconnect wiring connector. 7. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Technical Service Bulletins > Customer Interest: > 902510 > Dec > 90 > Horn Button - High Operation Effort Horn Switch: Customer Interest Horn Button - High Operation Effort HORN - HIGH EFFORTS TO DEPRESS PAD DURING LOW AMBIENT TEMPERATURES NON-SUPERCHARGED CARS Article No. 90-25-10 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: High effort may be required when depressing the horn pad to sound the horn. This is caused by a steering wheel horn pad that is too stiff in low ambient temperatures. The stiff horn pad may not allow the horn contacts to close. ACTION: Install a new horn pad made from urethane material. This improves low temperature flexibility and reduces the horn blowing effort. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 35-80, for service details. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902510A Install Horn Pad 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 13A805 99 OASIS CODES: 203000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 902510 > Dec > 90 > Horn Button - High Operation Effort Horn Switch: All Technical Service Bulletins Horn Button - High Operation Effort HORN - HIGH EFFORTS TO DEPRESS PAD DURING LOW AMBIENT TEMPERATURES NON-SUPERCHARGED CARS Article No. 90-25-10 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: High effort may be required when depressing the horn pad to sound the horn. This is caused by a steering wheel horn pad that is too stiff in low ambient temperatures. The stiff horn pad may not allow the horn contacts to close. ACTION: Install a new horn pad made from urethane material. This improves low temperature flexibility and reduces the horn blowing effort. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 35-80, for service details. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902510A Install Horn Pad 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 13A805 99 OASIS CODES: 203000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Horn Switch: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times Band: All Technical Service Bulletins A/T - AOD Delayed Shift Times Article No. 91-16-12 08/07/91 TRANSMISSION - AUTOMATIC - AOD - DELAYED 3-4/4-3 SHIFTS OR OVERDRIVE BAND/FORWARD CLUTCH REPEAT REPAIRS FORD: 1989-90 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989-90 BRONCO, E-150, E-250, F-150 This TSB article is being republished in its entirety to include Bronco and E-250 in the Light Truck application line. ISSUE: Increased shift times may be experienced during certain continuous driving conditions. When frequent 3-4/4-3 shifts or high ambient temperatures are encountered, overdrive band engagement or release times may increase. This slip at the friction surface creates excessive heat and may eventually fail the band. Forward clutch failure may also occur as the forward clutch operation is synchronized with the overdrive band during 3-4/4-3 shifting. ACTION: Whenever servicing the overdrive band or forward clutch, also replace the main control assembly with a 1991 service main control. Refer to the following AOD Main Control Application Chart. This chart reflects shift calibration revisions to the 1991 main control level. AOD MAIN CONTROL COMPLEXITY CHART MAIN DELETE ADD SERVICE CONTROL SERVICE PART PART NO. I.D. NO. MAIN CONTROL I.D. F1TZ-7A100-C GNO F0TZ-7A100-G DOA, MPA E9TZ-7A100-J MRA F1TZ-7A100-B GNN F0TZ-7A100-F DOX, MPX E9TZ-7A100-H MRX F1AZ-7A100-D JNF E9AZ-7A100-B COH, VPH, VRH, RRH F1SZ-7A100-B BNJ E9SZ-7A100-B URL, URY, SRY F0SZ-7A100-B GPJ, UPJ F1AZ-7A100-E JFK F0AZ-7A100-D CJH E9AZ-7A100-G VGH, RGH, WFR E5AZ-7A100-D BER, OER, ODR F1LY-7A-A DNX F0LY-7A100-B BOC, BOX, PPC E9LY-7A100-A PRX E9LY-7A100-B PRC F1SZ-TA100-A ANV F0SZ-7A100-A TPM E9SZ-7A100-D TRM, TRF PART NUMBER PART NAME CLASS F1TZ-7A100-C Main Control B F1TZ-7A100-B Main Control B F1AZ-7A100-D Main Control B F1SZ-7A100-B Main Control C F1AZ-7A100-E Main Control C F1LY-7A100-A Main Control B F1SZ-7A100-A Main Control C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-5-6 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 911612A Replace Main Control Valve 0.6 Hr. Body To AOD - Cars 911612B Remove And Install AOD 3.1 Hr. Transmission Assembly - Crown Victoria, Grand Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Horn Switch: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times > Page 738 Marquis And Town Car 911612C Remove And Install AOD 3.5 Hr. Transmission Assembly - Thunderbird, Cougar, Mustang And Mark VII 911612D Overhaul Time For AOD 4.9 Hr. Transmission 911612E Remove And Install 2.8 Hr. Transmission - F-150, 4X2 Models, E-150, E-250 911612F Remove And Install 4.4 Hr. Transmission - F-150 And Bronco, 4X4 Models 911612G Remove And Install 2.6 Hr. Transmission - Econoline 911612H Overhaul Of AOD - Trucks 5.2 Hr. 9116121 Replace Main Control Valve 1.3 Hr. Body - Trucks DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Horn Switch: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times > Page 744 Marquis And Town Car 911612C Remove And Install AOD 3.5 Hr. Transmission Assembly - Thunderbird, Cougar, Mustang And Mark VII 911612D Overhaul Time For AOD 4.9 Hr. Transmission 911612E Remove And Install 2.8 Hr. Transmission - F-150, 4X2 Models, E-150, E-250 911612F Remove And Install 4.4 Hr. Transmission - F-150 And Bronco, 4X4 Models 911612G Remove And Install 2.6 Hr. Transmission - Econoline 911612H Overhaul Of AOD - Trucks 5.2 Hr. 9116121 Replace Main Control Valve 1.3 Hr. Body - Trucks DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Technical Service Bulletins > Page 745 Horn Switch: Service and Repair MODELS EQUIPPED w/TURN SIGNAL MOUNTED SWITCH Horn sounder is located on the turn signal, headlight dimmer and horn lever. Refer to Vehicle Lighting/Turn signals/Turn Signal Switch/Service and Repair when replacing switch. 1. Disconnect battery ground cable. 2. Pry switch cover off top. Use caution not to damage cover when removing. 3. Remove switch attaching screws, then lift switch from steering wheel. Use caution not to loose contact spring. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations Interior Light Switch: Locations Body & Chassis Components In Respective Door Jamb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 753 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 754 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 755 Hazard, Stop and Turn Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 756 Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove trim shroud or shroud halves. 3. Remove turn signal switch lever from switch. Grasp lever and use a pulling and twisting motion while pulling lever straight out from switch. 4. Peel back foam shield from turn signal switch, then disconnect two electrical connectors from switch. 5. Remove turn signal switch attaching screws, then remove switch. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 761 OASIS CODES: 201000, 201200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications Air Flow Meter/Sensor: Specifications Mass or Vane Airflow Sensor Engines with multi-port injection. 1.6L MFI, 1.9L MFI, 2.3L MFI: Vane Airflow Sensors, measured between second upper terminal (W/BK wire) and ground. 3.0L SHO, 3.8L Supercharged, 5.0L MFI H.O.: Mass Airflow Sensors, measured between terminal D (upper most) and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page 767 Air Flow Meter/Sensor: Locations Engine Compartment Component Locations RH Front Of Engine Compartment, In Air Duct Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page 768 Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart Barometric Pressure Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart Article No. 89-1-12 ^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART ^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS FORD: 1984-87 ALL CARLINES LINCOLN-MERCURY: 1984-89 ALL CARLINES LIGHT TRUCK: 1984-89 ALL TRUCKLINES This article is being republished in its entirety to include the MAP sensor application for the 2.3L HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine. ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP and BAP sensor application chart has been assembled to assist technicians in making sure the correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy, erratic engine idle or hesitation on acceleration may result. ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the correct service part applications. NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF THE FORD PARTS CATALOG. LIGHT TRUCK MAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE 1984-86 2.3L OHC All E6TZ-9F479-A MAP 1986-87 3.0L EFI All E6FZ-9F479-A MAP 1988-89 3.0L EFI All E7FZ-9F479-A MAP 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 4.9L EFI 5.0L EFI 7.5L EFI 1988-89 5.8L EFI All E7FZ-9F479-A MAP PASSENGER CAR MAP AND BAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE 1984-89 1.6L EFI All E7FZ-12A644-A BAP 1.9L EFI 2.3L Turbo 1989 3.0 "SHO" All E7FZ-12A644-A BAP 1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP (Mustang) 1989 5.0L Mass Air All E8FZ-12A644-A BAP 1984 2.3L HSC FBC All E6PZ-9F479-A MAP 1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP 2.5L HSC CFI 1984-85 3.8L CFI All E5SZ-9F479-A MAP 1984-85 5.0L CFI All E6TZ-9F479-A MAP 1986 2.3L OHC All E6FZ-9F479-A MAP Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart > Page 773 3.0L EFI 3.8L CFI 5.0 SEFI 1984-85 2.3L OHC All E6FZ-9F479-A MAP 1987-89 1.9L CFI All E7DZ-9F479-A MAP 2.3L HSC CFI 2.5L HSC CFI 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI PART NUMBER PART NAME CLASS E7FZ-12A644-A BAP Sensor B E8FZ-12A644-A BAP Sensor B E6PZ-9F479-A MAP Sensor B E5SZ-9F479-A MAP Sensor AM E6TZ-9F479-A MAP Sensor BM E6FZ-9F479-A MAP Sensor B E7DZ-9F479-A MAP Sensor B E7FZ-9F479-A MAP Sensor B OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 620800, 631900, 640200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > Page 774 Pinpoint Test DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP) Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation Fig. 15 Ignition barometric pressure switch This switch, Fig. 15, controls spark timing and/or other electrical devices according to altitude. Calibration resistors in the switch assembly cause the ignition module to vary the spark timing. Spark timing is advanced for vehicle operation above a predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some switch assemblies control both spark timing and another device while other switch assemblies control only one or the other. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing Fig. 33 Ignition barometric pressure switch resistance chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values in chart, Fig. 33. 3. Replace switch if resistance is not within specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair Camshaft Synchronizer Assembly: Service and Repair CAUTION: Prior to starting this procedure, set cylinder number one to 26 degrees After Top Dead Center (ATDC) of the compression stroke. Then note the position of the camshaft sensor electrical connector. The installation procedure requires that the connector be located in the same position. Removal 1. Disconnect negative battery cable. 2. Remove camshaft sensor assembly. 3. Remove synchronizer clamp (bolt and washer assembly). 4. Remove synchronizer from front engine cover assembly. NOTE: The intermediate oil pump driveshaft should be removed with the synchronizer assembly. Installation CAUTION: If the replacement synchronizer does not contain a plastic locator cover tool, a special service tool such as Syncro Positioner T89P-12200-A or equivalent must be obtained prior to installation of the replacement synchronizer. Failure to follow this procedure will result in improper synchronizer alignment. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. 1. If the plastic locator cover tool is not attached to the replacement synchronizer assembly, attach Syncro Positioner Tool T89P-12200-A or equivalent as follows: a. Engage synchronizer vane into the radial slot of the tool. b. Rotate tool on synchronizer base until tool boss engages the base notch. The cover tool should be square and in contact with entire top surface of synchronizer base. 2. Transfer intermediate oil pump driveshaft from old synchronizer to replacement synchronizer assembly. 3. Install synchronizer assembly so that gear engagement occurs when arrow on locator tool is pointed approximately 30 degrees counterclockwise from the front face of the engine block. This step will locate camshaft sensor electrical connector in the pre-removal position. 4. Install synchronizer base clamp (washer and bolt) and tighten bolt to 20-30 Nm (15-22 lb-ft). 5 Remove Syncro Positioner Tool T89P-12200-A or equivalent. 6. Install and connect camshaft sensor. CAUTION: If camshaft sensor electrical connector is not positioned properly (i.e. contacting the A/C bracket or forward of the supercharger drive belt), DO NOT reposition the connector by rotating the synchronizer base. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer and repeat installation procedure, beginning with Step 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair > Page 784 7. Connect negative battery cable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Temperature Sensors 1.3L VAT: Measured between upper terminal (GN/BK wire) of airflow sensor and ground. 1.6L VAT: Measured between terminal 25 (upper terminal on airflow connector) and ground. 2.2L VAT: Measured between first (R wire) and fifth (LG/W wire) of airflow sensor. All others with EEC IV VAT: Measured between upper terminal (LG/P wire) of airflow sensor and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 789 Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 790 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Compartment. Top Front Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 791 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 4 Engine coolant temperature sensor The ECT, Fig. 8, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Top Front Of Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 797 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 798 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 799 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft timing sensor is a single Hall effect magnetic switch, actuated by three vanes on the crankshaft damper and pulley assembly. The signal generated by this sensor the Profile Ignition Pick-up (PIP). It provides base timing and RPM information to the DIS module and EEC IV module. Initial or base, timing is set at 10 degrees BTDC and is not adjustable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 800 Crankshaft Position Sensor: Adjustments INITIAL TIMING Initial timing is preset at 10~ plus or minus 2~ BTDC and is not adjustable. PIP SENSOR 1. Install Crankshaft Sensor Gauge T89P-AH or equivalent to outside surface of one vane of shutter. Gauge is magnetic and will conform to the shape of the vane. 2. Rotate crankshaft by HAND to align shutter vane with gauge into sensor air gap. Push sensor housing inward to contact gauge and tighten screws to 22-31 lb-in. CAUTION: Over tightening can cause damage to timing sensor. 3. Rotate crankshaft by HAND to position shutter vane with gauge outside of air gap. Remove magnetic gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 801 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect negative battery cable. 2. If necessary, loosen tensioner pulleys for A/C compressor and supercharger idler pulley belts, as well as removing belts from crankshaft pulley. 3. Disconnect sensor electrical connectors from engine wiring harness. 4. Raise vehicle and suitably support. Then remove upper and lower damper shield assemblies. 5. ON 89 MODELS: Remove crankshaft damper and pulley assembly using Universal Puller T67L-3600-A or equivalent. 6. Remove crankshaft sensor mounting screws and remove sensor. Installation 1. Position crankshaft sensor assembly on bracket. 2. Install two sensor attaching screws and tighten to 22-31 lb-in. 3. Install crankshaft damper and pulley assembly using crank gear and damper replacer T83T-6316-B or equivalent. Tighten pulley bolt to 103-132 lb-ft. 4. Install upper and lower damper shields and tighten fasteners to specification. Lower vehicle. 5. Route sensor wiring harness and connect both electrical connectors. Then install A/C and power steering belts and adjust to proper tension. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 806 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 807 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 808 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 809 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 810 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 811 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 812 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 813 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 814 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 815 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 816 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 817 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 818 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 819 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 820 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 821 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 822 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 823 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 824 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 825 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 826 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 827 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 828 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 829 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 830 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 831 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 832 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 833 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 834 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 835 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 836 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 837 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 838 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 839 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 840 EGR Valve Position Sensor: Description and Operation EGR valve position sensor The EGR valve position sensor provides the EEC system with an EGR valve position signal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Temperature Sensors 1.3L VAT: Measured between upper terminal (GN/BK wire) of airflow sensor and ground. 1.6L VAT: Measured between terminal 25 (upper terminal on airflow connector) and ground. 2.2L VAT: Measured between first (R wire) and fifth (LG/W wire) of airflow sensor. All others with EEC IV VAT: Measured between upper terminal (LG/P wire) of airflow sensor and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 844 Intake Air Temperature Sensor: Locations Engine Compartment Component Locations Top Rear Of Engine Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 845 Intake Air Temperature Sensor: Description and Operation Fig. 1 Air charge temperature (ACT) sensor The ACT sensor, Fig. 1, used on EFI models, provides the EFI system mixture (air/fuel) temperature information. The ACT is used as both as a density corrector to air flow calculation and to proportion the cold enrichment fuel flow. This sensor is mounted on an intake manifold runner or on the air cleaner. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Rear Of Engine Lower RH Side Of Engine, Under Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 849 Knock Sensor: Description and Operation Knock Sensor The knock sensor is a piezoelectric accelerator accelerometer. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5 - 6 KHz). The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP Sensor - Pinpoint Test DF Manual Correction Article No. 89-5A-6 EEC IV - PINPOINT TEST "DF" - MAP SENSOR GRAPH - SHOP MANUAL CORRECTION FORD: 1989 ESCORT, MUSTANG, TEMPO, TAURUS, AND THUNDERBIRD LINCOLN-MERCURY: 1989 TOPAZ, SABLE, COUGAR, CONTINENTAL, MARK VII, LINCOLN TOWN CAR LIGHT TRUCK: 1989 RANGER, BRONCO, AEROSTAR, F-SERIES, ECONOLINE ISSUE: The MAP sensor graph and data table on page 17-67 of the 1989 Engine Emissions Diagnosis Manual, Volume H is incorrect. ACTION: If service is required, refer to this TSB for the correct graph and data. This information should be inserted into your 1989 Engine Emissions Diagnosis Manual, Volume H, Section 17-67 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-67 Manifold Absolute Pressure (MAP)/ Barometric Pressure (BP) Sensor Pinpoint Test DF Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 854 MAP Sensor Graph NOTE: MAP sensor output frequency versus manifold vacuum data is based on 30.0 in-Hg barometric pressure. 1989 17-68 EEC-IV - Pinpoint Tests - All Vehicles Manifold Absolute Pressure (MAP)/ Barometric Pressure (BP) Sensor Pinpoint Test DF Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 855 MAP/BP Sensor Graph (KOEO) NOTE: Frequency may vary plus or minus 3 Hz from the values given due to sensor variations. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 856 Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart Article No. 89-1-12 ^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART ^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS FORD: 1984-87 ALL CARLINES LINCOLN-MERCURY: 1984-89 ALL CARLINES LIGHT TRUCK: 1984-89 ALL TRUCKLINES This article is being republished in its entirety to include the MAP sensor application for the 2.3L HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine. ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP and BAP sensor application chart has been assembled to assist technicians in making sure the correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy, erratic engine idle or hesitation on acceleration may result. ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the correct service part applications. NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF THE FORD PARTS CATALOG. LIGHT TRUCK MAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE 1984-86 2.3L OHC All E6TZ-9F479-A MAP 1986-87 3.0L EFI All E6FZ-9F479-A MAP 1988-89 3.0L EFI All E7FZ-9F479-A MAP 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 4.9L EFI 5.0L EFI 7.5L EFI 1988-89 5.8L EFI All E7FZ-9F479-A MAP PASSENGER CAR MAP AND BAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE 1984-89 1.6L EFI All E7FZ-12A644-A BAP 1.9L EFI 2.3L Turbo 1989 3.0 "SHO" All E7FZ-12A644-A BAP 1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP (Mustang) 1989 5.0L Mass Air All E8FZ-12A644-A BAP 1984 2.3L HSC FBC All E6PZ-9F479-A MAP 1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP 2.5L HSC CFI 1984-85 3.8L CFI All E5SZ-9F479-A MAP 1984-85 5.0L CFI All E6TZ-9F479-A MAP 1986 2.3L OHC All E6FZ-9F479-A MAP Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 857 3.0L EFI 3.8L CFI 5.0 SEFI 1984-85 2.3L OHC All E6FZ-9F479-A MAP 1987-89 1.9L CFI All E7DZ-9F479-A MAP 2.3L HSC CFI 2.5L HSC CFI 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI PART NUMBER PART NAME CLASS E7FZ-12A644-A BAP Sensor B E8FZ-12A644-A BAP Sensor B E6PZ-9F479-A MAP Sensor B E5SZ-9F479-A MAP Sensor AM E6TZ-9F479-A MAP Sensor BM E6FZ-9F479-A MAP Sensor B E7DZ-9F479-A MAP Sensor B E7FZ-9F479-A MAP Sensor B OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 620800, 631900, 640200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 858 Pinpoint Test DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP) Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 859 Manifold Pressure/Vacuum Sensor: Locations Engine Compartment Component Locations RH Rear Of Engine Compartment Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 864 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 865 Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 866 Oxygen Sensor: Locations Rear Of Engine In RH Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 867 Oxygen Sensor: Description and Operation Fig. 9 Exhaust gas oxygen (EGO) sensor The EGO, Fig. 9, sensor supplies the ECA assembly with a rich or lean condition during engine operation. On 4-97.6 and 4-140 engines, the EGO sensor is threaded into the center of the exhaust manifold. On V6 engines, the EGO sensor is threaded into the rear portion of the left and right exhaust manifold assemblies. On V8 engines, the EGO sensor is threaded into the rear portion of the right exhaust manifold assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations I/P Components LH Side Of I/P, On Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Supercharger Removal/Assembly EGR Valve Installation The Pressure Feedback Electronic (PFE) Exhaust Gas Recirculation (EGR) Transducer is located at the Top Rear Center of the Engine. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 878 Technical Service Bulletin # 88265 Date: 881221 EEC IV Pinpoint - Test Manual Correction EEC IV - PINPOINT TESTS A, N AND P - 3.0L "SHO" AND 3.8L "SUPERCHARGED" ENGINES SHOP MANUAL CORRECTION Article No. 88-26-5 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: EEC IV pinpoint test "A" EEC IV No Start, "N" Ignition/Erratic and "P" Spark Timing Check are incorrect as published in the 1989 Engine/Emissions Diagnosis Manual, Section 17-5, 17-310 and 17-322. The Diagnostic schematics did not include the 3.0L "SHO" and 3.8L "Supercharged" crankshaft sensor connectors or the ignition coil connectors. ACTION: Use the pinpoint diagnostic information on pages 15 through 20 of this TSB article. This information should be inserted in your 1989 Engine/Emission Diagnosis Shop Manual, Section 17-5, 17-310 and 17-322 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODE: 680000 EEC-IV No Start EEC-IV-Pinpoint Tests - All Vehicles 1989 17-5 EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 879 Pinpoint Test Schematic 17-6 1989 EEC-IV-Pinpoint Tests - All Vehicles EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 880 WARNING STOP THIS TEST AT THE FIRST SIGN OF A FUEL LEAK AND SERVICE AS REQUIRED. CAUTION No open flame - No smoking during fuel delivery checks. Ignition/Erratic Diagnostic Monitor (IDM) EEC-IV - Pinpoint Tests - All Vehicles 1989 17-309 Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 881 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 882 Pinpoint Test Schematic 17-310 1989 EEC-IV - Pinpoint Tests - All Vehicles Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Spark Timing Check EEC-IV - Pinpoint Tests - All Vehicles 1989 17-321 Spark Timing Check Pinpoint P Note Test You should enter this Pinpoint Test only when directed here from Quick Test Step 4.0, when a Service Code 18 is received in Quick Test Step 5.0 or a code 49 is received in Quick Test Step 6.0. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 883 Remember To prevent the replacement of good components, be aware that the following non-EEC areas may be at fault: ^ Base Engine ^ Camshaft Sensor (CID) ^ Distributor ^ Single Hall Crankshaft Sensor (PIP) ^ TFI or DIS Module ^ Dual Hall Sensor This Pinpoint Test is intended to diagnose only the following: ^ Harness Spout Circuit ^ Base Timing ^ Processor Assembly (-12A650-) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 884 Pinpoint Test Schematic 17-322 1989 EEC-IV - Pinpoint Tests - All Vehicles Pinpoint Spark Timing Check Test P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications Throttle Position Sensor (TPS) Engines with EEC III: Turn ignition to RUN position and remove vacuum hose from throttle kicker as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV: Connect positive (+) probe of DVOM along the DG/LG wire of TPS. Connect negative (-) probe along the BK/W wire and turn ignition on but do not start engine. Adjust TPS to specified value. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 887 Throttle Position Sensor: Mechanical Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 888 Throttle Position Sensor: Description and Operation The throttle position sensor is used by the EEC computer to determine the operating mode (closed throttle, part throttle or wide open throttle) for selection of the proper air/fuel mixture, spark and EGR. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 889 Throttle Position Sensor: Adjustments Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision Vehicle Speed Sensor: Technical Service Bulletins Speed Sensor Resistance Reading - Manual Revision ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1988-PAGE 19-109-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-PAGE 17-142-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1990-PAGE 17-146-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED Article No. 90-18B-1 FORD: 1988-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1988-90 COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1988-90 AEROSTAR ISSUE: The resistance reading of 10,000 ohm shown in the Vehicle Speed Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 894 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 895 Pinpoint Test DP on page 19-109 OF THE 1988 Engine/Emissions Diagnosis Shop Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 896 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 897 Manual, page 17-142 of the 1989 Engine/Emissions Diagnosis Shop Manual Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 898 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 899 and page 17-146 of the 1990 Engine/Emissions Diagnosis Shop Manual is incorrect. The correct reading is 500 ohms. ACTION: Refer to the pages following this TSB article for the revised test procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 900 Vehicle Speed Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 901 Vehicle Speed Sensor: Locations LH Rear Side Of Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 902 Vehicle Speed Sensor: Service and Repair Fig. 26 Speed Sensor Replacement. Cougar, Crown Victoria, Town Car, Mark VII, Grand Marquis, & Thunderbird 1. Raise and support vehicle. 2. Remove bolt retaining the sensor attaching clip, then the sensor and driven gear from transmission, Fig. 26. 3. Disconnect sensor electrical connector. 4. Disconnect speedometer cable by pulling it out of speed sensor, Fig. 26. Do not attempt to remove spring retaining clip with speedometer cable in sensor. 5. Remove retainer, then separate sensor from driven gear. 6. Position sensor to driven gear and install retainer. 7. Connect electrical connector. 8. Ensure internal O-ring is properly seated in sensor housing. Snap speedometer cable into sensor housing. 9. Install sensor to transmission. 10. Lower vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 908 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 909 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 910 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 911 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 912 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 913 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 914 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 915 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 916 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 917 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 918 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 919 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 920 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 921 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 922 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 923 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 924 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 925 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 926 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 927 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 928 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 929 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 930 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 931 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 932 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 933 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 934 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 935 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 936 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 937 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 938 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 939 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 940 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 941 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 942 EGR Valve Position Sensor: Description and Operation EGR valve position sensor The EGR valve position sensor provides the EEC system with an EGR valve position signal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Supercharger Removal/Assembly EGR Valve Installation The Pressure Feedback Electronic (PFE) Exhaust Gas Recirculation (EGR) Transducer is located at the Top Rear Center of the Engine. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications Air Flow Meter/Sensor: Specifications Mass or Vane Airflow Sensor Engines with multi-port injection. 1.6L MFI, 1.9L MFI, 2.3L MFI: Vane Airflow Sensors, measured between second upper terminal (W/BK wire) and ground. 3.0L SHO, 3.8L Supercharged, 5.0L MFI H.O.: Mass Airflow Sensors, measured between terminal D (upper most) and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 950 Air Flow Meter/Sensor: Locations Engine Compartment Component Locations RH Front Of Engine Compartment, In Air Duct Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 951 Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations FUEL INJECTORS: The fuel injectors are mounted in the lower intake manifold. FUEL PRESSURE REGULATOR: The fuel pressure regulator is attached to the fuel supply manifold. FUEL FILTER: The filter is located downstream of the electric electric fuel pump and is mounted on the underbody. FUEL PUMP: The fuel pump is mounted on the fuel sender assembly inside of the fuel tank. FUEL PUMP RELAY: LH side of trunk, behind wheelwell. INERTIA SWITCH: The inertia switch is located on the LH side of trunk, behind wheelwell. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 957 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 958 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 959 Fuel Pump Inertia Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch PURPOSE The inertia switch is used to shut the fuel pump "Off" in the event of a collision. CONSTRUCTION The inertia switch consists of a steel ball held in place by a magnet. OPERATION When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate. This opens the electrical contacts of the switch and disrupts power to the electric fuel pump. The engine will quit running within a few seconds after the fuel pump loses power. The inertia switch must then be manually reset before the engine can be restarted. WARNING: DO NOT reset the inertia switch button if you see or smell fuel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 964 Technical Service Bulletin # 88265 Date: 881221 EEC IV Pinpoint - Test Manual Correction EEC IV - PINPOINT TESTS A, N AND P - 3.0L "SHO" AND 3.8L "SUPERCHARGED" ENGINES SHOP MANUAL CORRECTION Article No. 88-26-5 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: EEC IV pinpoint test "A" EEC IV No Start, "N" Ignition/Erratic and "P" Spark Timing Check are incorrect as published in the 1989 Engine/Emissions Diagnosis Manual, Section 17-5, 17-310 and 17-322. The Diagnostic schematics did not include the 3.0L "SHO" and 3.8L "Supercharged" crankshaft sensor connectors or the ignition coil connectors. ACTION: Use the pinpoint diagnostic information on pages 15 through 20 of this TSB article. This information should be inserted in your 1989 Engine/Emission Diagnosis Shop Manual, Section 17-5, 17-310 and 17-322 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODE: 680000 EEC-IV No Start EEC-IV-Pinpoint Tests - All Vehicles 1989 17-5 EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 965 Pinpoint Test Schematic 17-6 1989 EEC-IV-Pinpoint Tests - All Vehicles EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 966 WARNING STOP THIS TEST AT THE FIRST SIGN OF A FUEL LEAK AND SERVICE AS REQUIRED. CAUTION No open flame - No smoking during fuel delivery checks. Ignition/Erratic Diagnostic Monitor (IDM) EEC-IV - Pinpoint Tests - All Vehicles 1989 17-309 Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 967 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 968 Pinpoint Test Schematic 17-310 1989 EEC-IV - Pinpoint Tests - All Vehicles Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Spark Timing Check EEC-IV - Pinpoint Tests - All Vehicles 1989 17-321 Spark Timing Check Pinpoint P Note Test You should enter this Pinpoint Test only when directed here from Quick Test Step 4.0, when a Service Code 18 is received in Quick Test Step 5.0 or a code 49 is received in Quick Test Step 6.0. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 969 Remember To prevent the replacement of good components, be aware that the following non-EEC areas may be at fault: ^ Base Engine ^ Camshaft Sensor (CID) ^ Distributor ^ Single Hall Crankshaft Sensor (PIP) ^ TFI or DIS Module ^ Dual Hall Sensor This Pinpoint Test is intended to diagnose only the following: ^ Harness Spout Circuit ^ Base Timing ^ Processor Assembly (-12A650-) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 970 Pinpoint Test Schematic 17-322 1989 EEC-IV - Pinpoint Tests - All Vehicles Pinpoint Spark Timing Check Test P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications Throttle Position Sensor (TPS) Engines with EEC III: Turn ignition to RUN position and remove vacuum hose from throttle kicker as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV: Connect positive (+) probe of DVOM along the DG/LG wire of TPS. Connect negative (-) probe along the BK/W wire and turn ignition on but do not start engine. Adjust TPS to specified value. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 973 Throttle Position Sensor: Mechanical Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 974 Throttle Position Sensor: Description and Operation The throttle position sensor is used by the EEC computer to determine the operating mode (closed throttle, part throttle or wide open throttle) for selection of the proper air/fuel mixture, spark and EGR. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 975 Throttle Position Sensor: Adjustments Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair Camshaft Synchronizer Assembly: Service and Repair CAUTION: Prior to starting this procedure, set cylinder number one to 26 degrees After Top Dead Center (ATDC) of the compression stroke. Then note the position of the camshaft sensor electrical connector. The installation procedure requires that the connector be located in the same position. Removal 1. Disconnect negative battery cable. 2. Remove camshaft sensor assembly. 3. Remove synchronizer clamp (bolt and washer assembly). 4. Remove synchronizer from front engine cover assembly. NOTE: The intermediate oil pump driveshaft should be removed with the synchronizer assembly. Installation CAUTION: If the replacement synchronizer does not contain a plastic locator cover tool, a special service tool such as Syncro Positioner T89P-12200-A or equivalent must be obtained prior to installation of the replacement synchronizer. Failure to follow this procedure will result in improper synchronizer alignment. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. 1. If the plastic locator cover tool is not attached to the replacement synchronizer assembly, attach Syncro Positioner Tool T89P-12200-A or equivalent as follows: a. Engage synchronizer vane into the radial slot of the tool. b. Rotate tool on synchronizer base until tool boss engages the base notch. The cover tool should be square and in contact with entire top surface of synchronizer base. 2. Transfer intermediate oil pump driveshaft from old synchronizer to replacement synchronizer assembly. 3. Install synchronizer assembly so that gear engagement occurs when arrow on locator tool is pointed approximately 30 degrees counterclockwise from the front face of the engine block. This step will locate camshaft sensor electrical connector in the pre-removal position. 4. Install synchronizer base clamp (washer and bolt) and tighten bolt to 20-30 Nm (15-22 lb-ft). 5 Remove Syncro Positioner Tool T89P-12200-A or equivalent. 6. Install and connect camshaft sensor. CAUTION: If camshaft sensor electrical connector is not positioned properly (i.e. contacting the A/C bracket or forward of the supercharger drive belt), DO NOT reposition the connector by rotating the synchronizer base. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer and repeat installation procedure, beginning with Step 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair > Page 981 7. Connect negative battery cable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Top Front Of Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 987 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 988 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 989 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft timing sensor is a single Hall effect magnetic switch, actuated by three vanes on the crankshaft damper and pulley assembly. The signal generated by this sensor the Profile Ignition Pick-up (PIP). It provides base timing and RPM information to the DIS module and EEC IV module. Initial or base, timing is set at 10 degrees BTDC and is not adjustable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 990 Crankshaft Position Sensor: Adjustments INITIAL TIMING Initial timing is preset at 10~ plus or minus 2~ BTDC and is not adjustable. PIP SENSOR 1. Install Crankshaft Sensor Gauge T89P-AH or equivalent to outside surface of one vane of shutter. Gauge is magnetic and will conform to the shape of the vane. 2. Rotate crankshaft by HAND to align shutter vane with gauge into sensor air gap. Push sensor housing inward to contact gauge and tighten screws to 22-31 lb-in. CAUTION: Over tightening can cause damage to timing sensor. 3. Rotate crankshaft by HAND to position shutter vane with gauge outside of air gap. Remove magnetic gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 991 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect negative battery cable. 2. If necessary, loosen tensioner pulleys for A/C compressor and supercharger idler pulley belts, as well as removing belts from crankshaft pulley. 3. Disconnect sensor electrical connectors from engine wiring harness. 4. Raise vehicle and suitably support. Then remove upper and lower damper shield assemblies. 5. ON 89 MODELS: Remove crankshaft damper and pulley assembly using Universal Puller T67L-3600-A or equivalent. 6. Remove crankshaft sensor mounting screws and remove sensor. Installation 1. Position crankshaft sensor assembly on bracket. 2. Install two sensor attaching screws and tighten to 22-31 lb-in. 3. Install crankshaft damper and pulley assembly using crank gear and damper replacer T83T-6316-B or equivalent. Tighten pulley bolt to 103-132 lb-ft. 4. Install upper and lower damper shields and tighten fasteners to specification. Lower vehicle. 5. Route sensor wiring harness and connect both electrical connectors. Then install A/C and power steering belts and adjust to proper tension. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: Customer Interest Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Rear Of Engine Lower RH Side Of Engine, Under Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 1009 Knock Sensor: Description and Operation Knock Sensor The knock sensor is a piezoelectric accelerator accelerometer. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5 - 6 KHz). The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled Seat Belt Buckle Switch: Customer Interest Seat Belt Warning Lamp - Stays ON With Belt Buckled LAMP-WARNING STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES SAFETY BELT-WARNING LAMP STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES Article No. 89-14-1 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A safety belt warning lamp that stays "on" even though the safety belt is buckled may be caused by the passive restraint control assembly connectors. The two connectors may have been installed into the control assembly and not taped back to the wire harness on Canadian units without the motorized passive restraint system. Also, the jumper wire assembly to make sure of proper warning lamp/chime operation was not Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled > Page 1019 installed. ACTION: Disconnect passive restraint control assembly connectors and install a jumper wire assembly. Refer to the following procedure for service details. 1. Remove the left hand interior trim panel in the luggage compartment. Refer to the 1989 Thunderbird/Cougar Shop Manual, Page 45-03-05. 2. Disconnect both passive restraint control assembly connectors and tape them back to the wire harness, Figure 1. 3. Install a jumper wire assembly (E9SZ-14K691-A), Figure 1. 4. Reinstall the luggage compartment trim panel. PART NUMBER PART NAME CLASS E9SZ-14K691-A Jumper Wire Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Safety Restraint Warranty Coverage OPERATION DESCRIPTION TIME 891401A Install Jumper Wire 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 14A504 79 OASIS CODES: 1051, 2300, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled Seat Belt Buckle Switch: All Technical Service Bulletins Seat Belt Warning Lamp - Stays ON With Belt Buckled LAMP-WARNING STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES SAFETY BELT-WARNING LAMP STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES Article No. 89-14-1 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A safety belt warning lamp that stays "on" even though the safety belt is buckled may be caused by the passive restraint control assembly connectors. The two connectors may have been installed into the control assembly and not taped back to the wire harness on Canadian units without the motorized passive restraint system. Also, the jumper wire assembly to make sure of proper warning lamp/chime operation was not Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled > Page 1025 installed. ACTION: Disconnect passive restraint control assembly connectors and install a jumper wire assembly. Refer to the following procedure for service details. 1. Remove the left hand interior trim panel in the luggage compartment. Refer to the 1989 Thunderbird/Cougar Shop Manual, Page 45-03-05. 2. Disconnect both passive restraint control assembly connectors and tape them back to the wire harness, Figure 1. 3. Install a jumper wire assembly (E9SZ-14K691-A), Figure 1. 4. Reinstall the luggage compartment trim panel. PART NUMBER PART NAME CLASS E9SZ-14K691-A Jumper Wire Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Safety Restraint Warranty Coverage OPERATION DESCRIPTION TIME 891401A Install Jumper Wire 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 14A504 79 OASIS CODES: 1051, 2300, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 1026 Seat Belt Buckle Switch: Locations In Driver's Seat Belt Buckle Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications Seat Belt Retractor Limit Switch: Specifications A-Pillar Limit Switch Bracket Screws ........................................................................................................................................... 2.2-3.3 Nm (20-29 lb-in) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications > Page 1030 Seat Belt Retractor Limit Switch: Locations Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications > Page 1031 Seat Belt Retractor Limit Switch: Service and Repair REMOVAL and INSTALLATION 1. Disconnect switch from wiring harness. 2. Using an ohmmeter such as Rotunda Digital Volt Ohm Meter 007-00001 or equivalent, probe across switch terminals. NOTE: Switch is normally closed when plunger in free (extended) position. Switch must open when plunger is depressed. 3. Remove Torx(r) bolt and move spacer downward. This will allow limit switch removal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications > Page 1032 4. To install, reverse Steps 1, 2 and 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Clutch Switch Jumper Clutch Pedal Position Switch: Locations Clutch Switch Jumper On Clutch Pedal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Clutch Switch Jumper > Page 1038 Clutch Pedal Position Switch: Locations Clutch Pedal Switch I/P Components On Clutch Pedal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Page 1039 Clutch Pedal Position Switch: Adjustments Fig. 18 Clutch Interlock Three Function Switch. Cougar & Thunderbird 1. Disconnect switch electrical connector, Fig. 18. 2. Using a volt-ohmmeter, check for continuity at the following switch terminals. a. EFI switch terminals 5 and 6 should be open with clutch pedal released. Terminals 5 and 6 should show continuity, within two inches of clutch pedal travel. b. Speed control release switch terminals 3 and 4 should be show continuity with clutch pedal released. Terminals 3 and 4 should open within two inches of clutch pedal travel. c. Clutch interlock switch terminals 1 and 2 should be open with clutch pedal released. Terminals 1 and 2 should close within one inch from full clutch pedal travel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Page 1040 Clutch Pedal Position Switch: Service and Repair Fig. 18 Clutch Interlock Three Function Switch. Cougar & Thunderbird 1. Disconnect switch electrical connector, Fig. 18. 2. Separate switch tab from clip by pulling downward on the clip. 3. Expose switch plastic retainer by rotating switch 1/2 turn. 4. Separate switch from retainer by pressing tabs together and allowing retainer to move rearward. 5. Remove switch from push rod. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: Customer Interest Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair Removal 1. Place the selector lever in the MANUAL LOW position. 2. Disconnect battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the Neutral Start Switch electrical harness from the Neutral Start Switch by PUSHING the harness straight UP OFF the switch using a long-bladed screwdriver underneath the rubber plug section of the harness. 5. Remove the Neutral Start Switch and O-ring using Neutral Start Switch Socket or equivalent, assembled to a ratchet 24 cm (9 1/2 inches) in length. Once the socket and ratchet are on the switch, sufficient clearance for tool movement can be gained by reaching from the REAR of the transmission over the extension housing area while standing on a stool. CAUTION: Use the Neutral Start Switch Socket or equivalent for both removing and installing the switch. Other tools could crush or puncture the walls of the switch. Installation 1. Install the Neutral Start Switch and O-ring. CAUTION: Exercise care not to damage the switch terminals. Tighten to 11-15 Nm (8-11 ft-lbs) using a clicker-type torque wrench, the Neutral Start Switch socket tool, and by following the method in Step 4 of the REMOVAL procedure for tool clearance. 2. Connect the Neutral Start Switch electrical harness to the Neutral Start Switch. 3. Lower the vehicle from the hoist. 4. Connect battery ground cable. 5. Check the operation of the Neutral Start Switch in each position with the parking brake ENGAGED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations I/P Components LH Side Of I/P, On Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair The steering sensor is located at the lower end of the steering column. It may be removed with the steering column either in or out of the vehicle. 1. Disconnect sensor electrical connectors from wiring harness. 2. Disconnect sensor electrical connectors at bracket under instrument panel. 3. Remove speed sensor attaching screws, then remove sensor. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Brake Switch, Suspension Control > Component Information > Service and Repair Brake Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from brake sensor switch. 3. Remove sensor switch from brake control valve body. 4. Reverse procedure to install. Torque brake sensor switch to 8---10 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair The steering sensor is located at the lower end of the steering column. It may be removed with the steering column either in or out of the vehicle. 1. Disconnect sensor electrical connectors from wiring harness. 2. Disconnect sensor electrical connectors at bracket under instrument panel. 3. Remove speed sensor attaching screws, then remove sensor. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair 1. Remove console top to console base attaching screws, then disconnect top panel from console base. 2. Disconnect fog lamp switch and ride control switch electrical connectors. 3. Remove switch attaching screws under panel. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Gear Sensor/Switch, M/T > Component Information > Locations Gear Sensor/Switch: Locations LH Side Of Manual Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1089 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1090 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1091 Power Windows Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1092 Power Window Switch: Service and Repair Removal 1. Using a flat blade screwdriver, pry switch housing up. Rotate housing up and out of armrest to remove. 2. Remove two connector retaining screws from bottom of switch housing. 3. The switch is held in place by the electrical contact pins. To remove the switch, carefully pry the switch from the connector with a small screwdriver. Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 1093 1. To install, position switch to the connector and press firmly into place. NOTE: The switch is keyed to connector and can only be installed one way. 2. Install connector to switch housing using two retaining screws. 3. Install switch housing to armrest. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Engine Compartment Component Locations In Bottom Of Reservoir Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1102 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1103 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1104 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1109 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1110 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 1111 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1112 Wiper Switch: Testing and Inspection Continuity Test Fig. 40 Wiper Switch Continuity Test When testing a non-intermittent wiper switch, a self-powered test lamp or an ohmmeter can be used to check continuity. When testing an intermittent wiper switch, use only an ohmmeter to check continuity. When taking test readings move the switch lever to detect marginal switch operation. Refer to Fig. 40 for switch terminal identification and continuity readings. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 1113 Wiper Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove four steering column shroud attaching screws, then grasp top and bottom of shroud and separate. 3. Using a screwdriver, disconnect wire connector from wiper switch. 4. Remove two wiper switch attaching screws, then remove switch. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Wheel Alignment Wheel Alignment Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Front Wheel Alignment > Page 1119 Control System And Capacity Data Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber Alignment: Service and Repair Camber Camber is adjusted by rotating a cam bolt at lower control arm inner pivot. Loosen nut securing adjustment and adjust by rotating bolt head. Lock adjustment by holding bolt and torque nut to 125 ft lb. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber > Page 1122 Alignment: Service and Repair Caster Caster is adjusted by moving the tension strut relative to the front sub-frame. Loosen nuts securing strut to sub-frame and adjust caster by running the nuts in appropriate direction until desired setting is achieved. The setting should be locked by holding adjusting nut and torquing locknut to 117 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber > Page 1123 Alignment: Service and Repair Rear Camber Camber is adjusted by rotating a cam bolt at upper control arm inner pivot. Loosen nut securing adjustment and adjust by rotating head of bolt. Lock adjustment by holding bolt and torque nut to 98 ft lb. Toe The recommended adjustment sequence for rear alignment is to set toe then camber. Toe should be rechecked before final tightening. Toe is adjusted by rotating a cam bolt at lower arm inner pivot. Loosen nut securing adjustment and adjust by rotating bolt head. Lock adjustment by holding bolt and torque nut to 170 ft lb. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Camber > Page 1124 Alignment: Service and Repair Toe Toe-in Adjustment 1. Check to see that steering shaft and steering wheel marks are in alignment and in the top position. 2. Loosen clamp screw on tie rod bellows and free the seal on the rod to prevent twisting of bellows, Fig. 1. 3. Place opened end wrench on flats of tie rod socket to prevent socket from turning, then loosen tie rod jam nuts. 4. Use suitable pliers to turn tie rod inner end to correct the adjustment to specifications. Do not use pliers on tie rod threads. Turning to reduce number of threads showing will increase toe-in. Turning in opposite direction will reduce toe-in. 5. Torque tie rod jam nuts to 43-50 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections Fuel Pressure: Technical Service Bulletins Fuel Pressure Specification - Corrections ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-SECTION 11-SPECIFICATION CORRECTIONS ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-SECTION 17-SPECIFICATION CORRECTIONS Article No. 89-12A-25 FORD: 1989 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1989 AEROSTAR, BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER ISSUE: The pressure values shown for the 2.5L CFI engine in both "Key on engine off" and "running" conditions are incorrectly shown in the Electric Fuel Delivery System (EFD) on page 11-14 and the Fuel Control Pinpoint Test H on page 17-185. The 1988 date in the chart titles for both Passenger Car Engines and Light Truck Engines is incorrect on page 17-185. The 3.0L SHO SEFI "Key on engine off" value in the chart on page 11-14 is incorrect. ACTION: Refer to the pages following this TSB article for the corrected charts. This information should be inserted in your 1989 Engine Emissions Diagnosis Manual, pages 11-14 and 17-185. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 Fuel Delivery Systems 1989 11-13 Electric Fuel Delivery System EFD Electrical Schematic VEHICLE APPLICATION E Series 1988 and later model years, EFI F Series 1986 and later model years, EFI 11-14 1989 Fuel Delivery Systems Electric Fuel Delivery System EFD Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 1130 FUEL PRESSURE SPECIFICATION TABLE EEC-IV - Pinpoint Tests - All Vehicles 1989 17-185 Fuel Control Pinpoint Test GH Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 1131 FUEL PRESSURE SPECIFICATION TABLE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 1132 17-186 1989 EEC-IV-Pinpoint Tests-All Vehicles Fuel Control Pinpoint Test H Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 1133 Fuel Pressure: Specifications Key On Engine Off 35 - 40 psi Key On Engine Running 30 - 40 psi Engine Running Vacuum Hose Disconnected From Fuel Pressure Regulator 35 - 40 psi Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 1134 Fuel Pressure: Testing and Inspection STO Connector STATIC PRESSURE TEST 1. Check for adequate fuel supply. 2. Turn key OFF 3. Install fuel pressure gauge to test port on fuel rail. 4. Install test lead to fuel pump lead of STO test connector. 5. Turn Key ON Engine OFF (KOEO). 6. Ground test lead to run fuel pump. 7. Check to determine if fuel pressure is within acceptable limits. a. If pressure is low but greater than 3 psi (indicates fuel pump is running but not enough pressure) check for: ^ Plugged fuel filter ^ Kinked fuel line ^ Low voltage to pump (should be within 0.5 volts of battery voltage at connector). ^ Disconnect the fuel return line and note if fuel is being returned during this low pressure condition. If fuel is being returned, replace the fuel pressure regulator. Reconnect the fuel return line. b. If pressure is less than 3 psi (pump not running) check for: ^ Defective fuse link ^ Inertia switch open ^ Wiring at fuel pump/tank connector loose or open ^ Fuel pump ground connection at chassis loose or defective ^ Improper fuel pump relay operation If fuel supply and return lines are OK, and electrical supply and ground are OK, and fuel pressure is still low, replace fuel pump. DYNAMIC PRESSURE TEST 1. Disconnect and plug the vacuum line to the pressure regulator. 2. Start engine and run at idle. Check to determine if fuel pressure is within acceptable limits. Refer to SPECIFICATIONS. a. If pressure is low check for: ^ Plugged fuel filter ^ Restricted fuel line ^ Low voltage to pump (should be within 0.5 volts of battery voltage at connector). 3. Reconnect the vacuum line to the regulator. If fuel supply and return lines are OK, and electrical supply and ground is OK, and fuel pressure is still low, replace fuel pump. LEAKAGE TEST 1. Momentarily activate fuel pump by grounding test lead. Raise pressure to approximate operating pressure. 2. Remove ground from test lead and note pressure on gauge. Pressure should remain within 2 psi for 3 minutes after lead is ungrounded. a. If pressure is not maintained check for leaking fuel ^ Lines ^ Connectors ^ Injectors b. Disconnect fuel return line and plug engine side. Momentarily activate fuel pump by grounding test lead. Raise pressure to approximate operating pressure. If pressure holds replace regulator and retest. Reconnect the fuel return line. If pressure is not maintained replace fuel pump. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1143 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1144 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1145 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1146 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1147 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1148 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1149 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1150 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1151 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1152 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1153 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1154 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1155 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1156 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1157 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1158 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1159 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1165 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1166 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1167 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1168 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1169 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1170 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1171 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1172 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1173 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1174 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1175 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1176 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1177 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1178 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1179 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1180 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 1181 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1182 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1183 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1184 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1185 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1186 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1187 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1188 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1189 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1190 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1191 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1192 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1193 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1194 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1195 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1196 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1197 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1198 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1199 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1200 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1201 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1202 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1203 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1204 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1205 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1206 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1207 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1208 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1209 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1210 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1211 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1212 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1213 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1214 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1215 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 1216 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1217 Fuel injected Model, Idle Speed Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 1218 Idle Speed: Adjustments IDLE SPEED 1. Place automatic transmission in PARK. 2. Engine OFF, back out throttle plate stop screw clear off the throttle lever pad. 3. With a .010 in. feeler gauge between the throttle plate stop screw and throttle lever pad turn the screw in until contact is made then turn it an additional 1.5 turns. 4. Start engine and stabilize for 2 minutes then goose the engine and let it return to idle, lightly depress and release the accelerator and let engine idle. If idle problem still exists check for other possible causes. 5. On Automatic Overdrive Transmission (AOD) applications or Automatic Transaxle (AXOD) application check Throttle Valve (TV) adjustment. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when fueling vehicle or when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. NOTE: Methanol and ethanol are not interchangeable. Methanol fuel can be used only in vehicles designed for methanol fuels. Ethanol fuel can be used only in vehicles designed for ethanol fuels. WARNING: The fuel tubes leading from the fuel tank to the engine are under pressure during vehicle operation. When fuel injected engines are turned off, the fuel in the fuel tubes remains pressurized for long periods of time to provide quick start-ups. Special procedures for servicing these pressurized fuel systems are outlined in this section. These procedures should be followed to prevent accidental spraying of fuel, causing personal injury or a fire hazard. WARNING: Do not swallow fuel of any kind. Fuels such as methanol or fuel ethanol and gasoline or mixtures of these fuels are highly toxic and if swallowed can cause death or permanent injury. Swallowing methanol can also cause blindness. Immediately seek medical attention from a physician or poison control center to treat anyone who has swallowed fuel. Be aware that if fuel is swallowed, the onset of potential ill health effects may be delayed 12-24 hours. AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR OF ANY KIND CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY. AVOID GETTING FUEL LIQUID IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. ALLOWING ANY FUEL TO GET IN YOUR EYES WILL CAUSE SEVERE IRRITATION. FAILURE TO SEEK PROPER MEDICAL ATTENTION FOR FUEL CONTACT WITH THE EYES COULD LEAD TO PERMANENT INJURY. IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. MAKE SURE YOU WASH YOUR HANDS BEFORE HANDLING FOOD. FUELS CONTAINING GASOLINE SUCH AS FUEL METHANOL AND FUEL ETHANOL MAY CONTAIN BENZENE, WHICH IS A CANCER-CAUSING AGENT. IF YOU ARE TAKING MEDICATION FOR THE TREATMENT OF ALCOHOLISM, SUCH AS ANTABUSE OR OTHER FORMS OF DISULFIRAM, SKIN CONTACT WITH FUEL METHANOL, FUEL ETHANOL OR BREATHING THEIR VAPORS CAN CAUSE THE SAME KIND OF ADVERSE REACTION AS DRINKING ALCOHOLIC BEVERAGES. IN SENSITIVE INDIVIDUALS, SERIOUS PERSONAL INJURY OR SICKNESS COULD RESULT. IF YOU ARE TAKING SUCH MEDICATION, YOU SHOULD TAKE EXTRA CARE TO AVOID SKIN CONTACT WITH FUEL AND TO AVOID BREATHING ITS VAPORS. IF YOU DO GET FUEL ON YOUR SKIN, WASH IT OFF IMMEDIATELY. CONSULT A PHYSICIAN PROMPTLY IF YOU EXPERIENCE AN ADVERSE REACTION. WARNING: Do not modify the fuel system configuration or components or replace components with parts not especially designed for use with fuel methanol. Ford motor company has specially-designed the materials, components and system configuration for methanol-fueled vehicles and each particular system is precisely calibrated for efficient operation. Ford ethanol vehicles require the same parts as the methanol-fueled vehicles, but are calibrated specifically for gasoline/ethanol-blended fuels. The use of different parts or materials could produce an untested configuration that could result in fire, personal injury or cause engine damage. WARNING: Do not operate engine or smoke while refueling. WARNING: Use of the incorrect fuel or blending of fuels can result in severe engine damage. Refer to fuel filler door for vehicle-specific fuel usage. WARNING: It is important that your flexible fuel vehicle be properly maintained by ford flexible fuel trained personnel. If a problem occurs, it is important that properly trained personnel diagnose the cause. If the problem relates to the fuel system, proper part replacement is imperative to keep your vehicle operating at normal performance. Flexible fuel components and standard fuel components are not interchangeable. If your vehicle is not serviced in accordance with flexible fuel vehicle procedures, damage may occur and your warranty may be invalidated. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1223 Fuel Pressure Release: Service and Repair WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube. Release pressure from fuel system at the fuel pressure relief valve using tool No. T80L-9974-B or equivalent. When relieving fuel pressure, crank engine with fuel pump electrical connector disconnected. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V6 Firing Order: 1 4 2 5 3 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures Technical Service Bulletin # 9111B6 Date: 910614 Octane Adjust Shorting Bar - Revised Procedures Article No. 91-11B-6 ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1989 - PAGE 17-289 - PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1990 - PAGE 17-329 - PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1991 - PAGE 5-22 - EEC-IV QUICK TEST STEP 12.0 - CAR DIAGNOSIS BY SYMPTOM CHART REVISED ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1991 - PAGES 6-305 THROUGH 6-307 PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR FORD: 1989-91 TAURUS, THUNDERBIRD 1991 ESCORT, MUSTANG LINCOLN-MERCURY: 1989-90 COUGAR 1991 TRACER LIGHT TRUCK: 1989-91 RANGER 1991 AEROSTAR, EXPLORER ISSUE: Additional information regarding removal of the Octane Adjust Shorting Bar is required to assure compliance with Federal (EPA) Emission Standards. The following Manuals are affected on the pages indicated: ^ 1989 Engine/Emissions Diagnosis Page 17-289 ^ 1990 Engine/Emissions Diagnosis Page 17-329 ^ 1991 Engine/Emissions Diagnosis Page 5-22 and Pages 6-305 through 307 ACTION: Refer to the pages in this TSB article for the additional information. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 1232 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 1233 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 1234 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 1235 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 1236 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 1237 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 1238 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Locations > Component Locations Ignition Timing Connector: Component Locations Engine Compartment Component Locations RH Front Of Engine Compartment, Below VIP Test Connector Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Locations > Component Locations > Page 1241 Component Location - Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Mark 3.8L Supercharged Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams Component Location Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 1251 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 1252 Ignition Cable: Service and Repair When removing spark plug wires from plugs, use spark plug wire remover T74P-6666-A or equivalent. Grasp and twist the boot back and forth on the plug until boot is loose. Remove boot and wire from plug. Pull on boot only. Do not pull on wire. When removing wires from the ignition coil, squeeze the locking tabs of coil wire retainer by hand. Twist and pull on boot until free. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Description and Operation > TFI IV Distributor: Description and Operation TFI IV Distributor (Typical) - Exploded View This distributor directs high voltage to the spark plugs and supplies crankshaft position and frequency information to the control module using a Profile Ignition Pick-up. Hall Effect Device The universal distributor operates by using a Hall Effect vane switch assembly, which causes the ignition coil to be switched off and on by the EEC IV and TFI-IV modules. The vane switch consists of a Hall Sensor on one side and a permanent magnet on the other. Rotary Vane Cup A rotary vane cup is used to trigger the signal off and on. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Description and Operation > TFI IV > Page 1257 Figure 7 - Magnetic Flux Field When the window of the vane cup is between the magnet and the Hall Effect device, a magnetic field is completed from the magnet through the Hall Effect device and back to the magnet. Hall Effect Device Response To Vane As the vane passes through this opening, the flux lines are shunted through the vane and back to the magnet. At this time, a voltage is produced as the vane passes through the opening. When the vane clears the opening, the window edge causes the signal to go to zero volts. The signal is then used by the EEC system for Crankshaft position Sensing and the Desired Spark Advance based on engine demand and calibration. The spark advance and voltage distribution is accomplished through a conventional rotor, cap and ignition wires. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Description and Operation > TFI IV > Page 1258 Distributor: Description and Operation TFI Octane Rod Distributor (Typical) - Exploded View The octane rod adds a provision for a fixed octane adjustment. The adjustment is done by replacing the standard zero-degree rod located in the distributor bowl with a three degree or six degree retard rod. This is done only if the engine is experiencing a pinging or engine knocking condition and can not be repaired with the conventional methods (timing adjusted, proper operating temperature, higher gasoline octane rating....etc). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUG Tightening Torque ............................................................................................................................... .................................................................... 5-11 ft lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations Valve Clearance: Locations FRONT TO REAR Right Bank.............................................................................................................. .................................................................................................I-E-I-E-I-E Left Bank............................ .............................................................................................................................................................. .......................E-I-E-I-E-I Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations > Page 1265 Valve Clearance: Adjustments Fig. 5 Compressing Lifter To Check Valve Clearance Correct valve clearance is .09-.19 inch. A .060 inch longer or a .060 inch shorter pushrod is available to compensate for dimensional changes in the valve train. If clearance is less than specified, the .060 inch shorter pushrod should be used. If clearance is more than the maximum specified, the .060 inch longer pushrod should be used. Using an auxiliary starter switch crankshaft until No. 1 cylinder is at TDC compression stroke, then compress valve lifter using tool T82C-6500-A or equivalent, Fig. 5. At this point, the following valves can be checked: intake Nos. 1, 3 and 6; exhaust Nos. 1, 2 and 4. After clearance on these valves has been checked, rotate crankshaft until No. 5 cylinder is at TDC compression stroke (1 revolution of crankshaft), and then compress valve lifter using tool No. T82C-6500-A or equivalent, Fig. 5, and check the following valves: intake Nos. 2, 4 and 5; exhaust Nos. 3, 5 and 6. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams Serpentine Drive Belt Routing Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1269 Drive Belt: Service and Repair Serpentine Drive Belt Routing Serpentine Drive Belt Routing Fig. 15 Drive Belt Tensioner Fig. 16 Drive Belt Tension Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Drive Belt > Component Information > Diagrams > Page 1270 Fig. 17 Serpentine Drive Belt Tension Specifications Refer to Figs. 13 and 14 for drive belt installation. This engine is equipped with automatic drive belt tensioners, Fig. 15. These tensioners have built in drive belt wear indicators. With engine off, check position of tensioner belt length indicator. If indicator is not between minimum belt length and maximum belt stretch lines, replace drive belt. Belt tension can be checked using a suitable belt tension gauge, Figs. 16 and 17. Belt tension should be checked at the middle of longest accessible span. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Filters > Air Injection Filter > Component Information > Service and Repair Air Injection Filter: Service and Repair Fig. 68 Removing centrifugal type air pump filter 1. Remove drive pulley and outer disc from air pump. 2. Remove filter fan from pump, Fig. 68. Do not attempt to remove the metal drive hub. 3. Install new filter fan using the pulley and bolts. Alternately tighten bolts to draw fan down evenly. A slight interference between the fan and housing is normal. A new fan may make noise during initial operation, until its outer diameter sealing lip has worn in, after approximately 20---30 miles of operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when fueling vehicle or when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. NOTE: Methanol and ethanol are not interchangeable. Methanol fuel can be used only in vehicles designed for methanol fuels. Ethanol fuel can be used only in vehicles designed for ethanol fuels. WARNING: The fuel tubes leading from the fuel tank to the engine are under pressure during vehicle operation. When fuel injected engines are turned off, the fuel in the fuel tubes remains pressurized for long periods of time to provide quick start-ups. Special procedures for servicing these pressurized fuel systems are outlined in this section. These procedures should be followed to prevent accidental spraying of fuel, causing personal injury or a fire hazard. WARNING: Do not swallow fuel of any kind. Fuels such as methanol or fuel ethanol and gasoline or mixtures of these fuels are highly toxic and if swallowed can cause death or permanent injury. Swallowing methanol can also cause blindness. Immediately seek medical attention from a physician or poison control center to treat anyone who has swallowed fuel. Be aware that if fuel is swallowed, the onset of potential ill health effects may be delayed 12-24 hours. AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR OF ANY KIND CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY. AVOID GETTING FUEL LIQUID IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. ALLOWING ANY FUEL TO GET IN YOUR EYES WILL CAUSE SEVERE IRRITATION. FAILURE TO SEEK PROPER MEDICAL ATTENTION FOR FUEL CONTACT WITH THE EYES COULD LEAD TO PERMANENT INJURY. IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. MAKE SURE YOU WASH YOUR HANDS BEFORE HANDLING FOOD. FUELS CONTAINING GASOLINE SUCH AS FUEL METHANOL AND FUEL ETHANOL MAY CONTAIN BENZENE, WHICH IS A CANCER-CAUSING AGENT. IF YOU ARE TAKING MEDICATION FOR THE TREATMENT OF ALCOHOLISM, SUCH AS ANTABUSE OR OTHER FORMS OF DISULFIRAM, SKIN CONTACT WITH FUEL METHANOL, FUEL ETHANOL OR BREATHING THEIR VAPORS CAN CAUSE THE SAME KIND OF ADVERSE REACTION AS DRINKING ALCOHOLIC BEVERAGES. IN SENSITIVE INDIVIDUALS, SERIOUS PERSONAL INJURY OR SICKNESS COULD RESULT. IF YOU ARE TAKING SUCH MEDICATION, YOU SHOULD TAKE EXTRA CARE TO AVOID SKIN CONTACT WITH FUEL AND TO AVOID BREATHING ITS VAPORS. IF YOU DO GET FUEL ON YOUR SKIN, WASH IT OFF IMMEDIATELY. CONSULT A PHYSICIAN PROMPTLY IF YOU EXPERIENCE AN ADVERSE REACTION. WARNING: Do not modify the fuel system configuration or components or replace components with parts not especially designed for use with fuel methanol. Ford motor company has specially-designed the materials, components and system configuration for methanol-fueled vehicles and each particular system is precisely calibrated for efficient operation. Ford ethanol vehicles require the same parts as the methanol-fueled vehicles, but are calibrated specifically for gasoline/ethanol-blended fuels. The use of different parts or materials could produce an untested configuration that could result in fire, personal injury or cause engine damage. WARNING: Do not operate engine or smoke while refueling. WARNING: Use of the incorrect fuel or blending of fuels can result in severe engine damage. Refer to fuel filler door for vehicle-specific fuel usage. WARNING: It is important that your flexible fuel vehicle be properly maintained by ford flexible fuel trained personnel. If a problem occurs, it is important that properly trained personnel diagnose the cause. If the problem relates to the fuel system, proper part replacement is imperative to keep your vehicle operating at normal performance. Flexible fuel components and standard fuel components are not interchangeable. If your vehicle is not serviced in accordance with flexible fuel vehicle procedures, damage may occur and your warranty may be invalidated. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 1279 Fuel Pressure Release: Service and Repair WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube. Release pressure from fuel system at the fuel pressure relief valve using tool No. T80L-9974-B or equivalent. When relieving fuel pressure, crank engine with fuel pump electrical connector disconnected. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1284 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1285 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 1286 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 92174 > Aug > 92 > A/C Compressor - Moan At Idle to 1,500RPM Hose/Line HVAC: Customer Interest A/C Compressor - Moan At Idle to 1,500RPM Article No. 92-17-4 08/12/92 ^ AIR CONDITIONING - "MOAN" FROM COMPRESSOR AT IDLE TO 1,500 R.P.M. - 3.8L BASE ENGINE - VEHICLES BUILT PRIOR TO 10/15/92 ^ NOISE - "MOAN" FROM A/C COMPRESSOR AT IDLE TO 1,500 R.P.M. - 3.8L BASE ENGINE VEHICLES BUILT PRIOR TO 10/15/92 FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR ISSUE: An air conditioning compressor "moan" may be heard during idle and up to 1,500 R.P.M. The noise may also be described as a "groaning" or "growling" (low pitched humming) sound. ACTION: Install new hose assemblies which incorporate a muffler on both the suction and discharge side of the compressor. Use an accumulator and switch assembly (F1SZ-19C836-B) on the suction side and a manifold and tube assembly (F1SZ-19D734-B) on the discharge side. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 12-03, for service details. PART NUMBER OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992 Models, Basic Warranty For All Other Models OPERATION DESCRIPTION TIME 921704A Replace Suction and 1.1 Hrs. Discharge Hoses A/C Compressor, Includes Discharge, Evacuate And Charge System. DEALER CODING BASIC PART NO. CONDITION CODE 19C836 56 OASIS CODES: 208000, 208999, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92174 > Aug > 92 > A/C Compressor - Moan At Idle to 1,500RPM Hose/Line HVAC: All Technical Service Bulletins A/C Compressor - Moan At Idle to 1,500RPM Article No. 92-17-4 08/12/92 ^ AIR CONDITIONING - "MOAN" FROM COMPRESSOR AT IDLE TO 1,500 R.P.M. - 3.8L BASE ENGINE - VEHICLES BUILT PRIOR TO 10/15/92 ^ NOISE - "MOAN" FROM A/C COMPRESSOR AT IDLE TO 1,500 R.P.M. - 3.8L BASE ENGINE VEHICLES BUILT PRIOR TO 10/15/92 FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR ISSUE: An air conditioning compressor "moan" may be heard during idle and up to 1,500 R.P.M. The noise may also be described as a "groaning" or "growling" (low pitched humming) sound. ACTION: Install new hose assemblies which incorporate a muffler on both the suction and discharge side of the compressor. Use an accumulator and switch assembly (F1SZ-19C836-B) on the suction side and a manifold and tube assembly (F1SZ-19D734-B) on the discharge side. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 12-03, for service details. PART NUMBER OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992 Models, Basic Warranty For All Other Models OPERATION DESCRIPTION TIME 921704A Replace Suction and 1.1 Hrs. Discharge Hoses A/C Compressor, Includes Discharge, Evacuate And Charge System. DEALER CODING BASIC PART NO. CONDITION CODE 19C836 56 OASIS CODES: 208000, 208999, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hose/Line HVAC: > 8934 > Feb > 89 > Speed Control - Abnormal Operation When Hot Cruise Control Brush Assembly: All Technical Service Bulletins Speed Control - Abnormal Operation When Hot Article No. 89-3-4 SPEED CONTROL - COAST AND ACCELERATION MODES - ABNORMAL OPERATION IN HIGH AMBIENT TEMPERATURES FORD: 1986-89 ALL LINCOLN-MERCURY: 1986-89 ALL LIGHT TRUCK: 1986-89 ALL ISSUE: Abnormal speed control operation in the coast and acceleration modes may be caused by loss of electrical contact between the steering wheel slip rings and brush assembly. This condition usually occurs in high ambient temperatures when the steering wheel slip rings and brush assembly are warm. ACTION: Improve the electrical continuity of the steering wheel slip rings and brush assembly by applying a new service released grease on the contact area. Refer to the following procedure for service details. 1. Remove the steering wheel, Refer to the appropriate Car or Light Truck Shop Manual for service details. 2. Clean the old grease from the steering wheel slip rings and brush assembly contact areas. 3. Apply the new service released grease, (E8AZ-19590-A), on the steering wheel slip rings and brush assembly contact surfaces. This new grease can be identified by its bright orange/red color. 4. Reinstall steering wheel. PART NUMBER PART NAME CLASS E8AZ-19590-A Grease B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 890304A TIME: 0.4 Hr. DLR. CODING: Basic Part No. 9C899 Condition Code: 53 OASIS CODES: 2900 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Hose To Gear 16-25 ft.lb Quick Connect Tube Nut 35-45 ft.lb Return Hose To Gear 25-34 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1319 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1320 Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips Article No. 95-18-2 09/11/95 ^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP ^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994 and after ASPIRE 1995 and after CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and after MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR This TSB is being republished in its entirety to include warranty information when using recycled coolant ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda Coolant Recycler (181-00003) process is the only approved coolant recycling method available through Ford that is capable of producing recycled engine coolant that meets Ford specification ESE-M97B44-A. ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using Rotunda Coolant Recycler (181-00003). NOTE: WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND LABELING CONCERNS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1321 ASSOCIATED WITH THE RETAIL SALE OF CHEMICAL PRODUCTS. CAUTION: THE REINHIBITOR CHEMICALS PROVIDED WITH THIS EQUIPMENT ARE NOT APPROPRIATE FOR USE ON MEDIUM/HEAVY TRUCK APPLICATIONS. WARNING: ROTUNDA PREMIUM COOLANT REINHIBITORS # 1 AND # 2 HAVE BEEN SPECIFICALLY FORMULATED TO WORK WITH ROTUNDA COOLANT RECYCLER (181-00003). USE OF ANY OTHER CHEMICAL ADDITIVES WITH THIS SYSTEM WILL VOID ALL WARRANTIES FOR THE EQUIPMENT AND FOR THE FINAL COOLANT PRODUCT. SERVICE PROCEDURE DIRECTIONS FOR PROCESSING USED ENGINE COOLANT WITH ROTUNDA COOLANT RECYCLER 1. Close the drain valve on the unit. 2. Open the fill valve. 3. Pour used engine coolant into the funnel on the side of the unit. NOTE: MAXIMUM CAPACITY 15 25 GALLONS (95 L). 4. Insert the outlet hoses of the recycler into clean, properly labeled containers. One (1) container is for the outlet process water and the other container is for distilled ethylene glycol. 5. Push the "ON" switch on the front to start the operation. The unit will process 1 gallon (3.8 L) per hour of operation and will automatically shut off when cycle is complete. 6. Add reinhibitor following the directions in this article. 7. Open the drain valve to drain the residue from the distillation vessel. Dispose of residue in accordance with all local. state and federal regulations. ADDING REINHIBITOR CHEMICALS 1. Process the coolant according to the directions listed in this article 2. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 1 to each gallon of distilled ethylene glycol. 3. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 2 to each gallon of distilled ethylene glycol. 4. Mix well. 5. Check the pH level of the coolant. The pH level must be between 9 and 11. 6. Add enough water to the concentrated coolant to produce a 50/50 mixture of coolant and water. NOTE: THE CONCENTRATED COOLANT MUST BE MIXED WITH WATER TO MEET THE NECESSARY ENGINE FREEZE PROTECTION. 7. Check the coolant freeze point of the 50% coolant solution. Freeze point should be -34°F (-37°C). Consult the Rotunda Coolant Recycler Manual for more detailed operating instructions. Call 1-800-ROTUNDA, 8 AM to 8 PM EST, for inquiries regarding the Rotunda Coolant Recycler and to order the Reinhibitor (187-R0001). PART NUMBER PART NAME Rotunda # 187-R0001 Rotunda Premium Coolant Reinhibitor WARRANTY CLAIMS: Dealer can claim recycled engine coolant by Ford approved process via a warranty repair on an 1863 claim as follows: Part Number: RECCOOL (not a valid part number, but it is recognized on an 1863 claim). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1322 Quantity: Indicate the number of QUARTS of recycled coolant used. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-16-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1323 Coolant: Technical Service Bulletins Engine Coolant - Recycled Coolant Not Authorized Article No. 90-4-10 COOLING SYSTEM - USE OF RECYCLED ENGINE COOLANT - SERVICE TIP FORD: 1984-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS 1988-90 FESTIVA 1989-90 PROBE LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE 1987-90 TRACER MERKUR: 1985-90 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR MEDIUM/HEAVY TRUCK: 1984-90 C SERIES, F & B SERIES, L SERIES 1986-90 CARGO SERIES ISSUE: Ford Motor Company does not authorize the use of recycled engine coolant nor do they sanction the use of any machines or devices that recycle engine coolant. Recycled engine coolant is not equivalent to the factory fill OEM coolant, the Ford premium cooling system fluid (E2FZ-19549-AA) or the Ford heavy duty low silicate cooling fluid (E6HZ-19549-A). The quality of engine coolant degenerates with use. Recycling used engine coolant is very difficult to do without exposing the used coolant to additional foreign substances. Merely adding an additive to the coolant will not restore it. ACTION: Use new engine coolant that meets Ford Motor coolant specifications for the engine being serviced. Properly dispose of the used coolant. WARNING: THE DISPOSAL OF ALL USED ENGINE COOLANT MUST ALWAYS BE DONE IN ACCORDANCE WITH ALL APPLICABLE FEDERAL, STATE AND LOCAL LAWS AND REGULATIONS. PART NUMBER PART NAME CLASS E2FZ-19549-AA Coolant System Fluid - Ford V Premium E6HZ-19549-A Coolant System Fluid - Ford V Heavy Duty Low Silicate (For use in diesel powered med/hvy trucks) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1324 Coolant: Technical Service Bulletins Cooling System - Proper Fluid Concentrations Article No. 93-1-10 01/05/93 COOLING SYSTEM - PROPER FLUID CONCENTRATIONS FORD: 1988 EXP 1988-93 CROWN VICTORIA, ESCORT, FESTIVA, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1989-93 PROBE LINCOLN-MERCURY: 1988-89 TRACER 1988-92 MARK VII 1988-93 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR 1991-93 CAPRI, TRACER 1993 MARK VIII MERKUR: 1988-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1988-90 BRONCO II 1988-93 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-93 EXPLORER 1993 VILLAGER ISSUE: It is important to confirm the coolant fluid concentration during any repair of a vehicle's cooling system. A 50/50 concentration of Ford cooling system fluid, or an equivalent solution meeting Ford specifications, and water is best for all normal operating conditions. ACTION: Check the coolant fluid concentration and use a 50/50 solution concentration for optimum results. CAUTION: IF THE CONCENTRATION IS ALLOWED TO VARY TO ANY LARGE EXTENT EITHER WAY, COOLING SYSTEM CONCERNS CAN RESULT. IF THE COOLING SYSTEM FLUID LEVEL IS BELOW THE 50/50 CONCENTRATION, OVERHEATING CAN OCCUR. CONCENTRATIONS ABOVE 50/50 CAN CONTRIBUTE TO EXCESSIVE AND EVEN PREMATURE FAILURE OF THE WATER PUMP (MORE IS NOT BETTER). 1. Obtain a balanced mixture ratio of 50/50 cooling system fluid to water. Premix the two fluids in a separate container by adding equal volumes of coolant and water. 2. Be aware that overfilling of the coolant system is just as bad as not maintaining the proper coolant concentration level. If the coolant system is overfilled, and the system is allowed to expand dropping the excess coolant past the expansion tank, many of the vital coolant additives will be lost out the overflow pipe. This reduces the protection to the engine. 3. Pour in only enough coolant as specified for the system, and top off as necessary. NOTE: TOP OFF ONLY WITH A PREMIXED 50/50 SOLUTION. 4. Check the coolant concentration, once the coolant system has been properly filled, to be sure that it is truly within the allowed tolerance range. a. Use only a hand held refractometer such as a Rotunda Optical Antifreeze/Battery Tester # 021-00046 or equivalent to verify results. The acceptable coolant/water concentration range is: Minimum (45/55); Maximum (60/40). b. If the coolant system is found to be low on coolant, top off only from a premixed solution. c. If a weak concentration is found, add straight coolant sparingly until concentration readings are within acceptable levels. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 1325 d. If too strong a concentration is found, remove a small volume of coolant, and add water sparingly until coolant readings again fall within the specified levels. NOTE: MAKE SURE THE COOLANT IS THOROUGHLY MIXED BEFORE TAKING READINGS. A cooling system is only as effective as the condition of the system coolant. ^ USE ONLY FORD COOLING SYSTEM FLUID OR AN EQUIVALENT SOLUTION MEETING FORD SPECIFICATIONS. ^ FOR ADDITIONAL INFORMATION, SEE THE APPROPRIATE VEHICLE SERVICE MANUAL OR OWNER GUIDE. WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000, 499000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 12 qts .............................................................................................................................................................. .......................................... Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity Specifications > Page 1328 Coolant: Fluid Type Specifications COOLING SYSTEM FLUID, PREMIUM Ford Part No. U.S.A (Except Oregon) ............................................................................................................................................................ E2FZ-19549-AA or -B Canada ............................................................................................................ .............................................................................................. CXC-8-B Oregon .................................. ............................................................................................................................................................. F5FZ-19549-CC Ford Specification ................................................................................................................................ ................................................... ESE-M97B44-A COOLING SYSTEM FLUSH Ford Part No. ....................................................................................................................................... ................................................... F1AZ-19A503-A Ford Specification ................................................. ..................................................................................................................................... ESR-M14P7-A Coolant Mixture with Water ................................................................................................................. ...................................................................... 50% Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1333 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 1334 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity Fluid - A/T: Specifications Type MA(MERCON (R) V Automatic Transmission Fluid) CAPACITY, Initial Refill*: 3.0 qt (US) With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Refill Capacity > Page 1337 Fluid - A/T: Specifications Type MA(MERCON (R) V Automatic Transmission Fluid) CAPACITY, Total Fill: AXOD 12.8 qt (US) 4WD Tempo, Topaz 10.0 qt (US) Taurus ex. O.D. 8.0 qt (US) Festiva 5.6 qt (US) Tracer 6.0 qt (US) Others 8.3 qt (US) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Page 1338 Fluid - A/T: Testing and Inspection CHECKING OIL LEVEL 1. With transmission at operating temperature, park vehicle on level surface. 2. Operate engine at idle speed with parking brake applied and move selector lever through each detent position. Return selector lever to PARK. 3. With engine idling, remove dipstick and check fluid level. Fluid level should be between arrows on dipstick. 4. Add fluid as necessary to bring fluid to proper level. Use only fluid meeting Ford Qualification No. M2C-138-CJ, Dexron II or Mercon. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 1343 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 1344 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - M/T > Component Information > Technical Service Bulletins > Page 1345 Fluid - M/T: Specifications Type MA(MERCON (R) V Automatic Transmission Fluid) CAPACITY, Refill: Mustang 5.5 pt (US) Thunderbird, Cougar 6.4 pt (US) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications Fluid - Differential: Specifications VIN C,R, Fluid Capacity VIN C,R, Fluid Capacity Rear Axle Oil Models W/7.5 inch ring gear, Conventional axle 3 pt (US) Note: Plus 4 oz. of friction modifier meeting Ford Motor Co. specification Traction-Lok axle 2.75 pt (US) Note: Plus 4 oz. of friction modifier meeting Ford Motor Co. specification Friction Modifier C8AZ-19B956-A 4 oz (US) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Motor Oil - Viscosity Grade Recommendation Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Technical Service Bulletins > Page 1353 Engine Oil: Specifications Engine Refill ........................................................................................................................................ ............................................................ 4.0 Qts.(3.8L) Note: Add 1 Qt. with filter change. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1358 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1359 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1360 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 1361 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1367 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1368 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1369 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 1370 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 1375 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 1376 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 1377 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Substitutes Service Tip Article No. 96-17-10 08/12/96 AIR CONDITIONING - USE OF R-12 REFRIGERANT SUBSTITUTES - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 COUGAR 1982-94 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1985-94 CARGO SERIES, F & B SERIES, L SERIES This TSB article is being republished in its entirety to list Environmental Protection Agency (EPA) reviewed NC substitutes for R-12 refrigerant. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. ACTION: If service is required, use only new or of known quality recycled refrigerant R-12. Ford Motor Company has approved R-134a as the only refrigerant substitute for R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. INFORMATION FROM THE EPA Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 1382 This information has been taken from EPA documents to address Ford specific applications and recommendations. Further EPA information on ozone-depleting substances and regulations regarding its handling can be found on the Internet at World Wide Web site: http://www.epa.gov/ozone/ In 1994, EPA established the Significant New Alternatives Policy (SNAP) program to review alternatives to ozone-depleting substances like R-12. EPA examines new substitutes for their ozone depleting, global warming, flammability, and toxicity characteristics. The SNAP process does not test these substitutes for A/C system compatibility, reliability, durability, or performance. Under the SNAP rule, each new refrigerant must be used in accordance with the following conditions: 1. Unique Fittings - Each new refrigerant must be used with a unique set of fittings to prevent the accidental mixing of different refrigerants. 2. Unique Equipment - Each refrigerant must have dedicated recovery/recycling equipment for that refrigerant. 3. Labels - Whether a vehicle is originally designed to use a new refrigerant or is retrofitted, the technician must apply a detailed label giving specific information about the alternative. This label covers up information about the old refrigerant and provides valuable details on the alternative and how it was used. The technician is required to fill in their name, company performing the retrofit, address and the date retrofitted. 4. Remove Original Refrigerant - The original R-12 must be removed from the system prior to charging with the new refrigerant. This will guarantee that the largest amount of clean R-12 is available for use in vehicles that still need it. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 1383 A summary of the refrigerants reviewed under EPA's SNAP program for use in motor vehicle air conditioning systems is in the table. OTHER APPLICABLE ARTICLES: 91-9-7, 96-15-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes Article No. 94-14-3 07/13/94 Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1986-89 SCORPIO, XR4TI LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000, CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES This TSB is being republished in its entirety to include Heavy Truck models. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C system components. ACTION: If service is required, use only NEW or RECYCLED refrigerant R-12. Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time. R-134a is approved only for systems which specify R-134a, Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes > Page 1388 and is not compatible with R-12 systems. R-22 likewise, is not compatible with R-12 systems. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: 91-9-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 93206 > Sep > 93 > Air Conditioning - Use of Correct Fluorescent Tracer Dye Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 9197 > May > 91 > A/C - R12 Refrigerant Service Tips Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Service Tips Article No. 91-9-7 05/01/91 AIR CONDITIONING - REFRIGERANT R-12 - SERVICE TIPS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK: 1985-90 C SERIES 1985-91 CL-CLT-9000 SERIES, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for Refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C components. ACTION: If service is required, use only NEW or RECYCLED Refrigerant R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update Technical Service Bulletin # 915B13 Date: 910322 Refrigerant System Leak Testing - Manual Update Article No. 91-5B-13 ^ SHOP MANUAL - 1988 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1989 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1990 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1991 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED FORD: 1988-90 ESCORT 1988-91 CROWN VICTORIA, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-91 COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR ISSUE: Information concerning leak testing the refrigerant system was not covered in the Shop Manual for 1988 through 1991 applications under "Checking For Leaks" in the A/C and Refrigerant System-Service Section. ACTION: Refer to the pages following this TSB article for the updated information. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1401 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1402 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1403 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1404 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1405 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1406 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1407 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1408 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1409 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1410 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1411 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1412 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1413 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1414 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1415 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1416 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1417 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1418 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1419 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1420 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1421 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1422 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1423 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1424 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1425 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 1426 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1427 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1428 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1429 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1430 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1431 Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1432 Technical Service Bulletin # 915B13 Date: 910322 Refrigerant System Leak Testing - Manual Update Article No. 91-5B-13 ^ SHOP MANUAL - 1988 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1989 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1990 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1991 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED FORD: 1988-90 ESCORT 1988-91 CROWN VICTORIA, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-91 COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR ISSUE: Information concerning leak testing the refrigerant system was not covered in the Shop Manual for 1988 through 1991 applications under "Checking For Leaks" in the A/C and Refrigerant System-Service Section. ACTION: Refer to the pages following this TSB article for the updated information. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1433 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1434 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1435 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1436 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1437 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1438 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1439 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1440 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1441 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1442 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1443 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1444 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1445 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1446 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1447 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1448 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1449 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1450 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1451 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1452 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1453 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1454 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1455 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1456 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1457 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 1458 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Specifications Capacity ............................................................................................................................................... ....................................................... 40 oz (2.5 lbs) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 1461 Refrigerant: Fluid Type Specifications Type ..................................................................................................................................................... ............................................... Refrigerant 12 (R-12) Ford Part Number ............................................. ........................................................................................................................................ D4AZ-19B519-A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C Compressor - Oil Recovery & Measuring Procedure Refrigerant Oil: Technical Service Bulletins A/C Compressor - Oil Recovery & Measuring Procedure Article No. 92-24-6 11/18/92 AIR CONDITIONING - FX-15 AIR COMPRESSOR - OIL RECOVERY AND MEASURING PROCEDURE FORD: 1988-93 TAURUS 1989-93 CROWN VICTORIA, THUNDERBIRD 1992-93 ESCORT, TEMPO LINCOLN-MERCURY: 1988-93 SABLE 1989-93 COUGAR 1991-93 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1992-93 TOPAZ, TRACER LIGHT TRUCK: 1989-90 BRONCO II 1989-93 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-93 EXPLORER This article is being republished in its entirety to clarify the information about removing oil from both the "old" and "new" compressors. ISSUE: When replacing the FX-15 Compressor it is very important to accurately match the amount of oil being replaced. Some dealerships have indicated that they are unable to properly match the amounts of oil being replaced. ACTION: Replace the amount of oil being drained from the FX-15 compressor with an equal amount of new oil to assure proper compressor operation. Refer to the following service procedure for service details. SERVICE - PROCEDURE 1. With both "OLD" and "NEW" compressors, remove as much oil as possible. On both compressors, the shaft should be rotated about six to eight revolutions while pouring the oil from the ports. This effectively empties the compressor of oil. a. Obtain a clean container that can also be used as a measuring device. b. Place the disc and hub assembly on the compressor shaft so the shaft can be rotated. c. Rotate the shaft by hand (6) six to (8) eight revolutions, collecting the oil in a clean measuring device. NOTE: SERVICE COMPRESSORS COME PRE-CHARGED WITH 7 OUNCES OF OIL 2. If the amount of oil drained from the old compressor is between (3) three and (5) five fluid ounces (85 and 142 cc), pour the same amount of clean Motorcraft YN-9 refrigerant oil into the new compressor. 3. If the amount of oil that was removed from the old compressor is greater than (5) fluid ounces (142 cc), pour five ounces of clean Motorcraft YN-9 refrigerant oil into the new compressor. 4. If the amount of refrigerant oil that was removed from the old compressor is less than (3) three fluid ounces (85 cc), pour three fluid ounces of clean Motorcraft YN-9 refrigerant oil into the new compressor. NOTE: THE SUCTION/ACCUMULATOR-DRYER AND ORIFICE TUBE MUST BE REPLACED WHENEVER THE COMPRESSOR IS REPLACED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C Compressor - Oil Recovery & Measuring Procedure > Page 1466 Part Number/Name Chart OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 92-18-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999, 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C Compressor - Oil Recovery & Measuring Procedure > Page 1467 Refrigerant Oil: Technical Service Bulletins A/C Compressor - Oil Recovery/Measuring Procedures Article No. 92-18-4 08/26/92 AIR CONDITIONING - FX-15 AIR COMPRESSOR - OIL RECOVERY AND MEASURING PROCEDURE FORD: 1988-93 TAURUS 1989-93 CROWN VICTORIA, THUNDERBIRD 1992-93 ESCORT, TEMPO LINCOLN-MERCURY: 1988-93 SABLE 1989-93 COUGAR 1991-93 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1992-93 TOPAZ, TRACER LIGHT TRUCK: 1989-90 BRONCO II 1989-93 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1990-93 EXPLORER ISSUE: When replacing the FX-15 compressor it is very important to accurately match the amount of oil being replaced. Some dealerships have indicated that they are unable to properly match the amounts of oil being replaced. ACTION: Replace the amount of oil being drained from the FX-15 compressor with an equal amount of new oil, to assure proper compressor operation. Refer to the following service procedure for service details. SERVICE - PROCEDURE 1. Remove as much oil as possible from the compressor. The compressor shaft should be rotated about six to eight revolutions allowing the oil to drain from the compressor ports. a. Obtain a clean container that can be also used as a measuring device. b. Place the disc and hub assembly on the compressor shaft so the shaft can be rotated. c. Rotate the shaft by hand (6) six to (8) eight revolutions allowing the oil to drain from the ports, while collecting the oil in the clean measuring device. NOTE: SERVICE COMPRESSORS COME PRE-CHARGED WITH 7 OUNCES OF OIL 2. If the amount of oil drained from the old compressor is between (3) three and (5) five fluid ounces, pour the same amount of clean Motorcraft YN-9 refrigerant oil into the new compressor. 3. If the amount of oil that was removed from the old compressor is greater than (5) fluid ounces, pour five ounces of clean Motorcraft YN-9 refrigerant oil into the new compressor. 4. If the amount of refrigerant oil that was removed from the old compressor is less than (3) three fluid ounces, pour three fluid ounces of clean Motorcraft YN-9 refrigerant oil into the new compressor. NOTE: THE SUCTION/ACCUMULATOR-DRYER AND ORIFICE TUBE MUST BE REPLACED WHENEVER THE COMPRESSOR IS REPLACED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C Compressor - Oil Recovery & Measuring Procedure > Page 1468 Part Number OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications When it is necessary to replace a component of the refrigerant system, the procedures in this Section must be followed to ensure that the total oil charge in the system is correct after the new part is installed. When the compressor is operated, oil gradually leaves the compressor and is circulated through the system with the refrigerant. Eventually a balanced condition is reached in which a certain amount of oil is retained in the compressor and a certain amount is continually circulated. If a component of the system is removed after the system has been operated, some oil will go with it. To maintain the original total oil charge, it is necessary to compensate for this by replacing the oil in the new replacement part. The procedures for replacing oil are as follows: FX-15 Compressor-3/4 View DURING COMPRESSOR REPLACEMENT A new service replacement FX-15 compressor contains 207ml (7 ounces) of refrigerant oil. Prior to installing the replacement compressor, drain the refrigerant oil from the removed compressor into a calibrated container. Then, drain the refrigerant oil from the new compressor into a clean calibrated container. If the amount of oil drained from the removed compressor was between 90 and 148ml (3 and 5 ounces), pour the same amount of clean refrigerant oil into the new compressor. If the amount of oil that was removed from the oil compressor is greater than 148ml (5 ounces), pour 148ml (5 ounces) of clean refrigerant oil into the new compressor. If the amount of refrigerant oil that was removed from the old compressor is less than 90ml (3 ounces), pour 90ml (3 ounces) of clean refrigerant oil into the new compressor. NOTE: The suction/accumulator-drier and the orifice tube should also be replaced whenever the compressor is replaced. DURING COMPONENT REPLACEMENT When replacing other components of the air conditioning system, measured quantities of the specified refrigerant oil should be added to the component to ensure that the total oil charge in the system is correct before the system is operated. Clean refrigerant oil should be added to the replacement components as follows: ^ Evaporator Core: Add 90ml (3 ounces). ^ Condenser: Add 30ml (1 ounce). ^ Accumulator: Drain oil from removed accumulator drier. Add same amount plus 30ml (1 ounce) of clean refrigerant oil to new accumulator. NOTE: Clean refrigerant oil should be poured directly into the replacement component. If any other components such as an orifice tube or a hose is replaced, no additional refrigerant oil is necessary unless a hose bursts with a fully charged system. Then, the addition of refrigerant oil may be necessary with the amount to be determined by the technician. The suction accumulator-drier should also be replaced under these circumstances. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 1471 Refrigerant Oil: Fluid Type Specifications FX-15 Compressor-3/4 View The FX-1 5 compressor uses unique, high quality refrigerant oil E73Z-19577-A or Motorcraft YN-9 or an equivalent refrigerant oil meeting Ford specification ESH-M2C31-A2. It is extremely important that only the specified type and quantity of refrigerant oil be used in the FX-15 compressor. If there is a surplus of oil in the system, it will circulate with the refrigerant, reducing the cooling capacity of the system. Using too little oil or an oil not meeting specification will result in poor lubrication of the compressor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding Pressure bleeding is recommended for all hydraulic brake systems. The bleeding operation itself is fairly well standardized. First step in all cases is cleaning the dirt from the filler cap before removing it from the master cylinder. This should be done thoroughly. Pressure bleeding is fastest because the master cylinder doesn't have to be refilled several times, and the job can be done by one man. To prevent air from the pressure tank getting into the lines, do not shake the tank while air is being added to the tank or after it has been pressurized. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full. On vehicles equipped with disc brakes and master cylinders without proportioners or pressure control valves located in the master cylinder outlet port, the brake metering valve or combination valve must be held in position using a suitable tool. If air does get into the fluid, releasing the pressure will cause the bubbles to increase in size, rise to the top of the fluid, and escape. Pressure should not be greater than about 35 psi. On vehicles equipped with plastic reservoirs, do not exceed 25 psi bleeding pressure. When bleeding without pressure, open the bleed valve three-quarters of a turn, depress the pedal a full stroke, then allow the pedal to return slowly to its released position. It is suggested that after the pedal has been depressed to the end of its stroke, the bleeder valve should be closed before the start of the return stroke. On models with power brakes, first reduce the vacuum in the power unit to zero by pumping the brake pedal several times with the engine off before starting to bleed the system. Pressure bleeding, of course, eliminates the need for pedal pumping. Discard drained or bled brake fluid. Care should be taken not to spill brake fluid, since this can damage the finish of the car. Flushing is essential if there is water, mineral oil or other contaminants in the lines, and whenever new parts are installed in the hydraulic system. Fluid contamination is usually indicated by swollen and deteriorated cups and other rubber parts. Wheel cylinders on disc brakes are equipped with bleeder valves, and are bled in the same manner as wheel cylinders for drum brakes. Bleeding is necessary on all four wheels if air has entered the system because of low fluid level, or the line or lines have been disconnected. If a line is disconnected at any one wheel cylinder, that cylinder only need be bled. Of course, on brake reline jobs, bleeding is advisable to remove any air or contaminants. Master cylinders equipped with bleeder valves should be bled first before the wheel cylinders are bled. In all cases where a master cylinder has been overhauled, it must be bled. Where there is no bleeder valve, this can be done by leaving the lines loose, actuating the brake pedal to expel the air and then tightening the lines. After overhauling a dual master cylinder used in conjunction with disc brakes, it is advisable to bleed the cylinder before installing it on the car. The reason for this recommendation is that air may be trapped between the master cylinder pistons because there is only one residual pressure valve (check valve) used in these units. WHEEL BLEEDING SEQUENCE Rear Wheel Drive................................................................................................................................. .............................................................RR-LR-RF-LF Front Wheel Drive............................................ .................................................................................................................................................RR-LFLR-RF Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1476 Brake Bleeding: Service and Repair Priming Brake System When a new master cylinder has been installed or the brake system emptied or partially emptied, fluid may not flow from the bleeder screws during normal bleeding. It may be necessary to prime the system using the following procedure: 1. Using a tubing wrench, remove the brake lines from the master cylinder. 2. Install short brake lines in the master cylinder and position them back into the reservoir, ensure that the short brake line ends are submerged in the reservoir brake fluid. 3. Fill the reservoir with recommended brake fluid, then cover master cylinder fluid reservoir with shop towel. 4. Pump the brakes until clear, bubble free fluid comes out of both brake lines. If any brake fluid spills on paint, wash it off immediately with water. 5. Remove the short brake lines, then reinstall original brake lines. 6. Bleed each brake line at the master cylinder using the following procedure: a. Have assistant pump brake pedal 10 times, then hold firm pressure on the pedal. b. Open the rear-most brake line fittings with a tubing wrench until a stream of brake fluid comes out. Have assistant maintain pressure on the brake pedal until the brake line fitting is tightened again. c. Repeat this operation until clear, bubble free fluid comes out from around tube fitting. d. Repeat this bleeding operation at the front brake line fitting. 7. If any of the brake lines or calipers have been removed, it may be helpful to prime the system by gravity bleeding. This should be done after the master cylinder is primed and bled. To prime the system using the gravity method, proceed as follows: a. Fill the master cylinder with manufacturer recommended brake fluid or equivalent. b. Loosen both rear bleeder screws and leave them open until clear brake fluid flows out. Check reservoir fluid level frequently, do not allow fluid level to drop below half full. c. Tighten rear bleeder screws. d. Loosen bleeder screw on front caliper, leave open until clear fluid flows out. Bleed front calipers one side at a time. 8. After the master cylinder has been primed, the lines bled at the master cylinder and the brake system primed, normal brake system bleeding can be resumed at each wheel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 1477 Brake Bleeding: Service and Repair With ABS FRONT BRAKES The front brakes can be bled in the same manner as conventional brakes, with or without the accumulator being charged. REAR BRAKES If the pump motor is allowed to operate continuously for approximately 20 minutes, a thermal safety switch (inside the motor) will automatically shut off the motor. A 2 to 10 minute cool down period is typical before normal operation can resume. Exercise care when opening the rear caliper bleeder screws, due to the high pressure available from a completely charged accumulator at the bleeder screws. Serious injury may result if care is not taken. Bleeding w/Accumulator Charged 1. With accumulator pressure applied to the system, bleed rear brakes by opening rear brake caliper bleed screws for 10 seconds at a time while applying brake pedal with ignition switch in Run position. 2. Repeat step 1 until air-free flow of brake fluid is observed at each caliper. 3. Close bleed screws, then pump brake pedal several times. 4. Adjust brake fluid quantity in reservoir to MAX level with accumulator fully charged. Bleeding w/Pressure Bleeder 1. Attach Rotunda bleeder No. 104-00064, or equivalent, to reservoir cap opening and apply a minimum pressure of 35 psi to system. 2. With brake pedal at rest and ignition switch in Off position, open rear caliper bleed screws for 10 seconds at a time. 3. When an air-free flow of brake fluid is observed at each caliper, close bleed screws and turn ignition switch to Run position. 4. Pump brake pedal several times, then adjust brake fluid quantity in reservoir to MAX level with accumulator fully charged. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Circuit Location Amp Cigar Lighter Fuse Panel 20 Power Door Locks Fuse Panel 20 Power Moon Roof Fuse Panel 20 Power Seats Fuse Panel 20 Power Windows Fuse Panel 20 Windshield Wiper Fuse Panel 8.25 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Fuse: Customer Interest Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Fuse: All Technical Service Bulletins Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Technical Service Bulletins > Page 1495 Fuse: Locations Behind LH Rear Wheelwell, In Window Regulator Harness Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised Fuse Block: Technical Service Bulletins EEC IV Test Step TA3 Check Fuse - Revised Article No. 89-25A-4 12/15/89 ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1989 - PAGE 22 - CIRCUIT PROTECTION/JUNCTION BLOCKS - FUSE PANEL DISTRIBUTION BOX TITLE REVISED ^ SHOP MANUAL - 1989 - PAGE 33-05-11 - TEST STEP TA3, CHECK FUSE - REVISED FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Page 22 of the 1989 Thunderbird/Cougar Electrical/Vacuum Troubleshooting Manual and page 33-05-11 of the 1989 Thunderbird/Cougar Shop Manual, have been revised to better describe the circuits protected by the "Memory" fuse. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 1500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 1501 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 1502 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 1503 ACTION: Refer to the pages in this TSB article for the revised circuit protection junction block and diagnostic procedures. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Panel Fuse Panel Details Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Locations > Fuse Panel > Page 1506 Fuse Block: Locations Fuse Panel & Flasher Location Fuse panel is on LH side of lower instrument panel. Combination turn signal/hazard flasher is located to RH side of steering column opening reinforcement, mounted on a bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1509 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1510 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 1511 Fuse Panel Details Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link A Fusible Link: Locations Fuse Link A LH Front Of Engine Compartment, At Starter Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link A > Page 1516 Fusible Link: Locations Fuse Link B LH Front Of Engine Compartment, Near Starter Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fusible Link > Component Information > Locations > Fuse Link A > Page 1517 Fusible Link: Locations Fuse Link C LH Front Of Engine Compartment, Near Starter Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions Vehicle Maintenance Monitor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 1523 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 1524 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 1525 Vehicle Maintenance Monitor: Electrical Diagrams Vehicle Maintenance Monitor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 1526 Vehicle Maintenance Monitor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 91177 > Aug > 91 > Tape Player - Hissing Noise Maintenance Reminder Control Module: Customer Interest Tape Player - Hissing Noise Article No. 91-17-7 08/21/91 ^ RADIO - TAPE PLAYER - MAKES HISSING NOISE - CARS WITH VEHICLE MAINTENANCE MONITOR (VMM) ^ NOISE - "HISS" FROM TAPE PLAYER DURING QUIET PASSAGES - VEHICLES WITH VMM FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hissing noise may be heard from the tape player during quiet passages. This occurs because of electromagnetic interference from the transformer being picked up by the head of the tape player. ACTION: Install a new vehicle maintenance monitor. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-38, for service details. NOTE: SUSPECT VEHICLE MAINTENANCE MONITORS MUST BE REPLACED ONLY BY A VMM WITH A DATE CODE OF MAY 1990 OR LATER. THE DATE CODE IS ON A LABEL LOCATED ON THE TOP OF THE MODULE IN MONTH/DAY/YEAR FORMAT. FOR EXAMPLE, 10/09/90 MEANS OCTOBER 9, 1990. THIS ISSUE DOES NOT AFFECT 1991 MODELS. PART NUMBER PART NAME CLASS F1SZ-10E850-A Vehicle Maintenance Monitor B WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911707A Install Vehicle Maintenance 0.3 Hr. Monitor DEALER CODING BASIC PART NO. CONDITION CODE 10E850 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Maintenance Reminder Control Module: > 91177 > Aug > 91 > Tape Player - Hissing Noise Maintenance Reminder Control Module: All Technical Service Bulletins Tape Player - Hissing Noise Article No. 91-17-7 08/21/91 ^ RADIO - TAPE PLAYER - MAKES HISSING NOISE - CARS WITH VEHICLE MAINTENANCE MONITOR (VMM) ^ NOISE - "HISS" FROM TAPE PLAYER DURING QUIET PASSAGES - VEHICLES WITH VMM FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hissing noise may be heard from the tape player during quiet passages. This occurs because of electromagnetic interference from the transformer being picked up by the head of the tape player. ACTION: Install a new vehicle maintenance monitor. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-38, for service details. NOTE: SUSPECT VEHICLE MAINTENANCE MONITORS MUST BE REPLACED ONLY BY A VMM WITH A DATE CODE OF MAY 1990 OR LATER. THE DATE CODE IS ON A LABEL LOCATED ON THE TOP OF THE MODULE IN MONTH/DAY/YEAR FORMAT. FOR EXAMPLE, 10/09/90 MEANS OCTOBER 9, 1990. THIS ISSUE DOES NOT AFFECT 1991 MODELS. PART NUMBER PART NAME CLASS F1SZ-10E850-A Vehicle Maintenance Monitor B WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911707A Install Vehicle Maintenance 0.3 Hr. Monitor DEALER CODING BASIC PART NO. CONDITION CODE 10E850 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Maintenance Reminder Control Module: > 9038 > Jan > 90 > VMM Oil Change Indicator - Reset Procedure Maintenance Reminder Control Module: All Technical Service Bulletins VMM Oil Change Indicator Reset Procedure VEHICLE MAINTENANCE MONITOR (VMM) - OIL CHANGE INDICATOR - RESET PROCEDURE Article No. 90-3-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The VMM oil change indicator must be reset every time that the vehicle's oil is changed. This means... ^ The oil change indicator must be reset even if the vehicle's oil is changed before the VMM has indicated an oil change is needed. ^ The reset procedure is necessary to keep the information in the oil change indicator updated whenever the oil is changed. ^ If the reset procedure is not done, the VMM will indicate an oil change prematurely. ACTION: After the oil is changed, manually reset the VMM oil change indicator by using the following procedure. 1. With the ignition key in the OFF position, turn the ignition key to the RUN position, but do not start the engine. Figure 1 2. Within 15 seconds of turning the ignition to RUN, reset the VMM by inserting a straightened paper clip or similar tool through the reset hole and press firmly. The module is located in the top center of the instrument panel directly above the radio, Figure 1. ^ You will not be able to feel the reset switch operating because it has no perceptible movement when it is pushed. ^ The oil change message window will begin to flash when the switch has been activated. NOTE: IF THE RESET PROCEDURE IS NOT DONE WITHIN 15 SECONDS, THE PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. IF "NOW" IS FLASHING, DO NOT WAIT FOR IT TO STOP BEFORE PUSHING THE RESET SWITCH TO INITIATE THE OIL CHANGE RESET. 3. Continue to depress the reset switch until the oil change display stops flashing, which will take about 4 seconds. NOTE: IF THE RESET SWITCH IS RELEASED BEFORE THE OIL CHANGE DISPLAY STOPS FLASHING, THE RESET PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Maintenance Reminder Control Module: > 9038 > Jan > 90 > VMM Oil Change Indicator - Reset Procedure Maintenance Reminder Control Module: All Technical Service Bulletins VMM Oil Change Indicator Reset Procedure VEHICLE MAINTENANCE MONITOR (VMM) - OIL CHANGE INDICATOR - RESET PROCEDURE Article No. 90-3-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The VMM oil change indicator must be reset every time that the vehicle's oil is changed. This means... ^ The oil change indicator must be reset even if the vehicle's oil is changed before the VMM has indicated an oil change is needed. ^ The reset procedure is necessary to keep the information in the oil change indicator updated whenever the oil is changed. ^ If the reset procedure is not done, the VMM will indicate an oil change prematurely. ACTION: After the oil is changed, manually reset the VMM oil change indicator by using the following procedure. 1. With the ignition key in the OFF position, turn the ignition key to the RUN position, but do not start the engine. Figure 1 2. Within 15 seconds of turning the ignition to RUN, reset the VMM by inserting a straightened paper clip or similar tool through the reset hole and press firmly. The module is located in the top center of the instrument panel directly above the radio, Figure 1. ^ You will not be able to feel the reset switch operating because it has no perceptible movement when it is pushed. ^ The oil change message window will begin to flash when the switch has been activated. NOTE: IF THE RESET PROCEDURE IS NOT DONE WITHIN 15 SECONDS, THE PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. IF "NOW" IS FLASHING, DO NOT WAIT FOR IT TO STOP BEFORE PUSHING THE RESET SWITCH TO INITIATE THE OIL CHANGE RESET. 3. Continue to depress the reset switch until the oil change display stops flashing, which will take about 4 seconds. NOTE: IF THE RESET SWITCH IS RELEASED BEFORE THE OIL CHANGE DISPLAY STOPS FLASHING, THE RESET PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > Page 1550 Maintenance Reminder Control Module: Locations I/P Components Center Of Dash Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Malfunction Indicator Lamp: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 1555 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 1556 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 1557 Malfunction Indicator Lamp: Electrical Diagrams Warning Indicators Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 1558 Warning Indicators Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 1559 Warning Indicators Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Page 1560 Malfunction Indicator Lamp: Description and Operation The MIL light is intended to alert the driver of certain malfunctions in the engine control system. If such a fault occurs, the EEC-IV processor will substitute a value or values and continue operating. In some cases this action may result in a slight change in vehicle driveability. On 1988 models, the check engine light can be used to read codes. The check engine light on the front dash panel will remain on when a hard fault is present. During the Self-test sequence, a service code is reported by the check engine light. It will represent itself as a flash on the check engine light display on the dash panel. A single digit number of three will be reported by three flashes. However, as previously stated, a service code is represented by a two digit number, such as 2-3. As a result, the Self-test service code of 2-3 will appear on the check engine light display as two flashes, then after a two second pause, the light will flash three times. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > VMM Oil Change Indicator - Reset Procedure Oil Change Reminder Lamp: Technical Service Bulletins VMM Oil Change Indicator - Reset Procedure VEHICLE MAINTENANCE MONITOR (VMM) - OIL CHANGE INDICATOR - RESET PROCEDURE Article No. 90-3-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The VMM oil change indicator must be reset every time that the vehicle's oil is changed. This means... ^ The oil change indicator must be reset even if the vehicle's oil is changed before the VMM has indicated an oil change is needed. ^ The reset procedure is necessary to keep the information in the oil change indicator updated whenever the oil is changed. ^ If the reset procedure is not done, the VMM will indicate an oil change prematurely. ACTION: After the oil is changed, manually reset the VMM oil change indicator by using the following procedure. 1. With the ignition key in the OFF position, turn the ignition key to the RUN position, but do not start the engine. Figure 1 2. Within 15 seconds of turning the ignition to RUN, reset the VMM by inserting a straightened paper clip or similar tool through the reset hole and press firmly. The module is located in the top center of the instrument panel directly above the radio, Figure 1. ^ You will not be able to feel the reset switch operating because it has no perceptible movement when it is pushed. ^ The oil change message window will begin to flash when the switch has been activated. NOTE: IF THE RESET PROCEDURE IS NOT DONE WITHIN 15 SECONDS, THE PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. IF "NOW" IS FLASHING, DO NOT WAIT FOR IT TO STOP BEFORE PUSHING THE RESET SWITCH TO INITIATE THE OIL CHANGE RESET. 3. Continue to depress the reset switch until the oil change display stops flashing, which will take about 4 seconds. NOTE: IF THE RESET SWITCH IS RELEASED BEFORE THE OIL CHANGE DISPLAY STOPS FLASHING, THE RESET PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest: > 932410 > Nov > 93 > Instrument Cluster Warning Lights Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest: > 932410 > Nov > 93 > Instrument Cluster Warning Lights Dimly Lit > Page 1573 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Oil Level Warning Indicator: Customer Interest Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1583 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89206 > Oct > 89 > Instrument Cluster/Radio Memory Failures Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Level Warning Indicator: > 91177 > Aug > 91 > Tape Player - Hissing Noise Maintenance Reminder Control Module: All Technical Service Bulletins Tape Player - Hissing Noise Article No. 91-17-7 08/21/91 ^ RADIO - TAPE PLAYER - MAKES HISSING NOISE - CARS WITH VEHICLE MAINTENANCE MONITOR (VMM) ^ NOISE - "HISS" FROM TAPE PLAYER DURING QUIET PASSAGES - VEHICLES WITH VMM FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hissing noise may be heard from the tape player during quiet passages. This occurs because of electromagnetic interference from the transformer being picked up by the head of the tape player. ACTION: Install a new vehicle maintenance monitor. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-38, for service details. NOTE: SUSPECT VEHICLE MAINTENANCE MONITORS MUST BE REPLACED ONLY BY A VMM WITH A DATE CODE OF MAY 1990 OR LATER. THE DATE CODE IS ON A LABEL LOCATED ON THE TOP OF THE MODULE IN MONTH/DAY/YEAR FORMAT. FOR EXAMPLE, 10/09/90 MEANS OCTOBER 9, 1990. THIS ISSUE DOES NOT AFFECT 1991 MODELS. PART NUMBER PART NAME CLASS F1SZ-10E850-A Vehicle Maintenance Monitor B WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911707A Install Vehicle Maintenance 0.3 Hr. Monitor DEALER CODING BASIC PART NO. CONDITION CODE 10E850 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Other Service Bulletins for Oil Level Warning Indicator: > 9038 > Jan > 90 > VMM Oil Change Indicator - Reset Procedure Maintenance Reminder Control Module: All Technical Service Bulletins VMM Oil Change Indicator Reset Procedure VEHICLE MAINTENANCE MONITOR (VMM) - OIL CHANGE INDICATOR - RESET PROCEDURE Article No. 90-3-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The VMM oil change indicator must be reset every time that the vehicle's oil is changed. This means... ^ The oil change indicator must be reset even if the vehicle's oil is changed before the VMM has indicated an oil change is needed. ^ The reset procedure is necessary to keep the information in the oil change indicator updated whenever the oil is changed. ^ If the reset procedure is not done, the VMM will indicate an oil change prematurely. ACTION: After the oil is changed, manually reset the VMM oil change indicator by using the following procedure. 1. With the ignition key in the OFF position, turn the ignition key to the RUN position, but do not start the engine. Figure 1 2. Within 15 seconds of turning the ignition to RUN, reset the VMM by inserting a straightened paper clip or similar tool through the reset hole and press firmly. The module is located in the top center of the instrument panel directly above the radio, Figure 1. ^ You will not be able to feel the reset switch operating because it has no perceptible movement when it is pushed. ^ The oil change message window will begin to flash when the switch has been activated. NOTE: IF THE RESET PROCEDURE IS NOT DONE WITHIN 15 SECONDS, THE PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. IF "NOW" IS FLASHING, DO NOT WAIT FOR IT TO STOP BEFORE PUSHING THE RESET SWITCH TO INITIATE THE OIL CHANGE RESET. 3. Continue to depress the reset switch until the oil change display stops flashing, which will take about 4 seconds. NOTE: IF THE RESET SWITCH IS RELEASED BEFORE THE OIL CHANGE DISPLAY STOPS FLASHING, THE RESET PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 1606 Oil Level Warning Indicator: Description and Operation This system is used to indicate when engine oil level is 1-1/2 quarts or more below the specified level. The system consist an instrument panel warning lamp, electronic relay and a float type sensor which is located in the oil pan. The warning lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go out when engine is operating. If oil level is low, the lamp will remain on until engine oil is added or until ignition switch is placed in the off position. The module will take approximately 5 minutes to reset. If engine is started during this reset period, the last reading obtained will be displayed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Service Reminder Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 1607 Oil Level Warning Indicator: Testing and Inspection Fig. 12 Low Oil Level Indicator Diagnosis SYSTEM CHECK With oil at Full mark on dipstick and engine warm, start engine. Warning indicator should come on briefly in Start for bulb test, then go out. Turn engine Off. Drain 2 quarts of oil from engine. Wait for 5 minutes, then restart engine. Warning indicator should come On and stay On. If indicator does not come On, check the following; indicator, fuse, oil level relay and/or oil level sensor. SENSOR TEST If is best to conduct test with sensor in oil pan with hot oil to ensure oil properly drains from sensor. If removed from pan, sensor must first be submerged in warm oil to ensure proper positioning of float before testing. The sensor must be held horizontally during bench testing to ensure float remains correctly positioned. Connect positive lead of digital volt/ohmmeter to sensor terminal and negative lead to sensor housing. With sensor submerged in oil (engine full), meter should read Open. Resistance should be greater than 100,000 ohms. With sensor out of oil (oil drained), resistance should be less than 1000 ohms. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application Tires: Customer Interest Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 1617 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Tires: Customer Interest Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 1622 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 1623 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9562 > Mar > 95 > Brakes - Roughness During Application Tires: All Technical Service Bulletins Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 1629 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Tires: All Technical Service Bulletins Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 1634 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 1635 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tires: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 89173 > Aug > 89 > Aluminum Wheel - Air Leaks Wheels: Customer Interest Aluminum Wheel - Air Leaks Article No. 89-17-3 WHEEL-ALUMINUM-LEAKS AIR FORD: 1986-90 CROWN VICTORIA, ESCORT 1986-88 EXP 1986-90 MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-90 FESTIVA 1989-90 PROBE LINCOLN-MERCURY: 1986-90 CONTINENTAL, COUGAR, GRAND MARQUIS 1986-87 LYNX 1986-90 MARK VII, SABLE, TOPAZ, TOWN CAR 1987-90 TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO This article is being republished in its entirety to expand the model year coverage to include 1987 through 1990 model year vehicles. ISSUE: Slow air leaks may occur in cast aluminum wheels because of porous wheel castings. ACTION: Use "HOT MELT" sealant (E7AZ-19554-A) and the following diagnostic/service procedure to eliminate the leaks. NOTE: THIS TSB MUST BE PERFORMED PRIOR TO REPLACING THE WHEEL FOR A LEAKING CONDITION. 1. Remove the tire and wheel assembly and inspect the wheel for structural damage. If none exists, go on to Step 2. If the wheel is damaged, replace it. 2. Check the complete wheel for possible air leaks. With the tire mounted on the wheel, locate the air leak using the water bath or equivalent method and mark the location. 3. Dismount the tire and on the tire side of the wheel prepare the surface for sealant. a. Thoroughly clean the leaking area with methylene chloride (e.g., choke cleaner E8AZ-19A501-AA) Or b. Use sandpaper of about 80 grit to thoroughly remove all contamination and score the wheel surface to improve adhesion of sealer. c. Prepare an adequate area around the leak to ensure covering the leak. d. Remove the valve stem if it is close to the repair area. 4. Use a clean rag to remove all cleaner or sanding dust. CAUTION: DO NOT USE AN OXYACETYLENE TORCH TO PERFORM STEP 5. Figure 1 5. Proceed to heat and seal the leaking area. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 89173 > Aug > 89 > Aluminum Wheel - Air Leaks > Page 1654 a. Heat the prepared area of the wheel with an electric heat gun (Rotunda 107-00301 type) or propane torch (not oxyacetylene) until the melt stick (E7AZ-19554-A) flows. b. Apply the hot melt material over the prepared area using a liberal flow and a wiping action to assure coverage of the leaking area. NOTE: THE REPAIR IS MOST EFFECTIVE WHEN THE HEAT IS APPLIED TO THE BRAKE SIDE OF THE WHEEL AND THE SEALER IS MELTED BY THE HEAT IN THE METAL, SEE FIGURE 1. c. Apply only enough heat to melt the sealer and then remove the heat source. 6. Check for air leaks. a. After repairing the leak, allow the wheel to cool until it can be handled safely. b. Reassemble the tire and wheel. c. Inflate the tire to the recommended air pressure as indicated on the tire pressure decal. d. Check that the leak is repaired by using the procedure covered in Step 2. 7. After the repair is completed, balance and reinstall the wheel assembly on the vehicle. PART NUMBER PART NAME CLASS E8AZ-19A501-AA Choke Cleaner B E7AZ-19554-A Melt Stick Sealant BM OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-2-13, dated 1/28/87 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891703A Seal Aluminum Wheel - 0.8 Hr. ONE 891703B Seal Aluminum Wheel - 1.5 Hrs. TWO 891703C Seal Aluminum Wheel - 2.1 Hrs. THREE 891703D Seal Aluminum Wheel - 2.8 Hrs. FOUR DEALER CODING BASIC PART NO. CONDITION CODE 1007 48 OASIS CODES: 3300, 3500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 92124 > Jun > 92 > Brakes - Roughness/Runout Check Wheels: All Technical Service Bulletins Brakes - Roughness/Runout Check Article No. 92-12-4 DATE: 06-03-92 ^ BRAKES-ROTOR-REPLACEMENT SERVICE TIPS ^ BRAKES-ROUGHNESS DEVELOPED FROM INCREASE IN ROTOR RUNOUT ^ WHEELS-LUG NUT TIGHTENING PROCEDURE FORD: 1986-92 TAURUS 1989-92 THUNDERBIRD 1992 CROWN VICTORIA LINCOLN-MERCURY: 1986-92 SABLE 1988-92 CONTINENTAL 1989-92 COUGAR 1991-92 TOWN CAR 1992 GRAND MARQUIS ISSUE: Brake roughness may occur after the lug nuts are installed and tightened with an impact wrench. The resulting torque difference from stud to stud can be as high as 60 lb.ft (81 N-m). This torque difference stud to stud may cause an increase in rotor runout by as much as .003"-.005"(.076mm-.127mm). The increase in rotor runout may speed up the development of brake roughness. ACTION: Tighten the wheel lug nuts in the "final' torque in the sequence described in the Service Manual. Use a torque wrench set to 95 +/- 10 lb.ft (129 +/- l4N-m). When performing brake service work that involves replacing or removing the rotor, refer to the following service procedure which minimizes hub/rotor "stacked" runout, a cause of brake roughness and uneven rotor wear. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new/turned rotor installed on the hub) indicates more then .002" (.05mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. HIGH SYSTEM RUNOUT High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT SERVICE TIPS 1. Completely clean the hub area that will contact the new/turned rotor. Remove rust build up. 2. Install the new/turned rotor on the hub and secure it with at least three (3) lug nuts. Tighten the lug nuts to 20 lb.ft (27 N-m) for testing. 3. Using a dial indicator 4201-C or equivalent, determine the total runout of the system. The total system (rotor and hub) runout must not exceed .002" (.05mm). 4. If the runout exceeds .002" (.05mm), proceed as follows: a. Remove the rotor and rotate it clockwise until the next hole lines up with a stud. b. Secure the rotor in the new position, reindexed as described in Step 2. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.05mm) or less total runout. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 92124 > Jun > 92 > Brakes - Roughness/Runout Check > Page 1660 5. If .002" (.05mm) or less runout cannot be reached, the hub should be replaced and Steps 2 through 4 repeated when the new hub/rotor is installed. NOTE: IT IS RECOMMENDED THAT NEW BRAKE ROTORS NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUNOUT AND THICKNESS VARIATION SPECIFICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheels: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 90132 > Jun > 90 > Wheels - Loss Of Balance Weights Wheels: All Technical Service Bulletins Wheels - Loss Of Balance Weights Article No. 90-13-2 ^ WHEELS - AVAILABILITY OF NEW BALANCE WEIGHTS ^ WHEELS - LOSS OF BALANCE WEIGHTS AND CORROSION FORD: 1984-86 LTD 1984-88 EXP 1984-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE ISSUE: The loss of wheel balance weights and corrosion damage to aluminum and steel wheels may be caused by the use of improper balance weights. As a running change in the 1990 model year, a new series of metric wheel balance weights were introduced across all car lines. These metric wheel balance weights are compatible with previous Ford and Lincoln-Mercury passenger car wheels. The new balance weights come in two series -- one for steel wheels and the other for aluminum wheels. ACTION: If service is required, refer to the following guidelines. Refer to the application blocks on the following page to select the correct balance weights. A Technical Service Bulletin for Light Truck applications will be released in the near future. Until that time, refer to the Rotunda catalog for wheel weight application. METRIC WEIGHTS: The traditional ounce series wheel balance weights were available in .25 ounce increments (.25 oz. = 7 grams). The new metric weights are available in 5 gram increments. This allows for... ^ Tighter spacing of the metric weights ^ Increased accuracy when balancing a tire and wheel assembly ^ Improved overall vehicle ride quality. STEEL WHEEL BALANCE WEIGHTS: Ford has replaced the zinc electroplated coating on the weight's steel clip with a new coating called "Dacromet". This is an improvement because... ^ Zinc electroplated wheel balance weight clips are susceptible to cracking and may allow the balance weight to fall off the wheel. ^ Zinc clips cause cosmetic damage to aluminum wheels as they corrode. ^ "Dacromet" finish provides five times the corrosion resistance of the zinc plate and will not cause the clip to crack. ALUMINUM WHEEL BALANCE WEIGHTS: The new aluminum series wheel balance weights are totally polyester coated (encapsulated) to further improve their corrosion resistance and appearance. MAXIMUM CORROSION PROTECTION: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 90132 > Jun > 90 > Wheels - Loss Of Balance Weights > Page 1669 For maximum corrosion protection and customer satisfaction, it is highly recommended that all dealers begin using... ^ Ford approved polyester coated wheel weights on all aluminum wheels ^ "Dacromet" clip coated weights on steel wheels. Both series of wheel balance weights are available in 5 gram increments. It is recommended that dealers begin converting their current balance equipment to accept the metric series balance weights. GUIDELINES FOR IDENTIFYING BALANCE WEIGHTS: Since Ford passenger car aluminum wheels are not designed to use other manufacturer's balance weights, any mismatch will possibly allow the weight to fall off the wheel resulting in a repeat repair. To ensure retention and improve corrosion resistance, only Ford approved balance weights should be used on Ford wheels. Some guidelines for telling the difference between Ford aluminum wheel weights and GM aluminum wheel weights are ... Figure 1 ^ The GM weight has a larger clip than the Ford weight, Figure 1. Figure 2 ^ When a GM weight is installed on a Ford wheel, the balance weight will not lay flat against the wheel's face, Figure 2. NOTE: REFER TO THE ROTUNDA CATALOG FOR NON-DOMESTIC PASSENGER CAR WHEEL WEIGHTS. Refer to the following wheel weight charts for a description and Rotunda part number. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 90132 > Jun > 90 > Wheels - Loss Of Balance Weights > Page 1670 OASIS CODES: 3300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 89173 > Aug > 89 > Aluminum Wheel - Air Leaks Wheels: All Technical Service Bulletins Aluminum Wheel - Air Leaks Article No. 89-17-3 WHEEL-ALUMINUM-LEAKS AIR FORD: 1986-90 CROWN VICTORIA, ESCORT 1986-88 EXP 1986-90 MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-90 FESTIVA 1989-90 PROBE LINCOLN-MERCURY: 1986-90 CONTINENTAL, COUGAR, GRAND MARQUIS 1986-87 LYNX 1986-90 MARK VII, SABLE, TOPAZ, TOWN CAR 1987-90 TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO This article is being republished in its entirety to expand the model year coverage to include 1987 through 1990 model year vehicles. ISSUE: Slow air leaks may occur in cast aluminum wheels because of porous wheel castings. ACTION: Use "HOT MELT" sealant (E7AZ-19554-A) and the following diagnostic/service procedure to eliminate the leaks. NOTE: THIS TSB MUST BE PERFORMED PRIOR TO REPLACING THE WHEEL FOR A LEAKING CONDITION. 1. Remove the tire and wheel assembly and inspect the wheel for structural damage. If none exists, go on to Step 2. If the wheel is damaged, replace it. 2. Check the complete wheel for possible air leaks. With the tire mounted on the wheel, locate the air leak using the water bath or equivalent method and mark the location. 3. Dismount the tire and on the tire side of the wheel prepare the surface for sealant. a. Thoroughly clean the leaking area with methylene chloride (e.g., choke cleaner E8AZ-19A501-AA) Or b. Use sandpaper of about 80 grit to thoroughly remove all contamination and score the wheel surface to improve adhesion of sealer. c. Prepare an adequate area around the leak to ensure covering the leak. d. Remove the valve stem if it is close to the repair area. 4. Use a clean rag to remove all cleaner or sanding dust. CAUTION: DO NOT USE AN OXYACETYLENE TORCH TO PERFORM STEP 5. Figure 1 5. Proceed to heat and seal the leaking area. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheels: > 89173 > Aug > 89 > Aluminum Wheel - Air Leaks > Page 1675 a. Heat the prepared area of the wheel with an electric heat gun (Rotunda 107-00301 type) or propane torch (not oxyacetylene) until the melt stick (E7AZ-19554-A) flows. b. Apply the hot melt material over the prepared area using a liberal flow and a wiping action to assure coverage of the leaking area. NOTE: THE REPAIR IS MOST EFFECTIVE WHEN THE HEAT IS APPLIED TO THE BRAKE SIDE OF THE WHEEL AND THE SEALER IS MELTED BY THE HEAT IN THE METAL, SEE FIGURE 1. c. Apply only enough heat to melt the sealer and then remove the heat source. 6. Check for air leaks. a. After repairing the leak, allow the wheel to cool until it can be handled safely. b. Reassemble the tire and wheel. c. Inflate the tire to the recommended air pressure as indicated on the tire pressure decal. d. Check that the leak is repaired by using the procedure covered in Step 2. 7. After the repair is completed, balance and reinstall the wheel assembly on the vehicle. PART NUMBER PART NAME CLASS E8AZ-19A501-AA Choke Cleaner B E7AZ-19554-A Melt Stick Sealant BM OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-2-13, dated 1/28/87 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891703A Seal Aluminum Wheel - 0.8 Hr. ONE 891703B Seal Aluminum Wheel - 1.5 Hrs. TWO 891703C Seal Aluminum Wheel - 2.1 Hrs. THREE 891703D Seal Aluminum Wheel - 2.8 Hrs. FOUR DEALER CODING BASIC PART NO. CONDITION CODE 1007 48 OASIS CODES: 3300, 3500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 92124 > Jun > 92 > Brakes - Roughness/Runout Check Wheels: All Technical Service Bulletins Brakes - Roughness/Runout Check Article No. 92-12-4 DATE: 06-03-92 ^ BRAKES-ROTOR-REPLACEMENT SERVICE TIPS ^ BRAKES-ROUGHNESS DEVELOPED FROM INCREASE IN ROTOR RUNOUT ^ WHEELS-LUG NUT TIGHTENING PROCEDURE FORD: 1986-92 TAURUS 1989-92 THUNDERBIRD 1992 CROWN VICTORIA LINCOLN-MERCURY: 1986-92 SABLE 1988-92 CONTINENTAL 1989-92 COUGAR 1991-92 TOWN CAR 1992 GRAND MARQUIS ISSUE: Brake roughness may occur after the lug nuts are installed and tightened with an impact wrench. The resulting torque difference from stud to stud can be as high as 60 lb.ft (81 N-m). This torque difference stud to stud may cause an increase in rotor runout by as much as .003"-.005"(.076mm-.127mm). The increase in rotor runout may speed up the development of brake roughness. ACTION: Tighten the wheel lug nuts in the "final' torque in the sequence described in the Service Manual. Use a torque wrench set to 95 +/- 10 lb.ft (129 +/- l4N-m). When performing brake service work that involves replacing or removing the rotor, refer to the following service procedure which minimizes hub/rotor "stacked" runout, a cause of brake roughness and uneven rotor wear. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new/turned rotor installed on the hub) indicates more then .002" (.05mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. HIGH SYSTEM RUNOUT High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT SERVICE TIPS 1. Completely clean the hub area that will contact the new/turned rotor. Remove rust build up. 2. Install the new/turned rotor on the hub and secure it with at least three (3) lug nuts. Tighten the lug nuts to 20 lb.ft (27 N-m) for testing. 3. Using a dial indicator 4201-C or equivalent, determine the total runout of the system. The total system (rotor and hub) runout must not exceed .002" (.05mm). 4. If the runout exceeds .002" (.05mm), proceed as follows: a. Remove the rotor and rotate it clockwise until the next hole lines up with a stud. b. Secure the rotor in the new position, reindexed as described in Step 2. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.05mm) or less total runout. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 92124 > Jun > 92 > Brakes - Roughness/Runout Check > Page 1681 5. If .002" (.05mm) or less runout cannot be reached, the hub should be replaced and Steps 2 through 4 repeated when the new hub/rotor is installed. NOTE: IT IS RECOMMENDED THAT NEW BRAKE ROTORS NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUNOUT AND THICKNESS VARIATION SPECIFICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheels: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 90132 > Jun > 90 > Wheels - Loss Of Balance Weights Wheels: All Technical Service Bulletins Wheels - Loss Of Balance Weights Article No. 90-13-2 ^ WHEELS - AVAILABILITY OF NEW BALANCE WEIGHTS ^ WHEELS - LOSS OF BALANCE WEIGHTS AND CORROSION FORD: 1984-86 LTD 1984-88 EXP 1984-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE ISSUE: The loss of wheel balance weights and corrosion damage to aluminum and steel wheels may be caused by the use of improper balance weights. As a running change in the 1990 model year, a new series of metric wheel balance weights were introduced across all car lines. These metric wheel balance weights are compatible with previous Ford and Lincoln-Mercury passenger car wheels. The new balance weights come in two series -- one for steel wheels and the other for aluminum wheels. ACTION: If service is required, refer to the following guidelines. Refer to the application blocks on the following page to select the correct balance weights. A Technical Service Bulletin for Light Truck applications will be released in the near future. Until that time, refer to the Rotunda catalog for wheel weight application. METRIC WEIGHTS: The traditional ounce series wheel balance weights were available in .25 ounce increments (.25 oz. = 7 grams). The new metric weights are available in 5 gram increments. This allows for... ^ Tighter spacing of the metric weights ^ Increased accuracy when balancing a tire and wheel assembly ^ Improved overall vehicle ride quality. STEEL WHEEL BALANCE WEIGHTS: Ford has replaced the zinc electroplated coating on the weight's steel clip with a new coating called "Dacromet". This is an improvement because... ^ Zinc electroplated wheel balance weight clips are susceptible to cracking and may allow the balance weight to fall off the wheel. ^ Zinc clips cause cosmetic damage to aluminum wheels as they corrode. ^ "Dacromet" finish provides five times the corrosion resistance of the zinc plate and will not cause the clip to crack. ALUMINUM WHEEL BALANCE WEIGHTS: The new aluminum series wheel balance weights are totally polyester coated (encapsulated) to further improve their corrosion resistance and appearance. MAXIMUM CORROSION PROTECTION: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 90132 > Jun > 90 > Wheels - Loss Of Balance Weights > Page 1690 For maximum corrosion protection and customer satisfaction, it is highly recommended that all dealers begin using... ^ Ford approved polyester coated wheel weights on all aluminum wheels ^ "Dacromet" clip coated weights on steel wheels. Both series of wheel balance weights are available in 5 gram increments. It is recommended that dealers begin converting their current balance equipment to accept the metric series balance weights. GUIDELINES FOR IDENTIFYING BALANCE WEIGHTS: Since Ford passenger car aluminum wheels are not designed to use other manufacturer's balance weights, any mismatch will possibly allow the weight to fall off the wheel resulting in a repeat repair. To ensure retention and improve corrosion resistance, only Ford approved balance weights should be used on Ford wheels. Some guidelines for telling the difference between Ford aluminum wheel weights and GM aluminum wheel weights are ... Figure 1 ^ The GM weight has a larger clip than the Ford weight, Figure 1. Figure 2 ^ When a GM weight is installed on a Ford wheel, the balance weight will not lay flat against the wheel's face, Figure 2. NOTE: REFER TO THE ROTUNDA CATALOG FOR NON-DOMESTIC PASSENGER CAR WHEEL WEIGHTS. Refer to the following wheel weight charts for a description and Rotunda part number. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 90132 > Jun > 90 > Wheels - Loss Of Balance Weights > Page 1691 OASIS CODES: 3300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Bearing Adjusting Nut 17-25 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 1695 Wheel Bearing: Adjustments These models are equipped with sealed bearing units which do not require adjustment or maintenance. If bearing is found to be defective, then hub and bearing must be replaced as an assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Fig. 3 Hub & Wheel Bearing Assembly REPLACE 1. Raise and support front of vehicle, then remove wheel and tire assembly. 2. Remove grease cap from hub. 3. Remove disc brake caliper with brake hose attached. Suspend caliper from suspension with wire. Do not allow caliper to hang from brake hose. 4. Remove brake rotor. 5. Remove hub nut, then remove hub and bearing assembly, Fig. 3. If difficulty is encountered in hub removal, use hub removal tool No. T81P-1104-C or equivalent. 6. Reverse procedure to install. Use a new hub nut and tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1698 Wheel Bearing: Service and Repair Rear NOTE: There are two approved methods for removing the hub from the bearing. Both methods are outlined. Removal 1. Remove knuckle and hub assembly from vehicle as outlined. 2. Place knuckle and hub assembly in a vise. NOTE: On drum brakes, remove shoe and linings, springs, and adjuster from backing plate. Remove four screws that retain the backing plate to the knuckle. Method One A. Position 3-Jaw Puller D88L-1 037-A and Step Plate D8OL-630-5 or equivalent, on the knuckle and press out the hub from the knuckle assembly. Method Two Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1699 A. Position Rear Hub Remover T89P-1 225-AH or equivalent between the knuckle and the backing plate. B. Assemble Hub Remover/Replacer T81 P-il 04-C and Step Plate D8OL-630-5 or equivalent. C. With forcing nut below the crossbar, hold forcing screw and turn forcing nut to remove hub. 3. Remove the backing plate. 4. Remove bearing retainer snap ring. 5. Place knuckle and bearing assembly on a press bed using Hub Support T89P-1 104-A and Bearing Remover T83P-1 1 04-AH2 or equivalent, and press bearing out of knuckle assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1700 Installation 1. Place knuckle assembly on press bed and position bearing in the bearing bore of the knuckle. 2. Using Bearing Installer T86P-1 1 04-A3 or equivalent, press the bearing into the knuckle. 3. Install bearing retainer snap ring. 4. Position the backing plate on the knuckle. Install four retaining bolts and tighten to 61-81 Nm (45-59 lb-ft). 5. Place knuckle assembly on the Hub Support T89P-1 104-A or equivalent and position on press bed plate Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1701 6. Position hub on bearing and using Hub Installer/Bearing Remover T83P-1 104-AH2 or equivalent, press hub into bearing. NOTE: If vehicle is equipped with drum brakes, install shoe linings, springs, and adjuster on backing plate 7. Prior to hub/bearing/knuckle installation replace bearing dust seal on the outboard CV joint with new seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 1702 Dust Seal Installation 8. Install new dust seal, ensuring seal flange faces outboard toward bearing. Use Drive Tube T83T-31 32-Al and Bearing Dust Seal Installer T89P-l 249-A or equivalent. 9. Install hub and knuckle assembly. See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Wheel Hub: Customer Interest Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 1711 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 1712 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Wheel Hub: All Technical Service Bulletins Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 1718 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 1719 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 1729 Wheel Hub: Specifications Rear Axle Hub Nut 250 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 1730 Wheel Hub: Service and Repair NOTE: There are two approved methods for removing the hub from the bearing. Both methods are outlined. Removal 1. Remove knuckle and hub assembly from vehicle as outlined. 2. Place knuckle and hub assembly in a vise. NOTE: On drum brakes, remove shoe and linings, springs, and adjuster from backing plate. Remove four screws that retain the backing plate to the knuckle. Method One A. Position 3-Jaw Puller D88L-1 037-A and Step Plate D8OL-630-5 or equivalent, on the knuckle and press out the hub from the knuckle assembly. Method Two Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 1731 A. Position Rear Hub Remover T89P-1 225-AH or equivalent between the knuckle and the backing plate. B. Assemble Hub Remover/Replacer T81 P-il 04-C and Step Plate D8OL-630-5 or equivalent. C. With forcing nut below the crossbar, hold forcing screw and turn forcing nut to remove hub. 3. Remove the backing plate. 4. Remove bearing retainer snap ring. 5. Place knuckle and bearing assembly on a press bed using Hub Support T89P-1 104-A and Bearing Remover T83P-1 1 04-AH2 or equivalent, and press bearing out of knuckle assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 1732 Installation 1. Place knuckle assembly on press bed and position bearing in the bearing bore of the knuckle. 2. Using Bearing Installer T86P-1 1 04-A3 or equivalent, press the bearing into the knuckle. 3. Install bearing retainer snap ring. 4. Position the backing plate on the knuckle. Install four retaining bolts and tighten to 61-81 Nm (45-59 lb-ft). 5. Place knuckle assembly on the Hub Support T89P-1 104-A or equivalent and position on press bed plate Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 1733 6. Position hub on bearing and using Hub Installer/Bearing Remover T83P-1 104-AH2 or equivalent, press hub into bearing. NOTE: If vehicle is equipped with drum brakes, install shoe linings, springs, and adjuster on backing plate 7. Prior to hub/bearing/knuckle installation replace bearing dust seal on the outboard CV joint with new seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 1734 Dust Seal Installation 8. Install new dust seal, ensuring seal flange faces outboard toward bearing. Use Drive Tube T83T-31 32-Al and Bearing Dust Seal Installer T89P-l 249-A or equivalent. 9. Install hub and knuckle assembly. See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application Wheel Fastener: Customer Interest Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 1743 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1749 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1750 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 9562 > Mar > 95 > Brakes - Roughness During Application Wheel Fastener: All Technical Service Bulletins Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 1755 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 92124 > Jun > 92 > Brakes - Roughness/Runout Check Wheel Fastener: All Technical Service Bulletins Brakes - Roughness/Runout Check Article No. 92-12-4 DATE: 06-03-92 ^ BRAKES-ROTOR-REPLACEMENT SERVICE TIPS ^ BRAKES-ROUGHNESS DEVELOPED FROM INCREASE IN ROTOR RUNOUT ^ WHEELS-LUG NUT TIGHTENING PROCEDURE FORD: 1986-92 TAURUS 1989-92 THUNDERBIRD 1992 CROWN VICTORIA LINCOLN-MERCURY: 1986-92 SABLE 1988-92 CONTINENTAL 1989-92 COUGAR 1991-92 TOWN CAR 1992 GRAND MARQUIS ISSUE: Brake roughness may occur after the lug nuts are installed and tightened with an impact wrench. The resulting torque difference from stud to stud can be as high as 60 lb.ft (81 N-m). This torque difference stud to stud may cause an increase in rotor runout by as much as .003"-.005"(.076mm-.127mm). The increase in rotor runout may speed up the development of brake roughness. ACTION: Tighten the wheel lug nuts in the "final' torque in the sequence described in the Service Manual. Use a torque wrench set to 95 +/- 10 lb.ft (129 +/- l4N-m). When performing brake service work that involves replacing or removing the rotor, refer to the following service procedure which minimizes hub/rotor "stacked" runout, a cause of brake roughness and uneven rotor wear. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new/turned rotor installed on the hub) indicates more then .002" (.05mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. HIGH SYSTEM RUNOUT High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT SERVICE TIPS 1. Completely clean the hub area that will contact the new/turned rotor. Remove rust build up. 2. Install the new/turned rotor on the hub and secure it with at least three (3) lug nuts. Tighten the lug nuts to 20 lb.ft (27 N-m) for testing. 3. Using a dial indicator 4201-C or equivalent, determine the total runout of the system. The total system (rotor and hub) runout must not exceed .002" (.05mm). 4. If the runout exceeds .002" (.05mm), proceed as follows: a. Remove the rotor and rotate it clockwise until the next hole lines up with a stud. b. Secure the rotor in the new position, reindexed as described in Step 2. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.05mm) or less total runout. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 92124 > Jun > 92 > Brakes - Roughness/Runout Check > Page 1760 5. If .002" (.05mm) or less runout cannot be reached, the hub should be replaced and Steps 2 through 4 repeated when the new hub/rotor is installed. NOTE: IT IS RECOMMENDED THAT NEW BRAKE ROTORS NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUNOUT AND THICKNESS VARIATION SPECIFICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1766 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 1767 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 92124 > Jun > 92 > Brakes - Roughness/Runout Check Wheel Fastener: All Technical Service Bulletins Brakes - Roughness/Runout Check Article No. 92-12-4 DATE: 06-03-92 ^ BRAKES-ROTOR-REPLACEMENT SERVICE TIPS ^ BRAKES-ROUGHNESS DEVELOPED FROM INCREASE IN ROTOR RUNOUT ^ WHEELS-LUG NUT TIGHTENING PROCEDURE FORD: 1986-92 TAURUS 1989-92 THUNDERBIRD 1992 CROWN VICTORIA LINCOLN-MERCURY: 1986-92 SABLE 1988-92 CONTINENTAL 1989-92 COUGAR 1991-92 TOWN CAR 1992 GRAND MARQUIS ISSUE: Brake roughness may occur after the lug nuts are installed and tightened with an impact wrench. The resulting torque difference from stud to stud can be as high as 60 lb.ft (81 N-m). This torque difference stud to stud may cause an increase in rotor runout by as much as .003"-.005"(.076mm-.127mm). The increase in rotor runout may speed up the development of brake roughness. ACTION: Tighten the wheel lug nuts in the "final' torque in the sequence described in the Service Manual. Use a torque wrench set to 95 +/- 10 lb.ft (129 +/- l4N-m). When performing brake service work that involves replacing or removing the rotor, refer to the following service procedure which minimizes hub/rotor "stacked" runout, a cause of brake roughness and uneven rotor wear. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new/turned rotor installed on the hub) indicates more then .002" (.05mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. HIGH SYSTEM RUNOUT High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT SERVICE TIPS 1. Completely clean the hub area that will contact the new/turned rotor. Remove rust build up. 2. Install the new/turned rotor on the hub and secure it with at least three (3) lug nuts. Tighten the lug nuts to 20 lb.ft (27 N-m) for testing. 3. Using a dial indicator 4201-C or equivalent, determine the total runout of the system. The total system (rotor and hub) runout must not exceed .002" (.05mm). 4. If the runout exceeds .002" (.05mm), proceed as follows: a. Remove the rotor and rotate it clockwise until the next hole lines up with a stud. b. Secure the rotor in the new position, reindexed as described in Step 2. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.05mm) or less total runout. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 92124 > Jun > 92 > Brakes - Roughness/Runout Check > Page 1772 5. If .002" (.05mm) or less runout cannot be reached, the hub should be replaced and Steps 2 through 4 repeated when the new hub/rotor is installed. NOTE: IT IS RECOMMENDED THAT NEW BRAKE ROTORS NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUNOUT AND THICKNESS VARIATION SPECIFICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Lug Nut Torque Patterns IMPORTANT Check all parts, including rims, lug studs, lug nuts, and mating surfaces of hubs and tire rims for rust, damage, or dirt. Clean mating surfaces with a wire brush to remove any foreign material. Replace any damaged parts as needed. Careless installation of tire/rim assemblies in a vehicle is a major cause of tire installation problems. Proper installation, including fastener torque, is essential to economical, safe and trouble free service. Use only the proper sizes and types of fasteners for safe and proper service. Tighten the fasteners a quarter turn at a time using the tightening sequence diagram as a guide. This is very important to prevent misalignment of the wheel. Continue tightening the fasteners in sequence until the fasteners are tightened to the proper torque (See WHEEL FASTENER TORQUE). CAUTION: Improper torque or tightening sequence can cause distortion, fatigue cracks, or alignment problems. After driving the vehicle for a short distance, recheck the wheel fastener torque. Parts will usually seat naturally, reducing the torque on the fasteners. Retorque all fasteners to the proper torque. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 1775 Wheel Fastener: Specifications Wheel Lug Nuts 85-105 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications Camshaft: Specifications 3.8L/V6-232, 1989-94 Exhaust ................................................................................................................................................ .................................................................... .259 inch Intake .............................................................. ......................................................................................................................................................... .245 inch Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft, Engine > Component Information > Specifications > Page 1782 Camshaft: Service and Repair Camshaft Installation 1. Drain cooling system and remove radiator and grille. 2. On engines equipped with air conditioning, purge refrigerant from system and remove condenser. 3. On all engines, remove front cover, timing chain and sprockets. 4. Remove intake manifold. 5. Remove pushrods, lifters and oil pan. 6. Remove thrust plate, then carefully remove camshaft by pulling toward front of engine, Fig. 9. Use care to avoid damaging camshaft bearings. 7. Reverse procedure to install, noting the following: a. Lubricate cam lobes and bearing surfaces with Oil Conditioner D9AZ-19579-CA or equivalent. b. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash Adjuster, Valve > Component Information > Service and Repair Lifter / Lash Adjuster: Service and Repair Fig. 7 Hydraulic Valve Lifter 1. Disconnect secondary ignition wires from spark plugs using wire remover T74P-6666-A or equivalent. Remove ignition wire routing clips from rocker arm cover attaching bolt studs and position wires aside. 2. Remove intake manifold, refer to INTAKE MANIFOLD. 3. Remove rocker arm covers. On engines with stud mounted rocker arms, loosen stud nuts and rotate rocker arms to one side. On other engines, remove fulcrum bolt, fulcrum, rocker arm and fulcrum guide (if used). 4. Remove pushrods in sequence so they can be installed in their original bores. 5. Remove lifter guide retainer bolts, retainer and guide plate, if equipped. 6. Using a magnet rod, remove lifters and place in a numbered rack so they can be installed in their original bores. If lifters are stuck in bores by excessive varnish, etc., it may be necessary to use a plier-type tool to remove. Rotate lifter back and forth to loosen from gum or varnish. 7. The internal parts of each lifter are matched sets. Do not intermix parts. Keep assemblies intact until they are to be cleaned, Fig. 7. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 95243 > Dec > 95 > Engine - Rocker Arm Squeak/Chirp/Knock Noise Rocker Arm Assembly: Customer Interest Engine - Rocker Arm Squeak/Chirp/Knock Noise Article No. 95-24-3 12/04/95 ^ ROCKER ARM - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" NOISE ^ NOISE - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" FROM ROCKER ARM FORD: 1989-95 TAURUS, THUNDERBIRD 1994-95 MUSTANG LINCOLN-MERCURY: 1989-94 CONTINENTAL 1989-95 COUGAR, SABLE LIGHT TRUCK: 1995 WINDSTAR This TSB article is being republished in its entirety to correct the vehicle model years affected. ISSUE: A low medium-pitch noise, such as a "squeak", "chirp" or "knock" that can be heard under the hood or in the passenger compartment may be caused by the fulcrum and rocker arm assemblies. The noise is most noticeable at engine idle with the engine at normal operating temperature. ACTION: Use the following Diagnostic Procedure to determine if a Break-In Additive will eliminate the noise or if a new set of rocker arm assemblies are required. NOTE: A DESIGN CHANGE WAS INCORPORATED FOR THE 1996 MODEL YEAR TO REDUCE THE POSSIBILITY OF THIS CONDITION. USE OF THIS TSB IN AN ATTEMPT TO SERVICE 1996 VEHICLES IS NOT RECOMMENDED. DIAGNOSTIC PROCEDURE 1. Bring the engine to normal operating temperature. 2. Using a stethoscope on the rocker arm cover, determine if rocker arms are noisy. 3. If noisy rocker arms are present, add one (1) container of Break-In Additive (E9SZ-19579-A) to the crankcase. 4. Continue to idle the engine for 10 minutes. 5. Test drive the vehicle for no less than 5 minutes. 6. Check for the noise. It the noise is gone, change the crankcase oil and filter. If the noise is still present, proceed to Step 7. 7. Remove the rocker arm covers. Refer to the appropriate Service Manual, Section 21-15 for 1989-90 models and Section 03-01 for 1991-95 models, for service details 8. Remove all the rocker arms, fulcrums and retaining bolts. Refer to the appropriate Service Manual, Section 21-15 for 1989-90 models and Section 03-01 for 1991-95 models, for service details. 9. Install NEW rocker arms, fulcrums and retaining bolts as follows: a. Soak new rocker arms and fulcrums in Break-In Additive (E9SZ-19579-A) for a minimum of 3 minutes before installing. b. Rotate the crankshaft until the tappet is resting on the heel (base circle) of the camshaft lobe. c. Position the rocker arm over the push rod. d. Install the fulcrum and retaining bolt. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 95243 > Dec > 95 > Engine - Rocker Arm Squeak/Chirp/Knock Noise > Page 1794 e. Tighten the retaining bolt to 7-15 N.m (5-11 lb-ft). 10. Finally, tighten all the rocker arm retaining bolts to 30-40 N.m (22-30 lb-ft). NOTE: THE CAMSHAFT CAN BE IN ANY POSITION WHILE PERFORMING STEP 10. 11. Change the crankcase oil and filter. PART NUMBER PART NAME E9SZ-6564-A Rocker Arm (12 Req'd.) F4DZ-6A528-A Fulcrum (12 Req'd.) F4DZ-6A527-A Bolt (12 Req'd.) E9SZ-19579-A Break-In Additive XO-5W30-QSP Oil-5W30 (Pk/12) E4FZ-6731-A FL-400A Oil Filter OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-18-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-94 Lincolns And All Other 1992-95 Cars, Basic And Powertrain Warranty Coverage For 1989-91 Model Year Vehicles And Major Component Coverage For 1989-90 Model Year Continentals OPERATION DESCRIPTION TIME 952403A Add Break-In Additive - 0.7 Hr. Includes Changing Oil And Filter And Test Drive 952403B Remove And Replace 2.6 Hrs. Rocker Arm Assembly - Thunderbird/Cougar/Mustang - Base Engine 952403C Remove And Replace 3.9 Hrs. Rocker Arm Assembly - Thunderbird/Cougar - Supercharged Engine 952403D Remove And Replace 1.9 Hrs. Rocker Arm Assembly - Taurus/Sable/Continental 952403E Remove And Replace 2.8 Hrs. Rocker Assembly - Windstar DEALER CODING CONDITION BASIC PART NO. CODE 6564 56 OASIS CODES: 401000, 497000, 499000, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 94109 > May > 94 > Engine - Rocker Arm Squeak/Chirp/Knock Rocker Arm Assembly: Customer Interest Engine - Rocker Arm Squeak/Chirp/Knock Article No. 94-10-9 06/10/94 ^ ROCKER ARM - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" NOISE ^ NOISE - 3.8L ENGINE - LOW PITCHED "SQUEAK" "CHIRP" OR "KNOCK" FROM ROCKER ARM FORD: 1989-94 TAURUS, THUNDERBIRD 1994 MUSTANG LINCOLN-MERCURY: 1989-94 CONTINENTAL, COUGAR, SABLE This TSB article is being republished in its entirety to correct the labor allowances. ISSUE: A low medium-pitch noise, such as a "squeak", "chirp" or "knock" that can be heard under the hood or in the passenger compartment, may be caused by the fulcrum and rocker arm assemblies. The noise is most noticeable at engine idle with the engine at normal operating temperature. ACTION: Use the following diagnostic procedure to determine if a Break-In Additive will eliminate the noise or if a new set of rocker arm assemblies are required. 1. Bring the engine to normal operating temperature. 2. Using a stethoscope on the rocker arm cover, determine if rocker arms are noisy. 3. If noisy rocker arms are present, add one (1) container of Break-in Additive (E9SZ-19579-A) to the crankcase. 4. Continue to idle the engine for ten (10) minutes. 5. Test drive the vehicle for no less than five (5) minutes. 6. Check for the noise. If the noise is gone, change the crankcase oil and filter. If the noise is still present, proceed to Step 7. 7. Remove the rocker arm covers. Refer to the appropriate Service Manual, Section 21-15 for 1989/90 models and Section 03-01 for 1991/94 models, for service details. 8. Remove all the rocker arms, fulcrums and retaining bolts. Refer to the appropriate Service Manual, Section 21-15 for 1989/90 models and Section 03-01 for 1991/94 models, for service details. 9. Install NEW rocker arms, fulcrums and retaining bolts as follows: a. Soak new rocker arms and fulcrums in Break-in Additive (E9SZ-19579-A) for a minimum of three minutes before installing them. b. Rotate the crankshaft until the tappet is resting on the heel (base circle) of the camshaft lobe. c. Position the rocker arm over the push rod. d. Install the fulcrum and retaining bolt. e. Tighten the retaining bolt to 7-15 N-m (5-11 lb.ft.). 10. Final tighten all the rocker arm retaining bolts to 30-40 N-m (23-30 lb.ft.). NOTE: THE CAMSHAFT CAN BE IN ANY POSITION WHILE PERFORMING STEP 10. 11. Change the crankcase oil and filter. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 94109 > May > 94 > Engine - Rocker Arm Squeak/Chirp/Knock > Page 1799 Parts Block OTHER APPLICABLE ARTICLES: None SUPERSEDES: 94-2-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991/94 Lincolns And All Other 1992/94 Cars; Basic, Major Component And Powertrain Warranty Coverage For 1989/1991 Model Year Vehicles OPERATION DESCRIPTION TIME 941009A Remove And Replace 2.6 Hrs. Rocker Arm Assy. - Thunderbird/Cougar/Mustang - Base Engine 941009B Remove And Replace 3.9 Hrs. Rocker Arm Assy. - Thunderbird/Cougar - Supercharged Engine 941009C Remove And Replace 1.9 Hrs. Rocker Arm Assy. - Taurus/Sable/Continental DEALER CODING BASIC PART NO. CONDITION CODE 6564 56 OASIS CODES: 497000, 499000, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 95243 > Dec > 95 > Engine - Rocker Arm Squeak/Chirp/Knock Noise Rocker Arm Assembly: All Technical Service Bulletins Engine - Rocker Arm Squeak/Chirp/Knock Noise Article No. 95-24-3 12/04/95 ^ ROCKER ARM - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" NOISE ^ NOISE - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" FROM ROCKER ARM FORD: 1989-95 TAURUS, THUNDERBIRD 1994-95 MUSTANG LINCOLN-MERCURY: 1989-94 CONTINENTAL 1989-95 COUGAR, SABLE LIGHT TRUCK: 1995 WINDSTAR This TSB article is being republished in its entirety to correct the vehicle model years affected. ISSUE: A low medium-pitch noise, such as a "squeak", "chirp" or "knock" that can be heard under the hood or in the passenger compartment may be caused by the fulcrum and rocker arm assemblies. The noise is most noticeable at engine idle with the engine at normal operating temperature. ACTION: Use the following Diagnostic Procedure to determine if a Break-In Additive will eliminate the noise or if a new set of rocker arm assemblies are required. NOTE: A DESIGN CHANGE WAS INCORPORATED FOR THE 1996 MODEL YEAR TO REDUCE THE POSSIBILITY OF THIS CONDITION. USE OF THIS TSB IN AN ATTEMPT TO SERVICE 1996 VEHICLES IS NOT RECOMMENDED. DIAGNOSTIC PROCEDURE 1. Bring the engine to normal operating temperature. 2. Using a stethoscope on the rocker arm cover, determine if rocker arms are noisy. 3. If noisy rocker arms are present, add one (1) container of Break-In Additive (E9SZ-19579-A) to the crankcase. 4. Continue to idle the engine for 10 minutes. 5. Test drive the vehicle for no less than 5 minutes. 6. Check for the noise. It the noise is gone, change the crankcase oil and filter. If the noise is still present, proceed to Step 7. 7. Remove the rocker arm covers. Refer to the appropriate Service Manual, Section 21-15 for 1989-90 models and Section 03-01 for 1991-95 models, for service details 8. Remove all the rocker arms, fulcrums and retaining bolts. Refer to the appropriate Service Manual, Section 21-15 for 1989-90 models and Section 03-01 for 1991-95 models, for service details. 9. Install NEW rocker arms, fulcrums and retaining bolts as follows: a. Soak new rocker arms and fulcrums in Break-In Additive (E9SZ-19579-A) for a minimum of 3 minutes before installing. b. Rotate the crankshaft until the tappet is resting on the heel (base circle) of the camshaft lobe. c. Position the rocker arm over the push rod. d. Install the fulcrum and retaining bolt. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 95243 > Dec > 95 > Engine - Rocker Arm Squeak/Chirp/Knock Noise > Page 1805 e. Tighten the retaining bolt to 7-15 N.m (5-11 lb-ft). 10. Finally, tighten all the rocker arm retaining bolts to 30-40 N.m (22-30 lb-ft). NOTE: THE CAMSHAFT CAN BE IN ANY POSITION WHILE PERFORMING STEP 10. 11. Change the crankcase oil and filter. PART NUMBER PART NAME E9SZ-6564-A Rocker Arm (12 Req'd.) F4DZ-6A528-A Fulcrum (12 Req'd.) F4DZ-6A527-A Bolt (12 Req'd.) E9SZ-19579-A Break-In Additive XO-5W30-QSP Oil-5W30 (Pk/12) E4FZ-6731-A FL-400A Oil Filter OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-18-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-94 Lincolns And All Other 1992-95 Cars, Basic And Powertrain Warranty Coverage For 1989-91 Model Year Vehicles And Major Component Coverage For 1989-90 Model Year Continentals OPERATION DESCRIPTION TIME 952403A Add Break-In Additive - 0.7 Hr. Includes Changing Oil And Filter And Test Drive 952403B Remove And Replace 2.6 Hrs. Rocker Arm Assembly - Thunderbird/Cougar/Mustang - Base Engine 952403C Remove And Replace 3.9 Hrs. Rocker Arm Assembly - Thunderbird/Cougar - Supercharged Engine 952403D Remove And Replace 1.9 Hrs. Rocker Arm Assembly - Taurus/Sable/Continental 952403E Remove And Replace 2.8 Hrs. Rocker Assembly - Windstar DEALER CODING CONDITION BASIC PART NO. CODE 6564 56 OASIS CODES: 401000, 497000, 499000, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 94109 > May > 94 > Engine - Rocker Arm Squeak/Chirp/Knock Rocker Arm Assembly: All Technical Service Bulletins Engine - Rocker Arm Squeak/Chirp/Knock Article No. 94-10-9 06/10/94 ^ ROCKER ARM - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" NOISE ^ NOISE - 3.8L ENGINE - LOW PITCHED "SQUEAK" "CHIRP" OR "KNOCK" FROM ROCKER ARM FORD: 1989-94 TAURUS, THUNDERBIRD 1994 MUSTANG LINCOLN-MERCURY: 1989-94 CONTINENTAL, COUGAR, SABLE This TSB article is being republished in its entirety to correct the labor allowances. ISSUE: A low medium-pitch noise, such as a "squeak", "chirp" or "knock" that can be heard under the hood or in the passenger compartment, may be caused by the fulcrum and rocker arm assemblies. The noise is most noticeable at engine idle with the engine at normal operating temperature. ACTION: Use the following diagnostic procedure to determine if a Break-In Additive will eliminate the noise or if a new set of rocker arm assemblies are required. 1. Bring the engine to normal operating temperature. 2. Using a stethoscope on the rocker arm cover, determine if rocker arms are noisy. 3. If noisy rocker arms are present, add one (1) container of Break-in Additive (E9SZ-19579-A) to the crankcase. 4. Continue to idle the engine for ten (10) minutes. 5. Test drive the vehicle for no less than five (5) minutes. 6. Check for the noise. If the noise is gone, change the crankcase oil and filter. If the noise is still present, proceed to Step 7. 7. Remove the rocker arm covers. Refer to the appropriate Service Manual, Section 21-15 for 1989/90 models and Section 03-01 for 1991/94 models, for service details. 8. Remove all the rocker arms, fulcrums and retaining bolts. Refer to the appropriate Service Manual, Section 21-15 for 1989/90 models and Section 03-01 for 1991/94 models, for service details. 9. Install NEW rocker arms, fulcrums and retaining bolts as follows: a. Soak new rocker arms and fulcrums in Break-in Additive (E9SZ-19579-A) for a minimum of three minutes before installing them. b. Rotate the crankshaft until the tappet is resting on the heel (base circle) of the camshaft lobe. c. Position the rocker arm over the push rod. d. Install the fulcrum and retaining bolt. e. Tighten the retaining bolt to 7-15 N-m (5-11 lb.ft.). 10. Final tighten all the rocker arm retaining bolts to 30-40 N-m (23-30 lb.ft.). NOTE: THE CAMSHAFT CAN BE IN ANY POSITION WHILE PERFORMING STEP 10. 11. Change the crankcase oil and filter. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 94109 > May > 94 > Engine - Rocker Arm Squeak/Chirp/Knock > Page 1810 Parts Block OTHER APPLICABLE ARTICLES: None SUPERSEDES: 94-2-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991/94 Lincolns And All Other 1992/94 Cars; Basic, Major Component And Powertrain Warranty Coverage For 1989/1991 Model Year Vehicles OPERATION DESCRIPTION TIME 941009A Remove And Replace 2.6 Hrs. Rocker Arm Assy. - Thunderbird/Cougar/Mustang - Base Engine 941009B Remove And Replace 3.9 Hrs. Rocker Arm Assy. - Thunderbird/Cougar - Supercharged Engine 941009C Remove And Replace 1.9 Hrs. Rocker Arm Assy. - Taurus/Sable/Continental DEALER CODING BASIC PART NO. CONDITION CODE 6564 56 OASIS CODES: 497000, 499000, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 1811 Rocker Arm Assembly: Service and Repair Fig. 6 Rocker Arm Assembly These engines use stamped steel rocker arms retained by a fulcrum seat which bolts directly to the cylinder head and guides the rocker arm, Fig. 6. Torque fulcrum bolts in two steps as follows: For each valve rotate crankshaft until valve lifter rests on heel (base circle) of camshaft lobe and torque fulcrum bolt to 5-11 ft. lbs. After initial torquing of all fulcrum bolts, final torque to 19-25 ft. lbs. Final torque may be done with camshaft in any position. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Gear > Component Information > Technical Service Bulletins > Balance Shaft Drive Gear - Manual Revision Balance Shaft Gear: Technical Service Bulletins Balance Shaft Drive Gear - Manual Revision SHOP MANUAL - 1989 - PAGE 21-15-14 - ILLUSTRATION FOR REMOVAL AND INSTALLATION PROCEDURES INCORRECTLY SHOWS BALANCE SHAFT DRIVE GEAR ON 3.8L ENGINE Article No. 90-6B-35 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Balance Shaft Gear > Component Information > Technical Service Bulletins > Balance Shaft Drive Gear - Manual Revision > Page 1817 ISSUE: The illustration on page 21-15-14 of the 1989 Thunderbird/Cougar Shop Manual has been modified. The balance shaft drive gear for the 3.8L engine has been removed. ACTION: Refer to the pages following this TSB article for the updated illustration. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications Connecting Rod Bearing: Specifications Main and rod bearings are available in standard sizes and undersizes of .001, .002, .010, .020 and .030 inch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing > Component Information > Specifications > Page 1821 Connecting Rod Bearing: Service and Repair Main and rod bearings are available in standard sizes and undersizes of .001, .002, .010, .020 and .030 inch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications Connecting Rod: Specifications Refer to Engine/Specifications/Mechanical for tightening torque. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine > Component Information > Specifications > Page 1825 Connecting Rod: Service and Repair Fig. 10 Piston & Rod Assembly When installed, piston and rod assembly should have the notch or arrow in piston head toward front of engine with connecting rod numbers positioned as shown in Fig. 10. Check side clearance between connecting rods at each crankshaft journal. Correct side clearance is .0047-.0114 Inch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing > Component Information > Specifications Crankshaft Main Bearing: Specifications Main and rod bearings are available in standard sizes and undersizes of .001, .002, .010, .020 and .030 inch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Piston and Rod Assembly Service Piston: Service and Repair Piston and Rod Assembly Service Fig. 10 Piston & Rod Assembly When installed, piston and rod assembly should have the notch or arrow in piston head toward front of engine with connecting rod numbers positioned as shown in Fig. 10. Check side clearance between connecting rods at each crankshaft journal. Correct side clearance is .0047-.0114 Inch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine > Component Information > Service and Repair > Piston and Rod Assembly Service > Page 1833 Piston: Service and Repair Pistons, Oversize Pistons are available in standard sizes and oversizes of .003, .020, .030 and .040 inch. Piston rings are available in standard sizes and oversizes of .020, .030 and .040 inch. Piston pins are available in standard size and oversizes of .001 and .002 inch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine > Component Information > Service and Repair Piston Pin: Service and Repair Pistons are available in standard sizes and oversizes of .003, .020, .030 and .040 inch. Piston rings are available in standard sizes and oversizes of .020, .030 and .040 inch. Piston pins are available in standard size and oversizes of .001 and .002 inch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine > Component Information > Service and Repair Piston Ring: Service and Repair Pistons are available in standard sizes and oversizes of .003, .020, .030 and .040 inch. Piston rings are available in standard sizes and oversizes of .020, .030 and .040 inch. Piston pins are available in standard size and oversizes of .001 and .002 inch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Locations Valve Clearance: Locations FRONT TO REAR Right Bank.............................................................................................................. .................................................................................................I-E-I-E-I-E Left Bank............................ .............................................................................................................................................................. .......................E-I-E-I-E-I Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance > System Information > Locations > Page 1844 Valve Clearance: Adjustments Fig. 5 Compressing Lifter To Check Valve Clearance Correct valve clearance is .09-.19 inch. A .060 inch longer or a .060 inch shorter pushrod is available to compensate for dimensional changes in the valve train. If clearance is less than specified, the .060 inch shorter pushrod should be used. If clearance is more than the maximum specified, the .060 inch longer pushrod should be used. Using an auxiliary starter switch crankshaft until No. 1 cylinder is at TDC compression stroke, then compress valve lifter using tool T82C-6500-A or equivalent, Fig. 5. At this point, the following valves can be checked: intake Nos. 1, 3 and 6; exhaust Nos. 1, 2 and 4. After clearance on these valves has been checked, rotate crankshaft until No. 5 cylinder is at TDC compression stroke (1 revolution of crankshaft), and then compress valve lifter using tool No. T82C-6500-A or equivalent, Fig. 5, and check the following valves: intake Nos. 2, 4 and 5; exhaust Nos. 3, 5 and 6. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when fueling vehicle or when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. NOTE: Methanol and ethanol are not interchangeable. Methanol fuel can be used only in vehicles designed for methanol fuels. Ethanol fuel can be used only in vehicles designed for ethanol fuels. WARNING: The fuel tubes leading from the fuel tank to the engine are under pressure during vehicle operation. When fuel injected engines are turned off, the fuel in the fuel tubes remains pressurized for long periods of time to provide quick start-ups. Special procedures for servicing these pressurized fuel systems are outlined in this section. These procedures should be followed to prevent accidental spraying of fuel, causing personal injury or a fire hazard. WARNING: Do not swallow fuel of any kind. Fuels such as methanol or fuel ethanol and gasoline or mixtures of these fuels are highly toxic and if swallowed can cause death or permanent injury. Swallowing methanol can also cause blindness. Immediately seek medical attention from a physician or poison control center to treat anyone who has swallowed fuel. Be aware that if fuel is swallowed, the onset of potential ill health effects may be delayed 12-24 hours. AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR OF ANY KIND CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY. AVOID GETTING FUEL LIQUID IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. ALLOWING ANY FUEL TO GET IN YOUR EYES WILL CAUSE SEVERE IRRITATION. FAILURE TO SEEK PROPER MEDICAL ATTENTION FOR FUEL CONTACT WITH THE EYES COULD LEAD TO PERMANENT INJURY. IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. MAKE SURE YOU WASH YOUR HANDS BEFORE HANDLING FOOD. FUELS CONTAINING GASOLINE SUCH AS FUEL METHANOL AND FUEL ETHANOL MAY CONTAIN BENZENE, WHICH IS A CANCER-CAUSING AGENT. IF YOU ARE TAKING MEDICATION FOR THE TREATMENT OF ALCOHOLISM, SUCH AS ANTABUSE OR OTHER FORMS OF DISULFIRAM, SKIN CONTACT WITH FUEL METHANOL, FUEL ETHANOL OR BREATHING THEIR VAPORS CAN CAUSE THE SAME KIND OF ADVERSE REACTION AS DRINKING ALCOHOLIC BEVERAGES. IN SENSITIVE INDIVIDUALS, SERIOUS PERSONAL INJURY OR SICKNESS COULD RESULT. IF YOU ARE TAKING SUCH MEDICATION, YOU SHOULD TAKE EXTRA CARE TO AVOID SKIN CONTACT WITH FUEL AND TO AVOID BREATHING ITS VAPORS. IF YOU DO GET FUEL ON YOUR SKIN, WASH IT OFF IMMEDIATELY. CONSULT A PHYSICIAN PROMPTLY IF YOU EXPERIENCE AN ADVERSE REACTION. WARNING: Do not modify the fuel system configuration or components or replace components with parts not especially designed for use with fuel methanol. Ford motor company has specially-designed the materials, components and system configuration for methanol-fueled vehicles and each particular system is precisely calibrated for efficient operation. Ford ethanol vehicles require the same parts as the methanol-fueled vehicles, but are calibrated specifically for gasoline/ethanol-blended fuels. The use of different parts or materials could produce an untested configuration that could result in fire, personal injury or cause engine damage. WARNING: Do not operate engine or smoke while refueling. WARNING: Use of the incorrect fuel or blending of fuels can result in severe engine damage. Refer to fuel filler door for vehicle-specific fuel usage. WARNING: It is important that your flexible fuel vehicle be properly maintained by ford flexible fuel trained personnel. If a problem occurs, it is important that properly trained personnel diagnose the cause. If the problem relates to the fuel system, proper part replacement is imperative to keep your vehicle operating at normal performance. Flexible fuel components and standard fuel components are not interchangeable. If your vehicle is not serviced in accordance with flexible fuel vehicle procedures, damage may occur and your warranty may be invalidated. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release > System Information > Service Precautions > Page 1848 Fuel Pressure Release: Service and Repair WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube. Release pressure from fuel system at the fuel pressure relief valve using tool No. T80L-9974-B or equivalent. When relieving fuel pressure, crank engine with fuel pump electrical connector disconnected. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 95243 > Dec > 95 > Engine - Rocker Arm Squeak/Chirp/Knock Noise Rocker Arm Assembly: Customer Interest Engine - Rocker Arm Squeak/Chirp/Knock Noise Article No. 95-24-3 12/04/95 ^ ROCKER ARM - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" NOISE ^ NOISE - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" FROM ROCKER ARM FORD: 1989-95 TAURUS, THUNDERBIRD 1994-95 MUSTANG LINCOLN-MERCURY: 1989-94 CONTINENTAL 1989-95 COUGAR, SABLE LIGHT TRUCK: 1995 WINDSTAR This TSB article is being republished in its entirety to correct the vehicle model years affected. ISSUE: A low medium-pitch noise, such as a "squeak", "chirp" or "knock" that can be heard under the hood or in the passenger compartment may be caused by the fulcrum and rocker arm assemblies. The noise is most noticeable at engine idle with the engine at normal operating temperature. ACTION: Use the following Diagnostic Procedure to determine if a Break-In Additive will eliminate the noise or if a new set of rocker arm assemblies are required. NOTE: A DESIGN CHANGE WAS INCORPORATED FOR THE 1996 MODEL YEAR TO REDUCE THE POSSIBILITY OF THIS CONDITION. USE OF THIS TSB IN AN ATTEMPT TO SERVICE 1996 VEHICLES IS NOT RECOMMENDED. DIAGNOSTIC PROCEDURE 1. Bring the engine to normal operating temperature. 2. Using a stethoscope on the rocker arm cover, determine if rocker arms are noisy. 3. If noisy rocker arms are present, add one (1) container of Break-In Additive (E9SZ-19579-A) to the crankcase. 4. Continue to idle the engine for 10 minutes. 5. Test drive the vehicle for no less than 5 minutes. 6. Check for the noise. It the noise is gone, change the crankcase oil and filter. If the noise is still present, proceed to Step 7. 7. Remove the rocker arm covers. Refer to the appropriate Service Manual, Section 21-15 for 1989-90 models and Section 03-01 for 1991-95 models, for service details 8. Remove all the rocker arms, fulcrums and retaining bolts. Refer to the appropriate Service Manual, Section 21-15 for 1989-90 models and Section 03-01 for 1991-95 models, for service details. 9. Install NEW rocker arms, fulcrums and retaining bolts as follows: a. Soak new rocker arms and fulcrums in Break-In Additive (E9SZ-19579-A) for a minimum of 3 minutes before installing. b. Rotate the crankshaft until the tappet is resting on the heel (base circle) of the camshaft lobe. c. Position the rocker arm over the push rod. d. Install the fulcrum and retaining bolt. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 95243 > Dec > 95 > Engine - Rocker Arm Squeak/Chirp/Knock Noise > Page 1857 e. Tighten the retaining bolt to 7-15 N.m (5-11 lb-ft). 10. Finally, tighten all the rocker arm retaining bolts to 30-40 N.m (22-30 lb-ft). NOTE: THE CAMSHAFT CAN BE IN ANY POSITION WHILE PERFORMING STEP 10. 11. Change the crankcase oil and filter. PART NUMBER PART NAME E9SZ-6564-A Rocker Arm (12 Req'd.) F4DZ-6A528-A Fulcrum (12 Req'd.) F4DZ-6A527-A Bolt (12 Req'd.) E9SZ-19579-A Break-In Additive XO-5W30-QSP Oil-5W30 (Pk/12) E4FZ-6731-A FL-400A Oil Filter OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-18-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-94 Lincolns And All Other 1992-95 Cars, Basic And Powertrain Warranty Coverage For 1989-91 Model Year Vehicles And Major Component Coverage For 1989-90 Model Year Continentals OPERATION DESCRIPTION TIME 952403A Add Break-In Additive - 0.7 Hr. Includes Changing Oil And Filter And Test Drive 952403B Remove And Replace 2.6 Hrs. Rocker Arm Assembly - Thunderbird/Cougar/Mustang - Base Engine 952403C Remove And Replace 3.9 Hrs. Rocker Arm Assembly - Thunderbird/Cougar - Supercharged Engine 952403D Remove And Replace 1.9 Hrs. Rocker Arm Assembly - Taurus/Sable/Continental 952403E Remove And Replace 2.8 Hrs. Rocker Assembly - Windstar DEALER CODING CONDITION BASIC PART NO. CODE 6564 56 OASIS CODES: 401000, 497000, 499000, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 94109 > May > 94 > Engine - Rocker Arm Squeak/Chirp/Knock Rocker Arm Assembly: Customer Interest Engine - Rocker Arm Squeak/Chirp/Knock Article No. 94-10-9 06/10/94 ^ ROCKER ARM - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" NOISE ^ NOISE - 3.8L ENGINE - LOW PITCHED "SQUEAK" "CHIRP" OR "KNOCK" FROM ROCKER ARM FORD: 1989-94 TAURUS, THUNDERBIRD 1994 MUSTANG LINCOLN-MERCURY: 1989-94 CONTINENTAL, COUGAR, SABLE This TSB article is being republished in its entirety to correct the labor allowances. ISSUE: A low medium-pitch noise, such as a "squeak", "chirp" or "knock" that can be heard under the hood or in the passenger compartment, may be caused by the fulcrum and rocker arm assemblies. The noise is most noticeable at engine idle with the engine at normal operating temperature. ACTION: Use the following diagnostic procedure to determine if a Break-In Additive will eliminate the noise or if a new set of rocker arm assemblies are required. 1. Bring the engine to normal operating temperature. 2. Using a stethoscope on the rocker arm cover, determine if rocker arms are noisy. 3. If noisy rocker arms are present, add one (1) container of Break-in Additive (E9SZ-19579-A) to the crankcase. 4. Continue to idle the engine for ten (10) minutes. 5. Test drive the vehicle for no less than five (5) minutes. 6. Check for the noise. If the noise is gone, change the crankcase oil and filter. If the noise is still present, proceed to Step 7. 7. Remove the rocker arm covers. Refer to the appropriate Service Manual, Section 21-15 for 1989/90 models and Section 03-01 for 1991/94 models, for service details. 8. Remove all the rocker arms, fulcrums and retaining bolts. Refer to the appropriate Service Manual, Section 21-15 for 1989/90 models and Section 03-01 for 1991/94 models, for service details. 9. Install NEW rocker arms, fulcrums and retaining bolts as follows: a. Soak new rocker arms and fulcrums in Break-in Additive (E9SZ-19579-A) for a minimum of three minutes before installing them. b. Rotate the crankshaft until the tappet is resting on the heel (base circle) of the camshaft lobe. c. Position the rocker arm over the push rod. d. Install the fulcrum and retaining bolt. e. Tighten the retaining bolt to 7-15 N-m (5-11 lb.ft.). 10. Final tighten all the rocker arm retaining bolts to 30-40 N-m (23-30 lb.ft.). NOTE: THE CAMSHAFT CAN BE IN ANY POSITION WHILE PERFORMING STEP 10. 11. Change the crankcase oil and filter. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Customer Interest for Rocker Arm Assembly: > 94109 > May > 94 > Engine - Rocker Arm Squeak/Chirp/Knock > Page 1862 Parts Block OTHER APPLICABLE ARTICLES: None SUPERSEDES: 94-2-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991/94 Lincolns And All Other 1992/94 Cars; Basic, Major Component And Powertrain Warranty Coverage For 1989/1991 Model Year Vehicles OPERATION DESCRIPTION TIME 941009A Remove And Replace 2.6 Hrs. Rocker Arm Assy. - Thunderbird/Cougar/Mustang - Base Engine 941009B Remove And Replace 3.9 Hrs. Rocker Arm Assy. - Thunderbird/Cougar - Supercharged Engine 941009C Remove And Replace 1.9 Hrs. Rocker Arm Assy. - Taurus/Sable/Continental DEALER CODING BASIC PART NO. CONDITION CODE 6564 56 OASIS CODES: 497000, 499000, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 95243 > Dec > 95 > Engine - Rocker Arm Squeak/Chirp/Knock Noise Rocker Arm Assembly: All Technical Service Bulletins Engine - Rocker Arm Squeak/Chirp/Knock Noise Article No. 95-24-3 12/04/95 ^ ROCKER ARM - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" NOISE ^ NOISE - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" FROM ROCKER ARM FORD: 1989-95 TAURUS, THUNDERBIRD 1994-95 MUSTANG LINCOLN-MERCURY: 1989-94 CONTINENTAL 1989-95 COUGAR, SABLE LIGHT TRUCK: 1995 WINDSTAR This TSB article is being republished in its entirety to correct the vehicle model years affected. ISSUE: A low medium-pitch noise, such as a "squeak", "chirp" or "knock" that can be heard under the hood or in the passenger compartment may be caused by the fulcrum and rocker arm assemblies. The noise is most noticeable at engine idle with the engine at normal operating temperature. ACTION: Use the following Diagnostic Procedure to determine if a Break-In Additive will eliminate the noise or if a new set of rocker arm assemblies are required. NOTE: A DESIGN CHANGE WAS INCORPORATED FOR THE 1996 MODEL YEAR TO REDUCE THE POSSIBILITY OF THIS CONDITION. USE OF THIS TSB IN AN ATTEMPT TO SERVICE 1996 VEHICLES IS NOT RECOMMENDED. DIAGNOSTIC PROCEDURE 1. Bring the engine to normal operating temperature. 2. Using a stethoscope on the rocker arm cover, determine if rocker arms are noisy. 3. If noisy rocker arms are present, add one (1) container of Break-In Additive (E9SZ-19579-A) to the crankcase. 4. Continue to idle the engine for 10 minutes. 5. Test drive the vehicle for no less than 5 minutes. 6. Check for the noise. It the noise is gone, change the crankcase oil and filter. If the noise is still present, proceed to Step 7. 7. Remove the rocker arm covers. Refer to the appropriate Service Manual, Section 21-15 for 1989-90 models and Section 03-01 for 1991-95 models, for service details 8. Remove all the rocker arms, fulcrums and retaining bolts. Refer to the appropriate Service Manual, Section 21-15 for 1989-90 models and Section 03-01 for 1991-95 models, for service details. 9. Install NEW rocker arms, fulcrums and retaining bolts as follows: a. Soak new rocker arms and fulcrums in Break-In Additive (E9SZ-19579-A) for a minimum of 3 minutes before installing. b. Rotate the crankshaft until the tappet is resting on the heel (base circle) of the camshaft lobe. c. Position the rocker arm over the push rod. d. Install the fulcrum and retaining bolt. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 95243 > Dec > 95 > Engine - Rocker Arm Squeak/Chirp/Knock Noise > Page 1868 e. Tighten the retaining bolt to 7-15 N.m (5-11 lb-ft). 10. Finally, tighten all the rocker arm retaining bolts to 30-40 N.m (22-30 lb-ft). NOTE: THE CAMSHAFT CAN BE IN ANY POSITION WHILE PERFORMING STEP 10. 11. Change the crankcase oil and filter. PART NUMBER PART NAME E9SZ-6564-A Rocker Arm (12 Req'd.) F4DZ-6A528-A Fulcrum (12 Req'd.) F4DZ-6A527-A Bolt (12 Req'd.) E9SZ-19579-A Break-In Additive XO-5W30-QSP Oil-5W30 (Pk/12) E4FZ-6731-A FL-400A Oil Filter OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-18-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-94 Lincolns And All Other 1992-95 Cars, Basic And Powertrain Warranty Coverage For 1989-91 Model Year Vehicles And Major Component Coverage For 1989-90 Model Year Continentals OPERATION DESCRIPTION TIME 952403A Add Break-In Additive - 0.7 Hr. Includes Changing Oil And Filter And Test Drive 952403B Remove And Replace 2.6 Hrs. Rocker Arm Assembly - Thunderbird/Cougar/Mustang - Base Engine 952403C Remove And Replace 3.9 Hrs. Rocker Arm Assembly - Thunderbird/Cougar - Supercharged Engine 952403D Remove And Replace 1.9 Hrs. Rocker Arm Assembly - Taurus/Sable/Continental 952403E Remove And Replace 2.8 Hrs. Rocker Assembly - Windstar DEALER CODING CONDITION BASIC PART NO. CODE 6564 56 OASIS CODES: 401000, 497000, 499000, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 94109 > May > 94 > Engine - Rocker Arm Squeak/Chirp/Knock Rocker Arm Assembly: All Technical Service Bulletins Engine - Rocker Arm Squeak/Chirp/Knock Article No. 94-10-9 06/10/94 ^ ROCKER ARM - 3.8L ENGINE - LOW PITCHED "SQUEAK", "CHIRP" OR "KNOCK" NOISE ^ NOISE - 3.8L ENGINE - LOW PITCHED "SQUEAK" "CHIRP" OR "KNOCK" FROM ROCKER ARM FORD: 1989-94 TAURUS, THUNDERBIRD 1994 MUSTANG LINCOLN-MERCURY: 1989-94 CONTINENTAL, COUGAR, SABLE This TSB article is being republished in its entirety to correct the labor allowances. ISSUE: A low medium-pitch noise, such as a "squeak", "chirp" or "knock" that can be heard under the hood or in the passenger compartment, may be caused by the fulcrum and rocker arm assemblies. The noise is most noticeable at engine idle with the engine at normal operating temperature. ACTION: Use the following diagnostic procedure to determine if a Break-In Additive will eliminate the noise or if a new set of rocker arm assemblies are required. 1. Bring the engine to normal operating temperature. 2. Using a stethoscope on the rocker arm cover, determine if rocker arms are noisy. 3. If noisy rocker arms are present, add one (1) container of Break-in Additive (E9SZ-19579-A) to the crankcase. 4. Continue to idle the engine for ten (10) minutes. 5. Test drive the vehicle for no less than five (5) minutes. 6. Check for the noise. If the noise is gone, change the crankcase oil and filter. If the noise is still present, proceed to Step 7. 7. Remove the rocker arm covers. Refer to the appropriate Service Manual, Section 21-15 for 1989/90 models and Section 03-01 for 1991/94 models, for service details. 8. Remove all the rocker arms, fulcrums and retaining bolts. Refer to the appropriate Service Manual, Section 21-15 for 1989/90 models and Section 03-01 for 1991/94 models, for service details. 9. Install NEW rocker arms, fulcrums and retaining bolts as follows: a. Soak new rocker arms and fulcrums in Break-in Additive (E9SZ-19579-A) for a minimum of three minutes before installing them. b. Rotate the crankshaft until the tappet is resting on the heel (base circle) of the camshaft lobe. c. Position the rocker arm over the push rod. d. Install the fulcrum and retaining bolt. e. Tighten the retaining bolt to 7-15 N-m (5-11 lb.ft.). 10. Final tighten all the rocker arm retaining bolts to 30-40 N-m (23-30 lb.ft.). NOTE: THE CAMSHAFT CAN BE IN ANY POSITION WHILE PERFORMING STEP 10. 11. Change the crankcase oil and filter. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rocker Arm Assembly: > 94109 > May > 94 > Engine - Rocker Arm Squeak/Chirp/Knock > Page 1873 Parts Block OTHER APPLICABLE ARTICLES: None SUPERSEDES: 94-2-16 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991/94 Lincolns And All Other 1992/94 Cars; Basic, Major Component And Powertrain Warranty Coverage For 1989/1991 Model Year Vehicles OPERATION DESCRIPTION TIME 941009A Remove And Replace 2.6 Hrs. Rocker Arm Assy. - Thunderbird/Cougar/Mustang - Base Engine 941009B Remove And Replace 3.9 Hrs. Rocker Arm Assy. - Thunderbird/Cougar - Supercharged Engine 941009C Remove And Replace 1.9 Hrs. Rocker Arm Assy. - Taurus/Sable/Continental DEALER CODING BASIC PART NO. CONDITION CODE 6564 56 OASIS CODES: 497000, 499000, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly > Component Information > Technical Service Bulletins > Page 1874 Rocker Arm Assembly: Service and Repair Fig. 6 Rocker Arm Assembly These engines use stamped steel rocker arms retained by a fulcrum seat which bolts directly to the cylinder head and guides the rocker arm, Fig. 6. Torque fulcrum bolts in two steps as follows: For each valve rotate crankshaft until valve lifter rests on heel (base circle) of camshaft lobe and torque fulcrum bolt to 5-11 ft. lbs. After initial torquing of all fulcrum bolts, final torque to 19-25 ft. lbs. Final torque may be done with camshaft in any position. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair Valve Cover: Service and Repair Valve Cover and Gasket Supercharged 3.8L Removal 1. Disconnect ignition wires from spark plugs. 2. Remove ignition wire separators from valve cover retaining stud bolts. 3. If LH valve cover is being removed, proceed with the following steps: a. Remove oil filler cap. b. Remove charge air cooler (CAC) tubes. c. Remove crankcase ventilation tube. d. Remove engine oil cooler inlet tube and hose. 4. If RH valve cover is being removed, proceed with the following steps: a. Partially drain cooling system. b. Remove positive crankcase ventilation valve (PCV valve). c. Remove air cleaner outlet tube. d. Remove oil filler pipe. e. Remove heater hose and position aside. f. Disconnect fuel lines. g. Remove throttle body. 5. Remove valve cover retaining bolts and stud bolts, valve cover and valve cover gasket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover > Component Information > Service and Repair > Page 1878 Installation 1. Position a new valve cover gasket into groove on valve cover. NOTE: Lightly oil bolt and stud threads before installation. Using solvent, clean cylinder head and valve cover sealing surfaces to remove all gasket material and dirt. 2. Position valve cover on the cylinder head and install retaining bolts. Note location of ignition wire routing clip stud bolts. Tighten retaining bolts to 9-12 N-m (7-9 lb-ft). 3. If LH valve cover is being installed, proceed with the following steps: a. Install oil filler cap. b. Install charge air cooler (CAC) tubes. c. Install crankcase ventilation tube. d. Install engine oil cooler inlet tube and hose. 4. If RH valve cover is being installed, perform the following: a. Install positive crankcase ventilation valve. b. Install throttle body. c. Reconnect fuel lines. d. Reconnect heater hose. e. Install oil filler pipe. f. Install air cleaner outlet tube. g. Install ignition wire separators. h. Connect ignition wires to spark plugs. i. Refill cooling system. j. Start engine and check for oil and coolant leaks. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide > Component Information > Service and Repair Valve Guide: Service and Repair Valve guides consist of holes bored in the cylinder head. For service the guide holes can be reamed oversize to accommodate valves with oversize stems of .015 and .030 inch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 93126 > Jun > 93 > Engine Stalls/Hesitates/Long Cranking Times Valve: Customer Interest Engine - Stalls/Hesitates/Long Cranking Times Article No. 93-12-6 06/09/93 ^ HESITATION ON ACCELERATION AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ IDLE - ROUGH - AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ LONG CRANK TIMES - 2.3L, 2.3L OHC, 3.8L NA ^ STALL AT IDLE AND UPON GEAR ENGAGEMENT AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ STALL AT IDLE AND UPON GEAR ENGAGEMENT AFTER COLD START - 2.3L, 2.3L OHC. 3.8L NA ^ ENGINE - INTAKE VALVE CLEANING PROCEDURE - 2.3L, 2.3L OHC, 3.8L NATURALLY ASPIRATED FORD: 1988-92 MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-92 CONTINENTAL, COUGAR, SABLE, TOPAZ LIGHT TRUCK: 1988-92 RANGER This TSB Article is being republished in its entirety to update the Intake Valve Deposit (IVD) inspection/cleaning procedure and to provide technical service tips for the 2.3L OHC engine. ISSUE: Vehicles with excessive intake valve deposit (IVD) may exhibit the following driveability concerns after a cold start. These drive concerns may also result from the use of fuels that have low volatility, such as high octane, "premium" fuels. ^ Long crank times ^ Idle stall after initial cold start ^ Stall upon gear engagement ^ Rough idle after cold start ^ Hesitation on acceleration after cold start ^ Hesitation/Stall on initial acceleration (3.8L N/A applications) When these deposits are dry, they act like sponges which absorb engine fuel. This may result in a lean engine run condition after an initial cold start. The drive conditions normally occur at ambient temperatures of 40~ F (4~ C) to 70~ F (21~ C). ACTION: An IVD inspection and cleaning procedure has been developed using the Rotunda 014-00975 Carbon Blaster Kit. If service is required, use the following procedure to correct the stated driveability concerns. NOTE: MANY FLUIDS ARE AVAILABLE TO CLEAN FUEL INJECTORS. SOME INJECTOR CLEANING FLUIDS ALSO CLAIM TO REMOVE INTAKE VALVE DEPOSITS (IVD). ENGINEERING EVALUATION OF THESE FLUIDS INDICATES NO ABILITY TO REMOVE THE IVD CAUSING THE STATED DRIVEABILITY CONCERNS. IF DRIVEABILITY CONCERNS HAVE BEEN AFFECTED BY INJECTOR CLEANING FLUIDS, IT IS MOST LIKELY DUE TO CLEAN-UP OF PORT FUEL INJECTOR DEPOSITS. IVD IS MORE DIFFICULT TO REMOVE THAN PORT FUEL INJECTOR DEPOSITS. IVD MUST BE COMPLETELY REMOVED AS OUTLINED IN THIS TSB ARTICLE TO RESTORE COLD-START DRIVEABILITY PERFORMANCE. THE OVERUSE OF THESE FLUIDS MAY CAUSE ENGINE DAMAGE NOT COVERED UNDER WARRANTY. 1. Perform underhood inspection of vacuum lines and wiring. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 93126 > Jun > 93 > Engine Stalls/Hesitates/Long Cranking Times > Page 1890 2. Perform normal Engine Emissions Diagnostics. Refer to the Engine/Emissions Diagnostics Shop Manual or the Powertrain Control/Emissions Diagnosis Manual. 3. If normal Engine/Emissions Diagnostics have not resolved the driveability concerns, proceed with the following IVD inspection. INTAKE VALVE DEPOSIT INSPECTION PROCEDURE 1. Remove any two (2) spark plugs. Use a remote starter switch to bump the engine over until the intake valve is fully open in the cylinder to be inspected. 2. Using the 014-00975 Automotive Borescope or equivalent, inspect the backside of the intake valves through the spark plug holes for the presence of carbon deposits. CAUTION: DO NOT BUMP THE ENGINE WITH THE BORESCOPE IN THE SPARK PLUG HOLE OR ATTEMPT TO VIEW THE VALVE WHILE ROTATING THE ENGINE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. CAUTION: DO NOT POWER THE BORESCOPE LIGHT SOURCE FROM A CAR BATTERY WHILE IT IS UNDER CHARGE. FOR EXAMPLE, IF THE ENGINE IS RUNNING, THE LAMP MAY FAIL. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 93126 > Jun > 93 > Engine Stalls/Hesitates/Long Cranking Times > Page 1891 3. Compare the deposits with the Intake Valve Deposit Rating System Chart, Figure 1. a. If either of the intake valves appear to have a carbon deposit level of 7 or less (lower number rating), intake valve cleaning is required. b. Proceed to the IVD Cleaning Procedure. 4. If no carbon deposits are seen or the deposit level is 8 or cleaner, the drive concern may be the result of low volatility fuel. Refer to TSB 91-8-13 and proceed to Fuel Recommendation. CLEANING PROCEDURE NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 93126 > Jun > 93 > Engine Stalls/Hesitates/Long Cranking Times > Page 1892 BEFORE BEGINNING THE IVD CLEANING PROCEDURE, USE THE FOLLOWING CARBON BLASTER TIPS: ^ Be sure that compressed shop air is dry. Drain compressor of water regularly. ^ remove any in-line equipment oilers from the air line to be used with the carbon blaster ^ Be sure to store walnut shells in a water tight container with the lid on. ^ Remove unused walnut shells from the carbon blaster when IVD procedure is completed. Do not store walnut shells in carbon blaster. 1. Remove the upper intake manifold assembly, fuel rail and injectors. Refer to the instructions in the appropriate Service Manual. 2. Insert the Rotunda 014-00975 Automotive Borescope or equivalent through the fuel injector holes into the lower intake manifold to determine which intake valves are in the closed position. CAUTION: DO NOT ROTATE THE ENGINE WITH THE BORESCOPE IN THE FUEL INJECTOR HOLE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. 3. Perform the intake valve carbon cleaning procedure, using the Rotunda Tool 014-00975 Carbon Blaster and Automotive Borescope Kit, or equivalent, on the intake valves that are in the closed position. NOTE: DETAILED WRITTEN INSTRUCTIONS AND A PROCEDURAL VIDEO TAPE ARE INCLUDED WITH THE ROTUNDA CARBON BLASTER AND AUTOMOTIVE BORESCOPE KIT. TECHNICAL TIP - 2.3L OHC ENGINE When IVD cleaning is performed on the 2.3L OHC dual plug engine, the vacuum should be connected to the lower intake manifold as follows: ^ Remove flex hose and manifold adapter from the hand held vacuum. ^ Insert tapered end of vacuum hose into intake port of manifold using a twisting motion to ensure a tight fit. ^ Proceed with the IVD cleaning process. (CLEANING PROCEDURE CONTINUED) When the cleaning procedure is complete, the backside of the intake valve and cylinder port area surrounding the valve will be free of deposits. Confirm complete deposit removal by borescope inspection. (Normal IVD cleaning time is 1 to 1-1/2 minutes per valve.) 4. Bump the engine until the remaining intake valves to be cleaned are in the closed position. Repeat Cleaning Procedure Step # 3. 5. Inspect all intake valves to verify complete carbon deposit removal. 6. Install the fuel rail, fuel injectors, and upper intake manifold using a new intake manifold gasket. Refer to the Dealer Master Parts Catalog for correct part number. 7. Proceed to FUEL RECOMMENDATION. FUEL RECOMMENDATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 93126 > Jun > 93 > Engine Stalls/Hesitates/Long Cranking Times > Page 1893 Fuels that do not contain the proper detergent additives may result in the formation of intake system deposits, including clogged port fuel injectors and intake valve deposits. To assist the customer in selecting the proper fuel, provide the customer with a copy of the "Clean Gasoline" Flyer, Figure 2. Refer to OASIS special service messages 9000 through 9023 to identify appropriate brands of fuel. To access these messages, enter the vehicle VIN and Service Code 404000. The fuel list will be updated periodically. Gasolines on this list are advertised as having intake system deposit control detergents. Regular use of these fuels should minimize or eliminate accumulation of intake system deposits. NOTE: IF A HIGH QUALITY FUEL IS CONTINUOUSLY USED WHICH CONTAINS INTAKE SYSTEM DEPOSIT CONTROL DETERGENTS AND OTHER ADDITIVES, AFTERMARKET ADDITIVES SHOULD NEVER NEED TO BE ADDED TO THE FUEL TANK. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Customer Interest for Valve: > 93126 > Jun > 93 > Engine Stalls/Hesitates/Long Cranking Times > Page 1894 Fuels that vaporize poorly may cause similar symptoms or may contribute to symptoms related to intake system deposits. Refer to TSB 91-8-13 for additional information. OTHER APPLICABLE ARTICLES: 91-10-9, 91-11-4, 91-8-13 SUPERSEDES: 92-19-3 WARRANTY STATUS: Eligible Under Basic Warranty Coverage and Powertrain For 1991 And Prior Cars And Light Trucks (Excluding Lincolns), Eligible For Bumper To Bumper For 1991 Lincolns And All 1992 Cars And Light Trucks OPERATION DESCRIPTION TIME 931206A Perform Engine Emission 0.5 Hr. Test And Underhood Inspection 931206B Perform Engine Emission 1.0 Hr. Test, Underhood Inspection And Intake Valve Inspection 931206C Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Ranger 931206D Perform Engine Emission 3.3 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Tempo/Topaz 931206E Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Mustang 931206F Perform Engine Emission 4.1 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Taurus/Sable And Continental 931206G Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Thunderbird/Cougar DEALER CODING BASIC PART NO. CONDITION CODE 6507 49 OASIS CODES: 499000, 602300, 607000, 607400, 608000, 608400, 609000, 609400, 611000, 611500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times Valve: All Technical Service Bulletins Engine - Stalls/Hesitates/Long Cranking Times Article No. 93-12-6 06/09/93 ^ HESITATION ON ACCELERATION AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ IDLE - ROUGH - AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ LONG CRANK TIMES - 2.3L, 2.3L OHC, 3.8L NA ^ STALL AT IDLE AND UPON GEAR ENGAGEMENT AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ STALL AT IDLE AND UPON GEAR ENGAGEMENT AFTER COLD START - 2.3L, 2.3L OHC. 3.8L NA ^ ENGINE - INTAKE VALVE CLEANING PROCEDURE - 2.3L, 2.3L OHC, 3.8L NATURALLY ASPIRATED FORD: 1988-92 MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-92 CONTINENTAL, COUGAR, SABLE, TOPAZ LIGHT TRUCK: 1988-92 RANGER This TSB Article is being republished in its entirety to update the Intake Valve Deposit (IVD) inspection/cleaning procedure and to provide technical service tips for the 2.3L OHC engine. ISSUE: Vehicles with excessive intake valve deposit (IVD) may exhibit the following driveability concerns after a cold start. These drive concerns may also result from the use of fuels that have low volatility, such as high octane, "premium" fuels. ^ Long crank times ^ Idle stall after initial cold start ^ Stall upon gear engagement ^ Rough idle after cold start ^ Hesitation on acceleration after cold start ^ Hesitation/Stall on initial acceleration (3.8L N/A applications) When these deposits are dry, they act like sponges which absorb engine fuel. This may result in a lean engine run condition after an initial cold start. The drive conditions normally occur at ambient temperatures of 40~ F (4~ C) to 70~ F (21~ C). ACTION: An IVD inspection and cleaning procedure has been developed using the Rotunda 014-00975 Carbon Blaster Kit. If service is required, use the following procedure to correct the stated driveability concerns. NOTE: MANY FLUIDS ARE AVAILABLE TO CLEAN FUEL INJECTORS. SOME INJECTOR CLEANING FLUIDS ALSO CLAIM TO REMOVE INTAKE VALVE DEPOSITS (IVD). ENGINEERING EVALUATION OF THESE FLUIDS INDICATES NO ABILITY TO REMOVE THE IVD CAUSING THE STATED DRIVEABILITY CONCERNS. IF DRIVEABILITY CONCERNS HAVE BEEN AFFECTED BY INJECTOR CLEANING FLUIDS, IT IS MOST LIKELY DUE TO CLEAN-UP OF PORT FUEL INJECTOR DEPOSITS. IVD IS MORE DIFFICULT TO REMOVE THAN PORT FUEL INJECTOR DEPOSITS. IVD MUST BE COMPLETELY REMOVED AS OUTLINED IN THIS TSB ARTICLE TO RESTORE COLD-START DRIVEABILITY PERFORMANCE. THE OVERUSE OF THESE FLUIDS MAY CAUSE ENGINE DAMAGE NOT COVERED UNDER WARRANTY. 1. Perform underhood inspection of vacuum lines and wiring. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 1900 2. Perform normal Engine Emissions Diagnostics. Refer to the Engine/Emissions Diagnostics Shop Manual or the Powertrain Control/Emissions Diagnosis Manual. 3. If normal Engine/Emissions Diagnostics have not resolved the driveability concerns, proceed with the following IVD inspection. INTAKE VALVE DEPOSIT INSPECTION PROCEDURE 1. Remove any two (2) spark plugs. Use a remote starter switch to bump the engine over until the intake valve is fully open in the cylinder to be inspected. 2. Using the 014-00975 Automotive Borescope or equivalent, inspect the backside of the intake valves through the spark plug holes for the presence of carbon deposits. CAUTION: DO NOT BUMP THE ENGINE WITH THE BORESCOPE IN THE SPARK PLUG HOLE OR ATTEMPT TO VIEW THE VALVE WHILE ROTATING THE ENGINE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. CAUTION: DO NOT POWER THE BORESCOPE LIGHT SOURCE FROM A CAR BATTERY WHILE IT IS UNDER CHARGE. FOR EXAMPLE, IF THE ENGINE IS RUNNING, THE LAMP MAY FAIL. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 1901 3. Compare the deposits with the Intake Valve Deposit Rating System Chart, Figure 1. a. If either of the intake valves appear to have a carbon deposit level of 7 or less (lower number rating), intake valve cleaning is required. b. Proceed to the IVD Cleaning Procedure. 4. If no carbon deposits are seen or the deposit level is 8 or cleaner, the drive concern may be the result of low volatility fuel. Refer to TSB 91-8-13 and proceed to Fuel Recommendation. CLEANING PROCEDURE NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 1902 BEFORE BEGINNING THE IVD CLEANING PROCEDURE, USE THE FOLLOWING CARBON BLASTER TIPS: ^ Be sure that compressed shop air is dry. Drain compressor of water regularly. ^ remove any in-line equipment oilers from the air line to be used with the carbon blaster ^ Be sure to store walnut shells in a water tight container with the lid on. ^ Remove unused walnut shells from the carbon blaster when IVD procedure is completed. Do not store walnut shells in carbon blaster. 1. Remove the upper intake manifold assembly, fuel rail and injectors. Refer to the instructions in the appropriate Service Manual. 2. Insert the Rotunda 014-00975 Automotive Borescope or equivalent through the fuel injector holes into the lower intake manifold to determine which intake valves are in the closed position. CAUTION: DO NOT ROTATE THE ENGINE WITH THE BORESCOPE IN THE FUEL INJECTOR HOLE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. 3. Perform the intake valve carbon cleaning procedure, using the Rotunda Tool 014-00975 Carbon Blaster and Automotive Borescope Kit, or equivalent, on the intake valves that are in the closed position. NOTE: DETAILED WRITTEN INSTRUCTIONS AND A PROCEDURAL VIDEO TAPE ARE INCLUDED WITH THE ROTUNDA CARBON BLASTER AND AUTOMOTIVE BORESCOPE KIT. TECHNICAL TIP - 2.3L OHC ENGINE When IVD cleaning is performed on the 2.3L OHC dual plug engine, the vacuum should be connected to the lower intake manifold as follows: ^ Remove flex hose and manifold adapter from the hand held vacuum. ^ Insert tapered end of vacuum hose into intake port of manifold using a twisting motion to ensure a tight fit. ^ Proceed with the IVD cleaning process. (CLEANING PROCEDURE CONTINUED) When the cleaning procedure is complete, the backside of the intake valve and cylinder port area surrounding the valve will be free of deposits. Confirm complete deposit removal by borescope inspection. (Normal IVD cleaning time is 1 to 1-1/2 minutes per valve.) 4. Bump the engine until the remaining intake valves to be cleaned are in the closed position. Repeat Cleaning Procedure Step # 3. 5. Inspect all intake valves to verify complete carbon deposit removal. 6. Install the fuel rail, fuel injectors, and upper intake manifold using a new intake manifold gasket. Refer to the Dealer Master Parts Catalog for correct part number. 7. Proceed to FUEL RECOMMENDATION. FUEL RECOMMENDATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 1903 Fuels that do not contain the proper detergent additives may result in the formation of intake system deposits, including clogged port fuel injectors and intake valve deposits. To assist the customer in selecting the proper fuel, provide the customer with a copy of the "Clean Gasoline" Flyer, Figure 2. Refer to OASIS special service messages 9000 through 9023 to identify appropriate brands of fuel. To access these messages, enter the vehicle VIN and Service Code 404000. The fuel list will be updated periodically. Gasolines on this list are advertised as having intake system deposit control detergents. Regular use of these fuels should minimize or eliminate accumulation of intake system deposits. NOTE: IF A HIGH QUALITY FUEL IS CONTINUOUSLY USED WHICH CONTAINS INTAKE SYSTEM DEPOSIT CONTROL DETERGENTS AND OTHER ADDITIVES, AFTERMARKET ADDITIVES SHOULD NEVER NEED TO BE ADDED TO THE FUEL TANK. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 1904 Fuels that vaporize poorly may cause similar symptoms or may contribute to symptoms related to intake system deposits. Refer to TSB 91-8-13 for additional information. OTHER APPLICABLE ARTICLES: 91-10-9, 91-11-4, 91-8-13 SUPERSEDES: 92-19-3 WARRANTY STATUS: Eligible Under Basic Warranty Coverage and Powertrain For 1991 And Prior Cars And Light Trucks (Excluding Lincolns), Eligible For Bumper To Bumper For 1991 Lincolns And All 1992 Cars And Light Trucks OPERATION DESCRIPTION TIME 931206A Perform Engine Emission 0.5 Hr. Test And Underhood Inspection 931206B Perform Engine Emission 1.0 Hr. Test, Underhood Inspection And Intake Valve Inspection 931206C Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Ranger 931206D Perform Engine Emission 3.3 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Tempo/Topaz 931206E Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Mustang 931206F Perform Engine Emission 4.1 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Taurus/Sable And Continental 931206G Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Thunderbird/Cougar DEALER CODING BASIC PART NO. CONDITION CODE 6507 49 OASIS CODES: 499000, 602300, 607000, 607400, 608000, 608400, 609000, 609400, 611000, 611500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust > Component Information > Technical Service Bulletins > Page 1905 Valve: Specifications 3.8L/V6-232, 1989-94 Intake ................................................................................................................................................... .................................................................... .424 inch Exhaust ........................................................... ......................................................................................................................................................... .447 inch Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams Serpentine Drive Belt Routing Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1910 Drive Belt: Service and Repair Serpentine Drive Belt Routing Serpentine Drive Belt Routing Fig. 15 Drive Belt Tensioner Fig. 16 Drive Belt Tension Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Drive Belt > Component Information > Diagrams > Page 1911 Fig. 17 Serpentine Drive Belt Tension Specifications Refer to Figs. 13 and 14 for drive belt installation. This engine is equipped with automatic drive belt tensioners, Fig. 15. These tensioners have built in drive belt wear indicators. With engine off, check position of tensioner belt length indicator. If indicator is not between minimum belt length and maximum belt stretch lines, replace drive belt. Belt tension can be checked using a suitable belt tension gauge, Figs. 16 and 17. Belt tension should be checked at the middle of longest accessible span. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories > Engine Mount > Component Information > Service and Repair Engine Mount: Service and Repair Engine Mount Removal Whenever self-locking mounting bolts and nuts are removed, they must be replaced with new self-locking bolts and nuts. 1. Remove fan shroud attaching screws, then remove air tube from remote air cleaner. 2. Raise and support vehicle, then support engine using a jack and wood block placed below engine. 3. Remove insulator to front subframe through bolts, Fig. 1. 4. Disconnect shift linkage, then raise engine enough to clear clevis brackets. 5. Remove accessories and oil cooler line attaching clips from engine support brackets. 6. Remove bolts attaching insulator bracket assembly to engine, then remove insulator and bracket. Left front engine mount removal on supercharged engine may require lowering front subframe. 7. Reverse procedure to install. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Motor Oil - Viscosity Grade Recommendation Engine Oil: Technical Service Bulletins Motor Oil - Viscosity Grade Recommendation Article No. 99-8-16 05/03/99 MOTOR OIL - SAE VISCOSITY GRADE RECOMMENDATION - SERVICE TIP FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-1999 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-1999 CONTOUR LINCOLN-MERCURY: 1989-1992 MARK VII 1989-1994 TOPAZ 1989-1997 COUGAR 1989-1999 CONTINENTAL, GRAND MARQUIS, SABLE, TOWN CAR, TRACER 1991-1994 CAPRI 1994-1998 MARK VIII 1995-1999 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-1999 ECONOLINE, F-150, F-250 LD, RANGER 1991-1999 EXPLORER 1993-1999 VILLAGER 1995-1999 WINDSTAR 1997-1999 EXPEDITION, MOUNTAINEER 1998-1999 NAVIGATOR 1999 SUPER DUTY F SERIES ISSUE Ford Motor Company now recommends SAE 5W-30 viscosity grade for servicing any Ford gasoline-powered vehicle regardless of model year. ACTION When servicing any Ford gasoline-powered vehicle, use SAE 5W-30 viscosity grade motor oil. Refer to the following text for further details. Both SAE 10W-30 and SAE 5W-30 viscosity grade motor oils have been recommended in the past depending on vehicle model and model year. Tests have proven SAE 5W-30 viscosity grade motor oil provides the optimum protection and benefits for Ford gasoline engines. At both high and low ambient temperature conditions, SAE 5W-30 provides the best overall protection. It allows faster starts under cold ambient temperatures. SAE 5W-30 also provides approximately 1/2% increase in fuel economy over SAE 10W-30. SAE 5W-30 viscosity grade motor oils certified for gasoline engines by the American Petroleum Institute (API) should be used for all service procedures requiring replacement of the motor oil. PART NUMBER PART NAME XO-5W30-QSP 5W-30 Motorcraft Super Premium Motor Oil OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 401000, 490000, 499000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component Information > Technical Service Bulletins > Page 1920 Engine Oil: Specifications Engine Refill ........................................................................................................................................ ............................................................ 4.0 Qts.(3.8L) Note: Add 1 Qt. with filter change. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1929 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Oil Level Warning Indicator: Customer Interest Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1939 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 1944 Oil Level Warning Indicator: Description and Operation This system is used to indicate when engine oil level is 1-1/2 quarts or more below the specified level. The system consist an instrument panel warning lamp, electronic relay and a float type sensor which is located in the oil pan. The warning lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go out when engine is operating. If oil level is low, the lamp will remain on until engine oil is added or until ignition switch is placed in the off position. The module will take approximately 5 minutes to reset. If engine is started during this reset period, the last reading obtained will be displayed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 1945 Oil Level Warning Indicator: Testing and Inspection Fig. 12 Low Oil Level Indicator Diagnosis SYSTEM CHECK With oil at Full mark on dipstick and engine warm, start engine. Warning indicator should come on briefly in Start for bulb test, then go out. Turn engine Off. Drain 2 quarts of oil from engine. Wait for 5 minutes, then restart engine. Warning indicator should come On and stay On. If indicator does not come On, check the following; indicator, fuse, oil level relay and/or oil level sensor. SENSOR TEST If is best to conduct test with sensor in oil pan with hot oil to ensure oil properly drains from sensor. If removed from pan, sensor must first be submerged in warm oil to ensure proper positioning of float before testing. The sensor must be held horizontally during bench testing to ensure float remains correctly positioned. Connect positive lead of digital volt/ohmmeter to sensor terminal and negative lead to sensor housing. With sensor submerged in oil (engine full), meter should read Open. Resistance should be greater than 100,000 ohms. With sensor out of oil (oil drained), resistance should be less than 1000 ohms. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Level Sensor > Component Information > Locations Oil Level Sensor: Locations Rear Of Engine RH Rear Corner Of Engine Below Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component Information > Service and Repair Oil Pan: Service and Repair 1. Disconnect battery ground cable, then remove air cleaner and air intake duct. 2. Remove two bolts attaching sight shield and position shield aside. 3. Remove hood weather seal and wiper assemblies. 4. Remove LH cowl vent screen and wiper module. 5. On supercharged engines, remove supercharger. 6. On all models, install engine lifting eyes, then engine support fixture D88L-6000-A or equivalent. 7. Raise and support vehicle. 8. Remove engine mount through bolts. 9. On supercharged engines, remove left side mount retaining strap. 10. Partially lower vehicle, then raise engine at support fixture. 11. Raise vehicle and remove starter motor assembly. 12. Drain engine oil, then remove oil filter. 13. Remove wire loom, ground strap and automatic transmission cooler lines. 14. Remove oil pan-to-bell housing bolts, then the crankshaft position sensor shield bolts. 15. Remove remaining oil pan retaining bolts. 16. Remove steering shaft pinch bolts and separate steering shaft. 17. Position a transmission jack under front of subframe. 18. Remove six rearward bolts on front of subframe, then loosen two front subframe bolts. 19. Remove lower strut to control arm bolts and nuts on both sides of vehicle. 20. Lower subframe, then remove oil pan. 21. Reverse procedure to install. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation The oil pressure indicating system is a magnetic type system, which consists of three primary coils, one of which is wound at a 90° angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet, to which a shaft and pointer are attached, rotates to align to this primary field, resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which as two holes for dial mounting. The is no adjustment, calibration or maintenance required for these gauges. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Gauge > Component Information > Description and Operation > Page 1955 Fig. 8 Gauge Type Oil Pressure Indicator Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations Lower Right Hand Side, Front Of Engine, Below the Power Steering Bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation A red warning indicator glow when the oil pressure is below a prescribed valve. The indicator should come on when the ignition switch is first turned to the Run position. The indicator should go out within a few seconds after the engines starts, indicating that oil pressure is satisfactory. The oil switch is calibrated to close between 4.5-7.5 psi. The indicator is connect between the oil pressure switch unit (mounted on the engine) and the coil terminal of the ignition switch. On some vehicles only one warning indicator serving both the oil pressure switch and the temperature switch. These combined systems are identified by the word ENGINE on the warning indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 1962 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Disconnect temperature switch wire before testing oil pressure indicating system on vehicles that have an engine warning indicator. To test the oil pressure switch and warning indicator, turn ignition switch to Run, but do not start the engine. The warning indicator should come on. If the indicator does not come on, remove the wire from the switch terminal and connect wire to ground. If the indicator now comes on, the oil pressure switch is inoperative. Replace switch. If indicator does not come on with the switch wire connected to ground, the warning indicator is burned out or the system wiring is open. Replace indicator or service wiring. If indicator stays on with engine running and engine has adequate oil pressure, disconnect wire from oil pressure switch. The indicator should go out. If indicator goes out, replace oil pressure switch. If indicator does not go out, service shorted wiring between switch and indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Component Information > Service and Repair Oil Pump: Service and Repair Oil Pump Replacement REPLACE On these engines, the oil pump is contained within the front cover, Fig. 12. To replace oil pump, remove front cover as described under FRONT COVER. REPAIR Referring to Fig. 12, disassemble pump. To remove oil pressure relief valve, insert a self-threading sheet metal screw of the proper diameter into oil pressure relief valve chamber cap and pull cap out of chamber. Remove spring and plunger. The inner rotor, shaft and outer race are serviced as an assembly. One part should not be replaced without replacing the other. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Oil Temperature Sensor/Switch: Locations Engine Compartment Component Locations Lower RH Of Engine Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Fuel Injected Intake Manifold: Specifications Fuel Injected Figure 2: EFI Shown, SC Similar Lower Intake Manifold Tighten the bolts in numerical sequence to the following specifications in two (2) separate steps: Step 1 11 N-m (8 lb-ft) Step 2 15 N-m (11 lb-ft) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Fuel Injected > Page 1973 Upper Intake Manifold Tighten in sequence in three (3) steps starting with the four center bolts to the following specifications: Step 1 10 N-m (8 lb-ft) Step 2 20 N-m (15 lb-ft) Step 3 32 N-m (24 lb-ft) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Fuel Injected > Page 1974 Intake Manifold: Specifications General Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Fuel Injected > Page 1975 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Fuel Injected > Page 1976 (1) 20-200 seconds to leakdown 3.18 (0.125 in) with 225 Newtons (50 pounds) load and tappet filled with leakdown fluid. (2) No end play. Camshaft is restrained by spring. (3) Runout of journals II and III to journals I and IV. (4) Runout of adjacent journals to each other. (5) Smaller than pin bore measured along center to center axis. * Passenger Car: 4 qt. + 1 with filter change. Truck: 5 qt. + 1 with filter change. ** Engine packages equipped with Tripminder: Return line must be closed when checking pressure. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Fuel Injected > Page 1977 Figure 2: EFI Shown, SC Similar Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Fuel Injected > Page 1978 Intake Manifold: Specifications Standard Torque Values NOTE: Oil threads with engine oil unless the threads require oil or water resistant sealer. Standard torque limits are for all other fasteners not shown in the special torque charts. US Thread Sizes 1/4-20 8-12 Nm 5/16-18 16-24 Nm 5/16-24 19-27 Nm 3/8-16 30-43 Nm 3/8-24 37-52 Nm 7/16-14 55-75 Nm 7/16-20 55-81 Nm 1/2-13 75-108 Nm Metric Thread Sizes M-6 8-12 Nm M-8 19-28 Nm M-10 38-54 Nm M-12 68-96 Nm M-14 108-155 Nm Pipe Thread Sizes 1/8 5-8 Nm 1/4 12-18 Nm 3/8 22-23 Nm Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Fuel Injected > Page 1979 Intake Manifold: Specifications Specific Applications A/C Lower Mounting Bracket to Engine Nuts 41-61 Nm Air Pump Pivot Bolt 40-55 Nm Air Pump to Support Bracket Bolt 40-55 Nm Alternator Pivot Bolt 61-75 Nm Bolt A/C Comp Mounting (5 Places) 41-61 Nm Bolt Front Brace to Engine Brace A/C 41-61 Nm Bracket, Idler Front Attach Bolt Lower 40-55 Nm Bracket, Idler Front Attach Bolt Upper 70-95 Nm Bracket, Idler Top Bolt 40-55 Nm Engine Bracket Reinforcement Brace to Engine Bracket 47-67 Nm - Bolt (Damper) Engine Bracket Reinforcement Brace to Engine Bracket 60-107 Nm - Nut (Damper) Front A/C Comp. Plate Nut to Engine Stud (2 Places) 41-61 Nm Front A/C Comp~ Plate to Lower A/C Mounting Bracket 41-61 Nm Bolt Front Brace, A/C To Engine Stud - Nut 20-30 Nm Idler Bracket to Alternator Top Attaching Flange Bolt 33-46 Nm Idler Pulley Adv. Bolts (2 Places) 40-55 Nm Nut Brace to Engine, A/C 20-30 Nm Support A/C Comp. Mounting Bolt to Bracket Assembly 41-61 Nm (2 Places) Power Steering With A/C Front Bracket to Power Steering Pump - Bolt (3 40-62 Nm Places) Power Steering Brace Bolt (Lower) 24-32 Nm Power Steering Brace Bolt (Upper) 40-62 Nm Power Steering Front Bracket Nut (2 Places) 40-62 Nm Power Steering Front Bracket to A/C Bracket - Bolt 40-62 Nm Power Steering Without A/C Power Steering Brace Bolt (2 Places) 40-62 Nm Power Steering Front Bracket Bolt (2 Places) 40-62 Nm Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Fuel Injected > Page 1980 Power Steering Front Bracket Bolt (3 Places) 40-62 Nm Camshaft Sprocket to Camshaft Bolt 20-30 Nm Connecting Rod Nut 41-49 Nm Coolant Temp Switch 11-16 Nm Crankshaft Damper to Crankshaft - Bolt 125-165 Nm Crankshaft Pulley to Damper - Bolt 26-38 Nm Cylinder Head Bolt (NEW) Tighten in (4) steps: Step 1. Tighten bolts in sequence shown to: 50 Nm (37 lb-ft) 60 Nm (45 lb-ft) 70 Nm (52 lb-ft) 80 Nm (59 lb-ft) Step 2. a) Back off all bolts one at a time 2-3 revolutions and retighten in numerical sequence as follows: Step 3. b) Tighten long and short bolts in sequence to 65-75 Nm (48 lb-ft). Step 4. c) Rotate long and short bolts in sequence an additional 90-110 degrees. EGR Spacer to Intake Manifold - Bolt 8-12 Nm EGR Valve to EGR Spacer - Nut 20-30 Nm Flywheel to Crankshaft - Bolt 73-87 Nm Front Cover to Cylinder Block - Bolt 20-30 Nm Fuel Pump to Front Cover - Bolt 20-30 Nm Fuel Tube Fitting 20-24 Nm Fuel Tube Fitting - Inlet 16-20 Nm Fuel Tube Fitting - Return 12-16 Nm Heater Elbow 8.5-13.5 Nm Heater Tube to Intake Manifold Stud - Bolt 10-15 Nm Intake Manifold Heat Cross-Over Valve - Bolt 8-12 Nm EFI Intake Manifold to Cylinder Head - Bolt (4) (4)Tighten in three steps: A. 10 Nm (7.5 lb-ft) B. 20 Nm (15 lb-ft) C. 32 Nm (24 lb-ft) SC Intake Manifold to Cylinder Head - Bolt (5) (5)Tighten in two Steps A. 10 Nm (7.5 lb-ft) B. 15 Nm (11 lb-ft) Low Level Oil Sensor 27-41 Nm Main Bearing Cap - Bolt 88-110 Nm MCT Sensor 8-13 Nm Oil Filter Adapter to Front Cover - Bolt 25-30 Nm Oil Filter to Oil Filter Adapter 10-15 Nm Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Fuel Injected > Page 1981 Oil Inlet Tube to Cylinder Block Bolt 20-30 Nm Oil Inlet Tube to Main Bearing Cap - Nut 40-55 Nm Oil Pan to Cylinder Block - Bolt 9-12 Nm PVS Valve (CFI) 6-13 Nm PVS Valves (2150-2V) 8-13 Nm Rocker Arm Cover to Cylinder Head - Bolts/Studs 9-12 Nm Rocker Arm Fulcrum to Cylinder Head - Bolt (3) (3) Tighten in two steps: A. 7-15 Nm (5.1-11.1 lb-ft) B. 25-35 Nm (18.4-25.6 lb-ft) Spark knock Senaor 20-26.5 Nm Spark Plug to Cylinder Head 7-15 Nm Thermactor Check Valve to Intake Manifold 22-26 Nm Thermostat Housing to Intake Manifold - Bolt 20-30 Nm Vacuum Fitting to Intake Manifold 17-25 Nm Vacuum Tree to Intake Manifold 8-13 Nm Vacuum Tubes to Intake Manifold - Studs Bolts 10-15 Nm Water Pump to Front Cover - Bolt 20-30 Nm FWD 3.8l Shown Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Fuel Injected > Page 1982 Figure 2: EFI Shown, SC Similar Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1983 Intake Manifold: Service and Repair The following procedure has been revised by a Technical Service Bulletin. Removal 1. Disconnect battery ground cable and drain engine cooling system. 2. Remove air cleaner assembly including air intake duct and heat tube. 3. Disconnect accelerator cable at throttle body assembly, then speed control cable, if equipped. 4. Disconnect transmission linkage at upper intake manifold. 5. Remove bolts from accelerator cable mounting bracket and position cables aside. 6. Disconnect Thermactor air supply hose at the check valve. the valve is located in the Y-pipe assembly 7. Disconnect flexible fuel lines from steel lines over rocker arm cover 8. Disconnect fuel lines at injector fuel rail assembly. 9. For supercharged models remove supercharger. Refer to Supercharger Assembly See: Powertrain Management/Fuel Delivery and Air Induction/Supercharger/Service and Repair 10. On all models, disconnect radiator hose at thermostat housing, then the coolant bypass hose from manifold. 11. Remove heater tube as follows: a. Disconnect heater tube from intake manifold. b. Remove tube support bracket retaining nuts, then remove heater hose from rear of heater tube. c. Loosen hose clamp at heater elbow, then remove heater tube with hose attached. d. Remove heater tube with lines attached and set assembly aside. 12. Disconnect vacuum lines at fuel rail assembly and intake manifold, then disconnect necessary electrical connectors. 13. Disconnect necessary electrical connectors. 14. Remove A/C compressor support bracket, if equipped. 15. Disconnect one PCV line from upper intake manifold and valve. Remove second PCV line from left rocker cover. 16. Remove throttle body assembly 17. Then the EGR valve assembly from upper manifold. 18. Remove wiring retainer bracket from left front side of intake manifold and position aside with spark plug wires. 19. Remove upper intake manifold bolts and studs 20. Remove the upper intake manifold. 21. Remove injectors and fuel rail assembly. 22. Remove heater water outlet hose. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1984 3.8 EFI Base 3.8 Supercharged 23. Remove the lower intake manifold attaching bolts and studs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1985 24. Remove lower intake manifold. Note: The manifold is sealed at each end with RTV-type sealer. To break seal, it may be necessary to pry on front of manifold with a screwdriver blade. Use care to prevent damage to machined surfaces when prying with screwdriver. 25. Remove and discard manifold side gaskets and end seals. 26. If lower manifold is to be disassembled, perform the following a. Remove thermostat housing and thermostat b. Remove temperature sending unit. c. Remove heater elbow. d. Remove all vacuum and electrical fittings. Installation NOTE: Lightly oil all attaching bolt and stud threads before installation. NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set-up, and its sealing effectiveness may be reduced. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1986 3.8 EFI Base 3.8 EFI Supercharged 1. The lower intake manifold, cylinder head, and cylinder block mating surfaces should be clean and free of old gasketing material. Use a suitable solvent to clean these surfaces. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1987 2. If intake manifold was disassembled: a. Apply a coat of Pipe Sealant with Teflon® DBAZ-19554-A (ESG-M4G194-A and ESRM18P7-A) or equivalent to the threads of the temperature sending unit, all vacuum fittings, heater elbows, and electrical fittings, if equipped. b. Install thermostat (note direction) and gasket. Install thermostat housing. Tighten attaching bolts to 20-30 N.m (15-22 lb-ft). 3. Apply a dab of Gasket and Trim Adhesive 19B508-AA (ESR-M1 1 P17-A) or equivalent to each cylinder head mating surface. Press new intake manifold gasket into place, using location pins as necessary to aid in assembly. NOTE: Using solvent, clean sealing surfaces of cylinder heads and intake manifold before applying Silicone Sealer. 4. Apply a 3-4mm (1/8-inch) bead of Silicone Sealer D6AZ-1 9562-B (ESB-M4G92-A and ESE-M4G1 95-A) or equivalent at each corner where the cylinder head joins the cylinder block. 5. Install front and rear intake manifold end seals. 6. Carefully lower intake manifold into position on cylinder block and cylinder heads. Use locating pins as necessary to guide manifold. 7. Install bolts and stud bolt (base only) in their original locations. Tighten in numerical sequence to the following specifications in three steps (base only): 1. 10 N.m (7.5 lb-ft). 2. 20 N.m (15 lb-ft). 3. 32 N.m (24 lb-ft). 8. On supercharged engines, tighten bolts in sequence to the following specifications in two steps: 1. 10 N.m (7.5 lb-ft). 2. 15 N.m (11 lb-ft). 9. Connect rear PCV line to upper intake tube. 10. Install front PCV tube so that the mounting bracket sits over the lower intake manifold stud. Tighten nut on stud to 20-30 N.m (15-22 lb-ft). 11. Install injectors and fuel rail assembly. 12. Position upper intake manifold gasket and manifold on top of lower intake. Use locating pins to secure position of gasket between manifolds. 13. Install bolts and stud bolts in original locations. Tighten four center bolts, and then end bolts using same tightening sequence as listed under Step 7. 14. Install EGR valve assembly on manifold. Tighten retaining bolts to 20-30 N.m (15-22 lb-ft). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1988 15. Install throttle body. Cross-tighten hold-down nuts to 20-30 N.m (15-22 lb-ft). 16. Connect rear PCV line at PCV valve on the upper intake manifold. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Specifications > Page 1989 3.8 EFI Supercharged 17. If vehicle is equipped with air conditioning, install compressor support bracket. Tighten attaching fasteners to 20-30 N.m (15-22 lb-ft). 18. Connect necessary electrical connectors. 19. Connect necessary vacuum hoses. 20. Connect heater tube hose to heater elbow. 21. Position heater tube support bracket and tighten attaching nut to 20-30 N.m (15-22 lb-ft). Tighten hose clamp at heater elbow securely. 22. Connect heater hose to the rear of the heater tube and tighten hose clamp. 23. Connect coolant bypass hose. Tighten hose clamp securely. 24. Connect radiator upper hose. Tighten hose clamp securely. 25. Connect fuel line(s) at injector fuel rail assembly. 26. Connect flexible fuel lines to steel lines. 27. Position accelerator cable mounting bracket. Install and tighten attaching bolts to 20-30 N.m (15-22 lb-ft). 28. Connect speed control cable, if so equipped, to the fuel charging assembly. 29. Connect transmission linkage at upper intake manifold assembly. 30. Fill cooling system with specified coolant. CAUTION: This engine has an aluminum cylinder head and requires a special corrosion inhibiting coolant to avoid radiator damage. 31. Start engine and check for coolant or fuel leaks. 32. Check and, if necessary, adjust engine idle speed, transmission throttle linkage and speed control. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 1999 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Oil Level Warning Indicator: Customer Interest Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 2009 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 2014 Oil Level Warning Indicator: Description and Operation This system is used to indicate when engine oil level is 1-1/2 quarts or more below the specified level. The system consist an instrument panel warning lamp, electronic relay and a float type sensor which is located in the oil pan. The warning lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go out when engine is operating. If oil level is low, the lamp will remain on until engine oil is added or until ignition switch is placed in the off position. The module will take approximately 5 minutes to reset. If engine is started during this reset period, the last reading obtained will be displayed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 2015 Oil Level Warning Indicator: Testing and Inspection Fig. 12 Low Oil Level Indicator Diagnosis SYSTEM CHECK With oil at Full mark on dipstick and engine warm, start engine. Warning indicator should come on briefly in Start for bulb test, then go out. Turn engine Off. Drain 2 quarts of oil from engine. Wait for 5 minutes, then restart engine. Warning indicator should come On and stay On. If indicator does not come On, check the following; indicator, fuse, oil level relay and/or oil level sensor. SENSOR TEST If is best to conduct test with sensor in oil pan with hot oil to ensure oil properly drains from sensor. If removed from pan, sensor must first be submerged in warm oil to ensure proper positioning of float before testing. The sensor must be held horizontally during bench testing to ensure float remains correctly positioned. Connect positive lead of digital volt/ohmmeter to sensor terminal and negative lead to sensor housing. With sensor submerged in oil (engine full), meter should read Open. Resistance should be greater than 100,000 ohms. With sensor out of oil (oil drained), resistance should be less than 1000 ohms. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation The oil pressure indicating system is a magnetic type system, which consists of three primary coils, one of which is wound at a 90° angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet, to which a shaft and pointer are attached, rotates to align to this primary field, resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which as two holes for dial mounting. The is no adjustment, calibration or maintenance required for these gauges. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Gauge > Component Information > Description and Operation > Page 2019 Fig. 8 Gauge Type Oil Pressure Indicator Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation A red warning indicator glow when the oil pressure is below a prescribed valve. The indicator should come on when the ignition switch is first turned to the Run position. The indicator should go out within a few seconds after the engines starts, indicating that oil pressure is satisfactory. The oil switch is calibrated to close between 4.5-7.5 psi. The indicator is connect between the oil pressure switch unit (mounted on the engine) and the coil terminal of the ignition switch. On some vehicles only one warning indicator serving both the oil pressure switch and the temperature switch. These combined systems are identified by the word ENGINE on the warning indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Lamps and Indicators - Engine > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 2023 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Disconnect temperature switch wire before testing oil pressure indicating system on vehicles that have an engine warning indicator. To test the oil pressure switch and warning indicator, turn ignition switch to Run, but do not start the engine. The warning indicator should come on. If the indicator does not come on, remove the wire from the switch terminal and connect wire to ground. If the indicator now comes on, the oil pressure switch is inoperative. Replace switch. If indicator does not come on with the switch wire connected to ground, the warning indicator is burned out or the system wiring is open. Replace indicator or service wiring. If indicator stays on with engine running and engine has adequate oil pressure, disconnect wire from oil pressure switch. The indicator should go out. If indicator goes out, replace oil pressure switch. If indicator does not go out, service shorted wiring between switch and indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main Bearing Seal > Component Information > Service and Repair Crankshaft Main Bearing Seal: Service and Repair Camshaft Rear Seal Installation 1. Using a sharp tool, punch one hole into seal metal surface between seal lip and engine block. 2. Remove seal using slide hammer No. T82L-9533-B or equivalent. Use care to prevent damage to sealing surface. 3. Lubricate new seal with clean engine oil and install using seal installation tool No. T82L-6701-A or equivalent. Tighten bolts alternately to seat seal properly, Fig. 11. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal > Component Information > Service and Repair Front Crankshaft Seal: Service and Repair Typical Engine View Removal 1. Disconnect electric cooling fan motor at wire harness. 2. Remove fan shroud assembly retaining bolts and remove cooling fan motor, fan blade (8600) and fan shroud (8148) as an assembly from vehicle. 3. Loosen belt idler pulleys (8678). 4. Raise vehicle on hoist. 5. Disengage drive belt (8620) and remove pulley from damper. 6. Remove crankshaft damper using Crankshaft Damper Remover T58P-63 16-D and Vibration Damper Remover Adapter 8-2L-631 6-B and Front Cover Seal Installer T7OP-6B070-A. CAUTION: Use care to prevent damage to engine front cover (6019) and crankshaft (6303) or possible component failure may occur. 7. Remove crankshaft front seal (6700) from the engine front cover using a suitable remover tool. Installation 1. Inspect engine front cover and crankshaft pulley (6312) for damage, nicks, burrs or other roughness which may cause the crankshaft front seal to fail. Service or replace components as necessary. 2. Lubricate the crankshaft front seal lip with clean engine oil and install the crankshaft front seal using Damper/Front Cover Seal Replacer T82L-63 16-A and Front Cover Seal Replacer T7OP-6B070-A. 3. Lubricate crankshaft front seal surface on the crankshaft damper with clean engine oil. 4. Install crankshaft damper retaining bolt and washer. Tighten bolt to 140-180 N.m (103-132 lb-ft). 5. Position pulley on damper and install retaining bolts. Tighten retaining bolts to 26-38 N.m (20-28 lb-ft). 6. Position drive belts over crankshaft pulley. 7. Lower vehicle. 8. Position cooling fan motor, fan blade and fan shroud as an assembly on radiator (8005) and install fan shroud retaining screws. 9. Connect electric cooling fan motor to wire harness. 10. Check drive belts for proper routing and engagement in the pulleys and install drive belts. 11. Start engine and check for oil leaks. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Intake Manifold - Revised Torque Specifications Intake Manifold Gasket: Technical Service Bulletins Intake Manifold - Revised Torque Specifications ^ ENGINE - 3.8L - INTAKE MANIFOLD - NEW GRAPHITE GASKET ^ SHOP MANUAL - 1988-91 - SECTION 21-15 - REVISED TORQUE SPECIFICATIONS AND TIGHTENING SEQUENCE FOR NEW GRAPHITE INTAKE MANIFOLD SERVICE GASKET - 3.8L ENGINE Article No. 91-1-8 FORD: 1988-91 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1988-91 CONTINENTAL, COUGAR, SABLE ISSUE: A new graphite intake manifold gasket service kit (F1SZ-9433-A) is now available for service use. The torque specifications and tightening sequence in the 1988-91 subject vehicle Shop Manuals, Section 21-15, have also been changed to accommodate the new graphite intake gasket. ACTION: If service is required, install a new graphite intake manifold gasket service kit and tighten the bolts in numerical sequence to the following specifications in two (2) separate steps. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Intake Manifold - Revised Torque Specifications > Page 2035 Figure 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket > Component Information > Technical Service Bulletins > Intake Manifold - Revised Torque Specifications > Page 2036 Figure 2: EFI Shown, SC Similar REVISED TORQUE SPECIFICATIONS ^ Step # 1 - Tighten to 8 lb.ft. (11 N-m) as shown in Figures 1 & 2. ^ Step # 2 - Tighten to 11 lb.ft. (15 N-m) as shown in Figures 1 & 2. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 499000, 490000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Level Sensor > Component Information > Locations Oil Level Sensor: Locations Rear Of Engine RH Rear Corner Of Engine Below Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations Lower Right Hand Side, Front Of Engine, Below the Power Steering Bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Temperature Sensor/Switch, Engine > Component Information > Locations Oil Temperature Sensor/Switch: Locations Engine Compartment Component Locations Lower RH Of Engine Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Gear > Component Information > Technical Service Bulletins > Balance Shaft Drive Gear - Manual Revision Balance Shaft Gear: Technical Service Bulletins Balance Shaft Drive Gear - Manual Revision SHOP MANUAL - 1989 - PAGE 21-15-14 - ILLUSTRATION FOR REMOVAL AND INSTALLATION PROCEDURES INCORRECTLY SHOWS BALANCE SHAFT DRIVE GEAR ON 3.8L ENGINE Article No. 90-6B-35 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Balance Shaft Gear > Component Information > Technical Service Bulletins > Balance Shaft Drive Gear - Manual Revision > Page 2052 ISSUE: The illustration on page 21-15-14 of the 1989 Thunderbird/Cougar Shop Manual has been modified. The balance shaft drive gear for the 3.8L engine has been removed. ACTION: Refer to the pages following this TSB article for the updated illustration. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair Timing Chain: Service and Repair Front Cover & Water Pump Bolt Locations To replace seal in timing gear cover, it is necessary to remove cover as outlined below. 1. Disconnect battery ground cable and drain cooling system. 2. Remove air cleaner and air intake duct. 3. On supercharged engines, remove electric cooling fan assembly. 4. On non-supercharged engines, remove fan/clutch assembly. 5. On all models, remove drive belts and water pump pulley. 6. Remove power steering pump mounting bracket bolts, if equipped. Leave hoses connected and position pump assembly aside. 7. Remove A/C compressor support bracket, if equipped. Leave compressor in place. 8. Disconnect coolant bypass hose and heater hoses at water pump and upper radiator hose at thermostat housing. 9. Disconnect ignition coil secondary wire from distributor cap, then remove distributor cap with ignition wires attached. 10. On non-supercharged engines, with No. 1 cylinder at TDC compression stroke, mark position of rotor to distributor housing and position of distributor housing to front cover. 11. Remove distributor hold-down clamp, then lift distributor from front cover. 12. On supercharged engines, remove hold-down clamp and lift camshaft synchronizer from front cover. 13. Raise and support vehicle. 14. Remove crankshaft pulley using crankshaft damper removal tool No. T85P-6316-D and vibration damper removal adapter tool No. T82L-6316-B or equivalents. 15. Remove oil filter and oil cooler, if equipped, then disconnect lower radiator hose from water pump. 16. Remove oil pan as described under OIL PAN 17. Lower vehicle and remove front cover attaching bolts, Fig. 8. A front cover attaching bolt is located behind oil filter adapter. Also tag bolts as they are removed so that they can be installed at same location. 18. Remove front cover and water pump as an assembly. 19. Remove camshaft bolt and washer from end of camshaft. 20. Remove distributor drive gear, then remove camshaft sprocket, crankshaft sprocket and timing chain. 21. If crankshaft sprocket is difficult to remove, pry off shaft using two large screwdrivers positioned on both sides of sprocket. 22. Remove chain tensioner assembly from front of cylinder block as follows: a. Pull back on ratcheting mechanism. b. Install pin through hole in bracket to relieve tension. c. Remove three mounting bolts. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2056 Timing Chain Components Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component Information > Service and Repair > Page 2057 Fig. 9 Timing Chain Alignment 23. Reverse procedure to install, noting the following: a. If a replacement front cover is to be installed, the water pump, oil pump, oil filter adapter and intermediate shaft must be removed from the front cover to be replaced and reinstalled on the replacement front cover. It may be necessary to rotate crankshaft 180° from the No. 1 cylinder TDC location to position fuel pump eccentric for fuel pump installation. When installing distributor, No. 1 cylinder must be at TDC position and marks made during removal must be aligned. b. Lightly oil all bolt and stud threads before installation, except those specifying special sealant. c. Rotate crankshaft as necessary to position piston No. 1 at TDC and crankshaft keyway at 12 o'clock position. d. Lubricate timing chain and front oil seal with new clean engine oil. e. Ensure timing marks are aligned across from each other. f. On non-supercharged engines, install distributor with rotor pointing at No. 1 cap tower. g. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair Timing Cover: Service and Repair Front Cover & Water Pump Bolt Locations To replace seal in timing gear cover, it is necessary to remove cover as outlined below. 1. Disconnect battery ground cable and drain cooling system. 2. Remove air cleaner and air intake duct. 3. On supercharged engines, remove electric cooling fan assembly. 4. On non-supercharged engines, remove fan/clutch assembly. 5. On all models, remove drive belts and water pump pulley. 6. Remove power steering pump mounting bracket bolts, if equipped. Leave hoses connected and position pump assembly aside. 7. Remove A/C compressor support bracket, if equipped. Leave compressor in place. 8. Disconnect coolant bypass hose and heater hoses at water pump and upper radiator hose at thermostat housing. 9. Disconnect ignition coil secondary wire from distributor cap, then remove distributor cap with ignition wires attached. 10. On non-supercharged engines, with No. 1 cylinder at TDC compression stroke, mark position of rotor to distributor housing and position of distributor housing to front cover. 11. Remove distributor hold-down clamp, then lift distributor from front cover. 12. On supercharged engines, remove hold-down clamp and lift camshaft synchronizer from front cover. 13. Raise and support vehicle. 14. Remove crankshaft pulley using crankshaft damper removal tool No. T85P-6316-D and vibration damper removal adapter tool No. T82L-6316-B or equivalents. 15. Remove oil filter and oil cooler, if equipped, then disconnect lower radiator hose from water pump. 16. Remove oil pan as described under OIL PAN 17. Lower vehicle and remove front cover attaching bolts, Fig. 8. A front cover attaching bolt is located behind oil filter adapter. Also tag bolts as they are removed so that they can be installed at same location. 18. Remove front cover and water pump as an assembly. 19. Remove camshaft bolt and washer from end of camshaft. 20. Remove distributor drive gear, then remove camshaft sprocket, crankshaft sprocket and timing chain. 21. If crankshaft sprocket is difficult to remove, pry off shaft using two large screwdrivers positioned on both sides of sprocket. 22. Remove chain tensioner assembly from front of cylinder block as follows: a. Pull back on ratcheting mechanism. b. Install pin through hole in bracket to relieve tension. c. Remove three mounting bolts. 23. Reverse procedure to install, noting the following: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component Information > Service and Repair > Page 2061 a. If a replacement front cover is to be installed, the water pump, oil pump, oil filter adapter and intermediate shaft must be removed from the front cover to be replaced and reinstalled on the replacement front cover. It may be necessary to rotate crankshaft 180° from the No. 1 cylinder TDC location to position fuel pump eccentric for fuel pump installation. When installing distributor, No. 1 cylinder must be at TDC position and marks made during removal must be aligned. b. Lightly oil all bolt and stud threads before installation, except those specifying special sealant. c. Rotate crankshaft as necessary to position piston No. 1 at TDC and crankshaft keyway at 12 o'clock position. d. Lubricate timing chain and front oil seal with new clean engine oil. e. Ensure timing marks are aligned across from each other. f. On non-supercharged engines, install distributor with rotor pointing at No. 1 cap tower. g. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections Fuel Pressure: Technical Service Bulletins Fuel Pressure Specification - Corrections ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-SECTION 11-SPECIFICATION CORRECTIONS ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-SECTION 17-SPECIFICATION CORRECTIONS Article No. 89-12A-25 FORD: 1989 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1989 AEROSTAR, BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER ISSUE: The pressure values shown for the 2.5L CFI engine in both "Key on engine off" and "running" conditions are incorrectly shown in the Electric Fuel Delivery System (EFD) on page 11-14 and the Fuel Control Pinpoint Test H on page 17-185. The 1988 date in the chart titles for both Passenger Car Engines and Light Truck Engines is incorrect on page 17-185. The 3.0L SHO SEFI "Key on engine off" value in the chart on page 11-14 is incorrect. ACTION: Refer to the pages following this TSB article for the corrected charts. This information should be inserted in your 1989 Engine Emissions Diagnosis Manual, pages 11-14 and 17-185. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 Fuel Delivery Systems 1989 11-13 Electric Fuel Delivery System EFD Electrical Schematic VEHICLE APPLICATION E Series 1988 and later model years, EFI F Series 1986 and later model years, EFI 11-14 1989 Fuel Delivery Systems Electric Fuel Delivery System EFD Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 2067 FUEL PRESSURE SPECIFICATION TABLE EEC-IV - Pinpoint Tests - All Vehicles 1989 17-185 Fuel Control Pinpoint Test GH Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 2068 FUEL PRESSURE SPECIFICATION TABLE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 2069 17-186 1989 EEC-IV-Pinpoint Tests-All Vehicles Fuel Control Pinpoint Test H Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 2070 Fuel Pressure: Specifications Key On Engine Off 35 - 40 psi Key On Engine Running 30 - 40 psi Engine Running Vacuum Hose Disconnected From Fuel Pressure Regulator 35 - 40 psi Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 2071 Fuel Pressure: Testing and Inspection STO Connector STATIC PRESSURE TEST 1. Check for adequate fuel supply. 2. Turn key OFF 3. Install fuel pressure gauge to test port on fuel rail. 4. Install test lead to fuel pump lead of STO test connector. 5. Turn Key ON Engine OFF (KOEO). 6. Ground test lead to run fuel pump. 7. Check to determine if fuel pressure is within acceptable limits. a. If pressure is low but greater than 3 psi (indicates fuel pump is running but not enough pressure) check for: ^ Plugged fuel filter ^ Kinked fuel line ^ Low voltage to pump (should be within 0.5 volts of battery voltage at connector). ^ Disconnect the fuel return line and note if fuel is being returned during this low pressure condition. If fuel is being returned, replace the fuel pressure regulator. Reconnect the fuel return line. b. If pressure is less than 3 psi (pump not running) check for: ^ Defective fuse link ^ Inertia switch open ^ Wiring at fuel pump/tank connector loose or open ^ Fuel pump ground connection at chassis loose or defective ^ Improper fuel pump relay operation If fuel supply and return lines are OK, and electrical supply and ground are OK, and fuel pressure is still low, replace fuel pump. DYNAMIC PRESSURE TEST 1. Disconnect and plug the vacuum line to the pressure regulator. 2. Start engine and run at idle. Check to determine if fuel pressure is within acceptable limits. Refer to SPECIFICATIONS. a. If pressure is low check for: ^ Plugged fuel filter ^ Restricted fuel line ^ Low voltage to pump (should be within 0.5 volts of battery voltage at connector). 3. Reconnect the vacuum line to the regulator. If fuel supply and return lines are OK, and electrical supply and ground is OK, and fuel pressure is still low, replace fuel pump. LEAKAGE TEST 1. Momentarily activate fuel pump by grounding test lead. Raise pressure to approximate operating pressure. 2. Remove ground from test lead and note pressure on gauge. Pressure should remain within 2 psi for 3 minutes after lead is ungrounded. a. If pressure is not maintained check for leaking fuel ^ Lines ^ Connectors ^ Injectors b. Disconnect fuel return line and plug engine side. Momentarily activate fuel pump by grounding test lead. Raise pressure to approximate operating pressure. If pressure holds replace regulator and retest. Reconnect the fuel return line. If pressure is not maintained replace fuel pump. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2080 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2081 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2082 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2083 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2084 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2085 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2086 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2087 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2088 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2089 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2090 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2091 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2092 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2093 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2094 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2095 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2096 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2102 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2103 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2104 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2105 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2106 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2107 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2108 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2109 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2110 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2111 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2112 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2113 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2114 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2115 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2116 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2117 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2118 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2119 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2120 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2121 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2122 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2123 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2124 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2125 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2126 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2127 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2128 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2129 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2130 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2131 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2132 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2133 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2134 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2135 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2136 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2137 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2138 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2139 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2140 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2141 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2142 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2143 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2144 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2145 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2146 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2147 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2148 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2149 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2150 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2151 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2152 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2153 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 2154 Fuel injected Model, Idle Speed Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 2155 Idle Speed: Adjustments IDLE SPEED 1. Place automatic transmission in PARK. 2. Engine OFF, back out throttle plate stop screw clear off the throttle lever pad. 3. With a .010 in. feeler gauge between the throttle plate stop screw and throttle lever pad turn the screw in until contact is made then turn it an additional 1.5 turns. 4. Start engine and stabilize for 2 minutes then goose the engine and let it return to idle, lightly depress and release the accelerator and let engine idle. If idle problem still exists check for other possible causes. 5. On Automatic Overdrive Transmission (AOD) applications or Automatic Transaxle (AXOD) application check Throttle Valve (TV) adjustment. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when fueling vehicle or when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. NOTE: Methanol and ethanol are not interchangeable. Methanol fuel can be used only in vehicles designed for methanol fuels. Ethanol fuel can be used only in vehicles designed for ethanol fuels. WARNING: The fuel tubes leading from the fuel tank to the engine are under pressure during vehicle operation. When fuel injected engines are turned off, the fuel in the fuel tubes remains pressurized for long periods of time to provide quick start-ups. Special procedures for servicing these pressurized fuel systems are outlined in this section. These procedures should be followed to prevent accidental spraying of fuel, causing personal injury or a fire hazard. WARNING: Do not swallow fuel of any kind. Fuels such as methanol or fuel ethanol and gasoline or mixtures of these fuels are highly toxic and if swallowed can cause death or permanent injury. Swallowing methanol can also cause blindness. Immediately seek medical attention from a physician or poison control center to treat anyone who has swallowed fuel. Be aware that if fuel is swallowed, the onset of potential ill health effects may be delayed 12-24 hours. AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR OF ANY KIND CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY. AVOID GETTING FUEL LIQUID IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. ALLOWING ANY FUEL TO GET IN YOUR EYES WILL CAUSE SEVERE IRRITATION. FAILURE TO SEEK PROPER MEDICAL ATTENTION FOR FUEL CONTACT WITH THE EYES COULD LEAD TO PERMANENT INJURY. IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. MAKE SURE YOU WASH YOUR HANDS BEFORE HANDLING FOOD. FUELS CONTAINING GASOLINE SUCH AS FUEL METHANOL AND FUEL ETHANOL MAY CONTAIN BENZENE, WHICH IS A CANCER-CAUSING AGENT. IF YOU ARE TAKING MEDICATION FOR THE TREATMENT OF ALCOHOLISM, SUCH AS ANTABUSE OR OTHER FORMS OF DISULFIRAM, SKIN CONTACT WITH FUEL METHANOL, FUEL ETHANOL OR BREATHING THEIR VAPORS CAN CAUSE THE SAME KIND OF ADVERSE REACTION AS DRINKING ALCOHOLIC BEVERAGES. IN SENSITIVE INDIVIDUALS, SERIOUS PERSONAL INJURY OR SICKNESS COULD RESULT. IF YOU ARE TAKING SUCH MEDICATION, YOU SHOULD TAKE EXTRA CARE TO AVOID SKIN CONTACT WITH FUEL AND TO AVOID BREATHING ITS VAPORS. IF YOU DO GET FUEL ON YOUR SKIN, WASH IT OFF IMMEDIATELY. CONSULT A PHYSICIAN PROMPTLY IF YOU EXPERIENCE AN ADVERSE REACTION. WARNING: Do not modify the fuel system configuration or components or replace components with parts not especially designed for use with fuel methanol. Ford motor company has specially-designed the materials, components and system configuration for methanol-fueled vehicles and each particular system is precisely calibrated for efficient operation. Ford ethanol vehicles require the same parts as the methanol-fueled vehicles, but are calibrated specifically for gasoline/ethanol-blended fuels. The use of different parts or materials could produce an untested configuration that could result in fire, personal injury or cause engine damage. WARNING: Do not operate engine or smoke while refueling. WARNING: Use of the incorrect fuel or blending of fuels can result in severe engine damage. Refer to fuel filler door for vehicle-specific fuel usage. WARNING: It is important that your flexible fuel vehicle be properly maintained by ford flexible fuel trained personnel. If a problem occurs, it is important that properly trained personnel diagnose the cause. If the problem relates to the fuel system, proper part replacement is imperative to keep your vehicle operating at normal performance. Flexible fuel components and standard fuel components are not interchangeable. If your vehicle is not serviced in accordance with flexible fuel vehicle procedures, damage may occur and your warranty may be invalidated. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2160 Fuel Pressure Release: Service and Repair WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube. Release pressure from fuel system at the fuel pressure relief valve using tool No. T80L-9974-B or equivalent. When relieving fuel pressure, crank engine with fuel pump electrical connector disconnected. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V6 Firing Order: 1 4 2 5 3 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar Revised Procedures Technical Service Bulletin # 9111B6 Date: 910614 Octane Adjust Shorting Bar - Revised Procedures Article No. 91-11B-6 ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1989 - PAGE 17-289 - PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1990 - PAGE 17-329 - PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1991 - PAGE 5-22 - EEC-IV QUICK TEST STEP 12.0 - CAR DIAGNOSIS BY SYMPTOM CHART REVISED ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1991 - PAGES 6-305 THROUGH 6-307 PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR FORD: 1989-91 TAURUS, THUNDERBIRD 1991 ESCORT, MUSTANG LINCOLN-MERCURY: 1989-90 COUGAR 1991 TRACER LIGHT TRUCK: 1989-91 RANGER 1991 AEROSTAR, EXPLORER ISSUE: Additional information regarding removal of the Octane Adjust Shorting Bar is required to assure compliance with Federal (EPA) Emission Standards. The following Manuals are affected on the pages indicated: ^ 1989 Engine/Emissions Diagnosis Page 17-289 ^ 1990 Engine/Emissions Diagnosis Page 17-329 ^ 1991 Engine/Emissions Diagnosis Page 5-22 and Pages 6-305 through 307 ACTION: Refer to the pages in this TSB article for the additional information. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar Revised Procedures > Page 2169 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar Revised Procedures > Page 2170 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar Revised Procedures > Page 2171 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar Revised Procedures > Page 2172 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar Revised Procedures > Page 2173 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar Revised Procedures > Page 2174 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar Revised Procedures > Page 2175 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Locations > Component Locations Ignition Timing Connector: Component Locations Engine Compartment Component Locations RH Front Of Engine Compartment, Below VIP Test Connector Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Locations > Component Locations > Page 2178 Component Location - Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Mark 3.8L Supercharged Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams Component Location Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 2188 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 2189 Ignition Cable: Service and Repair When removing spark plug wires from plugs, use spark plug wire remover T74P-6666-A or equivalent. Grasp and twist the boot back and forth on the plug until boot is loose. Remove boot and wire from plug. Pull on boot only. Do not pull on wire. When removing wires from the ignition coil, squeeze the locking tabs of coil wire retainer by hand. Twist and pull on boot until free. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Description and Operation > TFI IV Distributor: Description and Operation TFI IV Distributor (Typical) - Exploded View This distributor directs high voltage to the spark plugs and supplies crankshaft position and frequency information to the control module using a Profile Ignition Pick-up. Hall Effect Device The universal distributor operates by using a Hall Effect vane switch assembly, which causes the ignition coil to be switched off and on by the EEC IV and TFI-IV modules. The vane switch consists of a Hall Sensor on one side and a permanent magnet on the other. Rotary Vane Cup A rotary vane cup is used to trigger the signal off and on. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Description and Operation > TFI IV > Page 2194 Figure 7 - Magnetic Flux Field When the window of the vane cup is between the magnet and the Hall Effect device, a magnetic field is completed from the magnet through the Hall Effect device and back to the magnet. Hall Effect Device Response To Vane As the vane passes through this opening, the flux lines are shunted through the vane and back to the magnet. At this time, a voltage is produced as the vane passes through the opening. When the vane clears the opening, the window edge causes the signal to go to zero volts. The signal is then used by the EEC system for Crankshaft position Sensing and the Desired Spark Advance based on engine demand and calibration. The spark advance and voltage distribution is accomplished through a conventional rotor, cap and ignition wires. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Description and Operation > TFI IV > Page 2195 Distributor: Description and Operation TFI Octane Rod Distributor (Typical) - Exploded View The octane rod adds a provision for a fixed octane adjustment. The adjustment is done by replacing the standard zero-degree rod located in the distributor bowl with a three degree or six degree retard rod. This is done only if the engine is experiencing a pinging or engine knocking condition and can not be repaired with the conventional methods (timing adjusted, proper operating temperature, higher gasoline octane rating....etc). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUG Tightening Torque ............................................................................................................................... .................................................................... 5-11 ft lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations Valve Clearance: Locations FRONT TO REAR Right Bank.............................................................................................................. .................................................................................................I-E-I-E-I-E Left Bank............................ .............................................................................................................................................................. .......................E-I-E-I-E-I Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations > Page 2202 Valve Clearance: Adjustments Fig. 5 Compressing Lifter To Check Valve Clearance Correct valve clearance is .09-.19 inch. A .060 inch longer or a .060 inch shorter pushrod is available to compensate for dimensional changes in the valve train. If clearance is less than specified, the .060 inch shorter pushrod should be used. If clearance is more than the maximum specified, the .060 inch longer pushrod should be used. Using an auxiliary starter switch crankshaft until No. 1 cylinder is at TDC compression stroke, then compress valve lifter using tool T82C-6500-A or equivalent, Fig. 5. At this point, the following valves can be checked: intake Nos. 1, 3 and 6; exhaust Nos. 1, 2 and 4. After clearance on these valves has been checked, rotate crankshaft until No. 5 cylinder is at TDC compression stroke (1 revolution of crankshaft), and then compress valve lifter using tool No. T82C-6500-A or equivalent, Fig. 5, and check the following valves: intake Nos. 2, 4 and 5; exhaust Nos. 3, 5 and 6. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair Water Pump Removal 1. Drain cooling system. 2. On EFI engines, remove fan shroud retaining screws. Remove fan/clutch assembly retaining bolts. 3. Remove fan/clutch assembly and shroud. 4. Rotate main accessory drive belt tensioner. Remove main drive belt and water pump pulley. 5. Remove power steering pump pulley and remove water pump to power steering pump brace. NOTE:On supercharged engines, it may be necessary to remove the intercooler to gain access to power steering pump pulley. Refer to Intercooler/Charge Air Cooler (CAC) Service and Repair. 6. On EFI engines, disconnect coolant bypass hoses at water pump. On supercharged engines, disconnect oil cooler tube and bypass hose. 7. Disconnect heater hose at water pump (EFI engines) and disconnect lower radiator hose. 8. Remove upper crankshaft sensor cover (supercharged engines). 9. Remove water pump retaining bolts and pump. Discard old gasket. CAUTION:If using a prying device to assist in water pump removal, be careful not to damage the mating surfaces. Installation NOTE:Lightly oil all bolt and stud threads before installation except those specifying special sealant. 1. Clean gasket surfaces on water pump and front cover. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Service and Repair > Page 2206 2. Position a new gasket on water pump sealing surface. NOTE:Gasket and Trim Adhesive D7AZ-1 9B508-AA (ES R-M 11 P17-A and ESE-M2G52-A) or equivalent is recommended to hold the gasket in position. 3. Position water pump on the front cover. Install retaining bolts. NOTE:The threads of the No.1 water pump retaining bolt must be coated with Pipe Sealant with Teflon© D8AZ-19554-A (ESG-M4G194-A) or equivalent before installing. Tighten retaining bolts to 20-30 N-m (15-22 lb-ft). 4. Install upper crankshaft sensor cover (supercharged engines). 5. Connect cooling bypass hose, heater hose, oil cooler hose and radiator lower hose to water pump. Tighten clamps securely. 6. Install water pump to power steering pump brace and install pump pulley. NOTE:If removed, install intercooler assembly. Refer to Intercooler/Charge Air Cooler (CAC) Service and Repair. 7. Position main accessory drive belt over the pulleys. 8. Install water pump pulley, fan/clutch assembly and fan shroud. Cross-tighten fan/clutch assembly retaining bolts to 16-24 N-m (12-18 lb-ft). 9. Rotate tensioner and install drive belt. 10. Fill cooling system with specified coolant. CAUTION:This engine has aluminum cylinder heads and requires a special corrosion inhibiting coolant formula to avoid cooling system damage. 11. Start engine and check for coolant leaks. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations Coolant: Technical Service Bulletins Engine Coolant - Propylene Glycol Recommendations Article No. 01-23-6 11/26/01 ^ ENGINE COOLANT - PROPYLENE GLYCOL - FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL ^ ENGINE COOLANT - PROPYLENE GLYCOL-BASED - FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS FORD: 1989-1993 FESTIVA 1989-1994 TEMPO 1989-1997 PROBE, THUNDERBIRD 1989-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS 1994-1997 ASPIRE 1995-2000 CONTOUR 2000-2002 FOCUS 2002 THUNDERBIRD 1989-1990 BRONCO II 1989-1996 BRONCO 1989-1997 AEROSTAR, F SUPER DUTY 1989-2002 ECONOLINE, F-150, RANGER 1991-2002 EXPLORER 1995-2002 WINDSTAR 1997-2002 EXPEDITION 1999-2002 SUPER DUTY F SERIES 2000-2002 EXCURSION 2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT 2000-2002 F-650, F-750 LINCOLN: 1989-1992 MARK VII 1989-2002 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000-2002 LS 1998-2002 NAVIGATOR 2002 BLACKWOOD MERCURY: 1989-1994 TOPAZ 1989-1997 COUGAR 1989-2002 GRAND MARQUIS, SABLE 1991-1994 CAPRI 1991-1999 TRACER 1995-2000 MYSTIQUE 1999-2002 COUGAR 1993-2002 VILLAGER 1997-2002 MOUNTAINEER MERKUR: 1989 SCORPIO, XR4TI This article is being republished in its entirety to update the model year coverage. ISSUE This TSB article describes Ford Motor Company's position on the use of propylene glycol-based engine coolants. ACTION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2212 Ford Motor Company does not recommend nor endorse the use of engine coolants made with propylene glycol in Ford vehicles. Ford Motor Company currently recommends the use of ethylene glycol-based engine coolants. Published information suggests that engine coolants made with propylene glycol may provide engine cooling performance equivalent to engine coolants made with ethylene glycol. However, different brands of engine coolant provide varying corrosion protection for the cooling system. Ford does not have performance data for the multitude of engine coolants available in the aftermarket and therefore cannot recommend the use of any coolant except those sold by Ford Customer Service Division. Consult the vehicle's Owner's Guide to determine the appropriate Ford Customer Service Division coolant for the vehicle. Furthermore, claims of toxicological and environmental advantages of propylene glycol over ethylene glycol may be misleading. When significant new information is developed, Ford will review this policy. Ford Motor Company specifications recommend that vehicles be maintained using certain ethylene glycol-based engine coolants. Those specifications do not refer to engine coolants made with propylene glycol. Although the Ford New Vehicle Limited Warranty is not automatically voided upon the use of a coolant made with propylene glycol, if such use results in damage to the vehicle or its components, the cost of repairing the damage would not be covered by the Ford New Vehicle Limited Warranty. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2213 Coolant: Technical Service Bulletins Recycled Engine Coolant - Service Tips Article No. 95-18-2 09/11/95 ^ COOLANT - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP ^ COOLING SYSTEM - USE OF RECYCLED ENGINE, COOLANT - SERVICE TIP FORD: 1980 and after CROWN VICTORIA, MUSTANG, THUNDERBIRD 1981 and after ESCORT 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994 and after ASPIRE 1995 and after CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 and after MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR This TSB is being republished in its entirety to include warranty information when using recycled coolant ISSUE: Ford Motor Company authorizes the use of recycled engine coolant that, when properly processed and reinhibited, meets Ford specification ESE-M97B44-A. At this time, the Rotunda Coolant Recycler (181-00003) process is the only approved coolant recycling method available through Ford that is capable of producing recycled engine coolant that meets Ford specification ESE-M97B44-A. ACTION: Refer to the following Service Procedure for coolant processing and reinhibiting using Rotunda Coolant Recycler (181-00003). NOTE: WHILE TESTING SHOWS THAT RECYCLED ENGINE COOLANT CAN PROVIDE ACCEPTABLE PERFORMANCE, THE COOLANT PRODUCED FROM ROTUNDA EQUIPMENT IS INTENDED FOR USE WITHIN DEALERSHIPS ON WARRANTY AND CUSTOMER PAY REPAIRS ONLY AND NOT INTENDED FOR RETAIL SALE. THERE ARE REGULATORY, PACKAGING AND LABELING CONCERNS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2214 ASSOCIATED WITH THE RETAIL SALE OF CHEMICAL PRODUCTS. CAUTION: THE REINHIBITOR CHEMICALS PROVIDED WITH THIS EQUIPMENT ARE NOT APPROPRIATE FOR USE ON MEDIUM/HEAVY TRUCK APPLICATIONS. WARNING: ROTUNDA PREMIUM COOLANT REINHIBITORS # 1 AND # 2 HAVE BEEN SPECIFICALLY FORMULATED TO WORK WITH ROTUNDA COOLANT RECYCLER (181-00003). USE OF ANY OTHER CHEMICAL ADDITIVES WITH THIS SYSTEM WILL VOID ALL WARRANTIES FOR THE EQUIPMENT AND FOR THE FINAL COOLANT PRODUCT. SERVICE PROCEDURE DIRECTIONS FOR PROCESSING USED ENGINE COOLANT WITH ROTUNDA COOLANT RECYCLER 1. Close the drain valve on the unit. 2. Open the fill valve. 3. Pour used engine coolant into the funnel on the side of the unit. NOTE: MAXIMUM CAPACITY 15 25 GALLONS (95 L). 4. Insert the outlet hoses of the recycler into clean, properly labeled containers. One (1) container is for the outlet process water and the other container is for distilled ethylene glycol. 5. Push the "ON" switch on the front to start the operation. The unit will process 1 gallon (3.8 L) per hour of operation and will automatically shut off when cycle is complete. 6. Add reinhibitor following the directions in this article. 7. Open the drain valve to drain the residue from the distillation vessel. Dispose of residue in accordance with all local. state and federal regulations. ADDING REINHIBITOR CHEMICALS 1. Process the coolant according to the directions listed in this article 2. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 1 to each gallon of distilled ethylene glycol. 3. Thoroughly mix 4 fl oz (118 ml) of Reinhibitor # 2 to each gallon of distilled ethylene glycol. 4. Mix well. 5. Check the pH level of the coolant. The pH level must be between 9 and 11. 6. Add enough water to the concentrated coolant to produce a 50/50 mixture of coolant and water. NOTE: THE CONCENTRATED COOLANT MUST BE MIXED WITH WATER TO MEET THE NECESSARY ENGINE FREEZE PROTECTION. 7. Check the coolant freeze point of the 50% coolant solution. Freeze point should be -34°F (-37°C). Consult the Rotunda Coolant Recycler Manual for more detailed operating instructions. Call 1-800-ROTUNDA, 8 AM to 8 PM EST, for inquiries regarding the Rotunda Coolant Recycler and to order the Reinhibitor (187-R0001). PART NUMBER PART NAME Rotunda # 187-R0001 Rotunda Premium Coolant Reinhibitor WARRANTY CLAIMS: Dealer can claim recycled engine coolant by Ford approved process via a warranty repair on an 1863 claim as follows: Part Number: RECCOOL (not a valid part number, but it is recognized on an 1863 claim). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2215 Quantity: Indicate the number of QUARTS of recycled coolant used. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 95-16-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2216 Coolant: Technical Service Bulletins Engine Coolant - Recycled Coolant Not Authorized Article No. 90-4-10 COOLING SYSTEM - USE OF RECYCLED ENGINE COOLANT - SERVICE TIP FORD: 1984-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS 1988-90 FESTIVA 1989-90 PROBE LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE 1987-90 TRACER MERKUR: 1985-90 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR MEDIUM/HEAVY TRUCK: 1984-90 C SERIES, F & B SERIES, L SERIES 1986-90 CARGO SERIES ISSUE: Ford Motor Company does not authorize the use of recycled engine coolant nor do they sanction the use of any machines or devices that recycle engine coolant. Recycled engine coolant is not equivalent to the factory fill OEM coolant, the Ford premium cooling system fluid (E2FZ-19549-AA) or the Ford heavy duty low silicate cooling fluid (E6HZ-19549-A). The quality of engine coolant degenerates with use. Recycling used engine coolant is very difficult to do without exposing the used coolant to additional foreign substances. Merely adding an additive to the coolant will not restore it. ACTION: Use new engine coolant that meets Ford Motor coolant specifications for the engine being serviced. Properly dispose of the used coolant. WARNING: THE DISPOSAL OF ALL USED ENGINE COOLANT MUST ALWAYS BE DONE IN ACCORDANCE WITH ALL APPLICABLE FEDERAL, STATE AND LOCAL LAWS AND REGULATIONS. PART NUMBER PART NAME CLASS E2FZ-19549-AA Coolant System Fluid - Ford V Premium E6HZ-19549-A Coolant System Fluid - Ford V Heavy Duty Low Silicate (For use in diesel powered med/hvy trucks) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2217 Coolant: Technical Service Bulletins Cooling System - Proper Fluid Concentrations Article No. 93-1-10 01/05/93 COOLING SYSTEM - PROPER FLUID CONCENTRATIONS FORD: 1988 EXP 1988-93 CROWN VICTORIA, ESCORT, FESTIVA, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1989-93 PROBE LINCOLN-MERCURY: 1988-89 TRACER 1988-92 MARK VII 1988-93 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR 1991-93 CAPRI, TRACER 1993 MARK VIII MERKUR: 1988-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1988-90 BRONCO II 1988-93 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-93 EXPLORER 1993 VILLAGER ISSUE: It is important to confirm the coolant fluid concentration during any repair of a vehicle's cooling system. A 50/50 concentration of Ford cooling system fluid, or an equivalent solution meeting Ford specifications, and water is best for all normal operating conditions. ACTION: Check the coolant fluid concentration and use a 50/50 solution concentration for optimum results. CAUTION: IF THE CONCENTRATION IS ALLOWED TO VARY TO ANY LARGE EXTENT EITHER WAY, COOLING SYSTEM CONCERNS CAN RESULT. IF THE COOLING SYSTEM FLUID LEVEL IS BELOW THE 50/50 CONCENTRATION, OVERHEATING CAN OCCUR. CONCENTRATIONS ABOVE 50/50 CAN CONTRIBUTE TO EXCESSIVE AND EVEN PREMATURE FAILURE OF THE WATER PUMP (MORE IS NOT BETTER). 1. Obtain a balanced mixture ratio of 50/50 cooling system fluid to water. Premix the two fluids in a separate container by adding equal volumes of coolant and water. 2. Be aware that overfilling of the coolant system is just as bad as not maintaining the proper coolant concentration level. If the coolant system is overfilled, and the system is allowed to expand dropping the excess coolant past the expansion tank, many of the vital coolant additives will be lost out the overflow pipe. This reduces the protection to the engine. 3. Pour in only enough coolant as specified for the system, and top off as necessary. NOTE: TOP OFF ONLY WITH A PREMIXED 50/50 SOLUTION. 4. Check the coolant concentration, once the coolant system has been properly filled, to be sure that it is truly within the allowed tolerance range. a. Use only a hand held refractometer such as a Rotunda Optical Antifreeze/Battery Tester # 021-00046 or equivalent to verify results. The acceptable coolant/water concentration range is: Minimum (45/55); Maximum (60/40). b. If the coolant system is found to be low on coolant, top off only from a premixed solution. c. If a weak concentration is found, add straight coolant sparingly until concentration readings are within acceptable levels. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Technical Service Bulletins > Engine Coolant - Propylene Glycol Recommendations > Page 2218 d. If too strong a concentration is found, remove a small volume of coolant, and add water sparingly until coolant readings again fall within the specified levels. NOTE: MAKE SURE THE COOLANT IS THOROUGHLY MIXED BEFORE TAKING READINGS. A cooling system is only as effective as the condition of the system coolant. ^ USE ONLY FORD COOLING SYSTEM FLUID OR AN EQUIVALENT SOLUTION MEETING FORD SPECIFICATIONS. ^ FOR ADDITIONAL INFORMATION, SEE THE APPROPRIATE VEHICLE SERVICE MANUAL OR OWNER GUIDE. WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 402000, 499000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications Coolant: Capacity Specifications Coolant Capacity 12 qts .............................................................................................................................................................. .......................................... Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information > Specifications > Capacity Specifications > Page 2221 Coolant: Fluid Type Specifications COOLING SYSTEM FLUID, PREMIUM Ford Part No. U.S.A (Except Oregon) ............................................................................................................................................................ E2FZ-19549-AA or -B Canada ............................................................................................................ .............................................................................................. CXC-8-B Oregon .................................. ............................................................................................................................................................. F5FZ-19549-CC Ford Specification ................................................................................................................................ ................................................... ESE-M97B44-A COOLING SYSTEM FLUSH Ford Part No. ....................................................................................................................................... ................................................... F1AZ-19A503-A Ford Specification ................................................. ..................................................................................................................................... ESR-M14P7-A Coolant Mixture with Water ................................................................................................................. ...................................................................... 50% Warning: Do not mix coolant types. Check the owners manual or refer to your local dealer for the correct coolant type. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant Level Sensor > Component Information > Locations Coolant Level Sensor: Locations Engine Compartment Component Locations RH Fender Apron, Top Of Coolant Reservoir Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Engine Compartment Component Locations RH Front Of Engine Compartment Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2231 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2232 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2233 Cooling Fan (Supercharged Engine) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Locations Radiator Cooling Fan Motor: Locations Engine Compartment Component Locations Center Front Of Engine Compartment Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Motor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2239 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2240 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 2241 Cooling Fan (Supercharged Engine) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling Fan Motor > Component Information > Diagrams > Page 2242 Radiator Cooling Fan Motor: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect fan motor wiring connector located at side of fan shroud. 3. Remove male terminal connector retaining clip from shroud mounting tab. 4. Remove overflow hose from shroud, then two upper shroud to radiator support retaining bolts. 5. Lift cooling fan motor past radiator. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Fan Blade > Component Information > Technical Service Bulletins > Blade Fan Assembly - Part Return Fan Blade: Technical Service Bulletins Blade Fan Assembly - Part Return January 25, 1990 To: Ford and Lincoln Mercury Dealers Subject: Sort and Return of Fan Assembly, E73Z-8600-A Because certain Fan Assemblies may not meet Ford's high quality requirements, they should be withdrawn from all inventories. Action Required ^ One hundred percent (100%) sort all stock on hand. ^ Okay stock has 9 blades on fan or 11 blades and a manufacturing date code prior to 8/1/89 or later than 9/24/89. ^ Suspect stock has 11 blades and a manufacturing date code between 8/1/89 and 9/24/89. ^ Manufacturing dates are molded in as dials on the front face of the hub and indicate shift, month, day and year, when read in a clockwise manner. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge 1082". ^ Return parts to your Facing PDC using the least expensive transporation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Returns restricted to subject part. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacement stock of the same part number is available for ordering immediately. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Temperature Sensors 1.3L VAT: Measured between upper terminal (GN/BK wire) of airflow sensor and ground. 1.6L VAT: Measured between terminal 25 (upper terminal on airflow connector) and ground. 2.2L VAT: Measured between first (R wire) and fifth (LG/W wire) of airflow sensor. All others with EEC IV VAT: Measured between upper terminal (LG/P wire) of airflow sensor and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2252 Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2253 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Compartment. Top Front Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2254 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 4 Engine coolant temperature sensor The ECT, Fig. 8, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2263 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2264 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic Temperature Sensor (Gauge): All Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic > Page 2270 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2275 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2276 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic Temperature Sensor (Gauge): All Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic > Page 2282 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Page 2283 Temperature Sensor (Gauge): Locations Engine Compartment. Top Front Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection > Pinpoint Tests Fig. 5 Temperature Indicating System Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection > Pinpoint Tests > Page 2286 Temperature Sensor (Gauge): Component Tests and General Diagnostics Magnetic Type 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 73 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace gauge. Bimetal Type The instrument voltage regulator (IVR) supplies a common regulated voltage for temperature, oil pressure and fuel gauges. The IVR is malfunctioning only if all gauges show similar problems. Test temperature gauge with Rotunda Gauge Tester 021-00055 or equivalent or with a 10 ohm resistor for high calibration and a 75 ohm resistor for low calibration as follows: 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 75 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace IVR and retest. 6. If gauge is out of calibration, replace gauge. Refer to DIAGNOSTIC CHARTS for coolant temperature indicating system diagnosis. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Core Leak Test Procedure Heater Core: Technical Service Bulletins Heater Core - Core Leak Test Procedure HEATER CORE-CORE LEAK TEST PROCEDURE LEAKS-COOLANT-HEATER CORE LEAK TEST PROCEDURE Article No. 89-14-9 FORD: 1988-89 CROWN VICTORIA, ESCORT, FESTIVA, MUSTANG, PROBE, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1988-89 AEROSTAR, BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER ISSUE: Heater cores may be misdiagnosed and replaced unnecessarily. An inadequate seal between the heater core tubes can allow coolant to follow the tube to the heater core and appear as a leak. ACTION: If a heater core leak is suspected, use the following inspection and core leak testing procedure. INSPECTION 1. Look for evidence of coolant leakage at the hose to heater core attachments. A coolant leak at the hose could follow the heater core tube to the core and appear as a leak in the heater core. 2. Check the system for loose heater hose clamps. The clamps should be tightened to 16-22 in.lbs. (1.8-2.5 N-m). 3. If leakage is found and the hose clamps are tight, check the heater core tubes for distortion or evidence of being bent out of shape. Severe distortion of the tubes by such things as over-torqued clamps could cause leakage at the hose connection. Figure 1 PRESSURE TEST - HEATER CORE IN VEHICLE 1. Drain the coolant from the cooling system. 2. Disconnect the heater hoses from the heater core tubes. 3. Install a short piece of heater hose (approximately 4 inches or 10 cm. long) on each heater core tube. 4. Prepare the heater core as follows: a. Fill the heater core and hoses with water. b. Install plug BT-7422-B and adapter BT-7422-A from Rotunda model 021-0012 or equivalent in the hose ends, Figure 1. c. Secure the hoses, plug and adapter with hose clamps. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Core Leak Test Procedure > Page 2291 Figure 2 Figure 3 5. Air pressure test the heater core as described below: a. Attach the pump and gauge assembly Rotunda model 021-0012 or equivalent to the adapter, Figure 2. b. Close the bleed valve at the base of the gauge. c. Pump 30 psi of air pressure into the heater core, Figure 3. 6. Observe the pressure gauge for a minimum of three minutes. The pressure should not drop. 7. If the pressure does not drop, no leaks are indicated. 8. If the pressure drops, check the hose connections to core tubes for leaks. If the hoses do not leak, remove the heater core from the vehicle and perform the bench air pressure test. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Core Leak Test Procedure > Page 2292 Figure 4 PRESSURE TEST - HEATER CORE ON BENCH, OUT OF VEHICLE 1. Drain all coolant or water from the heater core. 2. Connect the four inch test hoses with the plug and adapter to the core tubes. 3. Connect the air pump and gauge assembly to the adapter, Figure 4. 4. Apply 30 psi of air pressure to the heater core with Rotunda model 021-0012 or equivalent. 5. Submerge the heater core in water. 6. If a leak is observed, service or replace the heater core as necessary. OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-12-4, Date 6-17-87 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2620 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information > Technical Service Bulletins > Page 2293 Heater Core: Service and Repair 1. Remove instrument panel, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair and evaporator case. See: Heating and Air Conditioning/Evaporator Case/Service and Repair 2. Remove heater core access cover attaching screws, then the access cover from evaporator case. 3. Lift heater core and seals from evaporator case. 4. Remove seals from heater core tubes. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2303 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2304 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2310 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2311 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Coolant Temperature Indicating System Calibration Test Temperature Gauge: Testing and Inspection Coolant Temperature Indicating System Calibration Test Magnetic Type 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 73 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace gauge. Bimetal Type The instrument voltage regulator (IVR) supplies a common regulated voltage for temperature, oil pressure and fuel gauges. The IVR is malfunctioning only if all gauges show similar problems. Test temperature gauge with Rotunda Gauge Tester 021-00055 or equivalent or with a 10 ohm resistor for high calibration and a 75 ohm resistor for low calibration as follows: 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 75 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace IVR and retest. 6. If gauge is out of calibration, replace gauge. Refer to DIAGNOSTIC CHARTS for coolant temperature indicating system diagnosis. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Coolant Temperature Indicating System Calibration Test > Page 2314 Fig. 5 Temperature Indicating System Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation Bimetal Type The temperature lamp system provides the driver with an indication of engine coolant temperature by means of a switch mounted in the intake manifold and a red engine lamp mounted on the instrument panel. The temperature switch has a temperature sensitive bimetallic arm which completes the lamp circuit through the switch to engine ground. Magnetic Type The temperature indicating system is a magnetic type system, which consists only of the sending unit located in the engine block or cylinder head and a temperature gauge in the instrument cluster. The sending unit changes resistance according to the temperature of engine coolant, which varies the current flow through the gauge. The pointer position varies proportionally to the current flow. The sender resistance is high when coolant temperature is low, and low when coolant temperature is high. The pointer of the magnetic gauge remains in position when ignition is turned to the Off position. It will move to the correct indication whenever the ignition is turned back to On position. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information > Specifications Radiator Cap: Specifications VIN C,R, Relief Pressure VIN C,R, Relief Pressure Radiator Cap Relief Pressure 16 psi Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Locations Radiator Cooling Fan Control Module: Locations Engine Compartment Component Locations RH Front Of Engine Compartment Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions Radiator Cooling Fan Control Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2327 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2328 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System > Radiator Cooling Fan Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2329 Cooling Fan (Supercharged Engine) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Coolant Level Sensor > Component Information > Locations Coolant Level Sensor: Locations Engine Compartment Component Locations RH Fender Apron, Top Of Coolant Reservoir Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Temperature Sensors 1.3L VAT: Measured between upper terminal (GN/BK wire) of airflow sensor and ground. 1.6L VAT: Measured between terminal 25 (upper terminal on airflow connector) and ground. 2.2L VAT: Measured between first (R wire) and fifth (LG/W wire) of airflow sensor. All others with EEC IV VAT: Measured between upper terminal (LG/P wire) of airflow sensor and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2339 Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2340 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Compartment. Top Front Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2341 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 4 Engine coolant temperature sensor The ECT, Fig. 8, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2350 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2351 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic Temperature Sensor (Gauge): All Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic > Page 2357 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2362 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2363 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge Reads Low/Erratic Temperature Sensor (Gauge): All Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge Reads Low/Erratic > Page 2369 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Page 2370 Temperature Sensor (Gauge): Locations Engine Compartment. Top Front Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection > Pinpoint Tests Fig. 5 Temperature Indicating System Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System > Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Testing and Inspection > Pinpoint Tests > Page 2373 Temperature Sensor (Gauge): Component Tests and General Diagnostics Magnetic Type 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 73 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace gauge. Bimetal Type The instrument voltage regulator (IVR) supplies a common regulated voltage for temperature, oil pressure and fuel gauges. The IVR is malfunctioning only if all gauges show similar problems. Test temperature gauge with Rotunda Gauge Tester 021-00055 or equivalent or with a 10 ohm resistor for high calibration and a 75 ohm resistor for low calibration as follows: 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 75 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace IVR and retest. 6. If gauge is out of calibration, replace gauge. Refer to DIAGNOSTIC CHARTS for coolant temperature indicating system diagnosis. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge Not Functioning Correctly > Page 2382 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge Not Functioning Correctly > Page 2383 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2389 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 2390 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Coolant Temperature Indicating System Calibration Test Temperature Gauge: Testing and Inspection Coolant Temperature Indicating System Calibration Test Magnetic Type 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 73 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace gauge. Bimetal Type The instrument voltage regulator (IVR) supplies a common regulated voltage for temperature, oil pressure and fuel gauges. The IVR is malfunctioning only if all gauges show similar problems. Test temperature gauge with Rotunda Gauge Tester 021-00055 or equivalent or with a 10 ohm resistor for high calibration and a 75 ohm resistor for low calibration as follows: 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 75 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace IVR and retest. 6. If gauge is out of calibration, replace gauge. Refer to DIAGNOSTIC CHARTS for coolant temperature indicating system diagnosis. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component Information > Testing and Inspection > Coolant Temperature Indicating System Calibration Test > Page 2393 Fig. 5 Temperature Indicating System Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation Bimetal Type The temperature lamp system provides the driver with an indication of engine coolant temperature by means of a switch mounted in the intake manifold and a red engine lamp mounted on the instrument panel. The temperature switch has a temperature sensitive bimetallic arm which completes the lamp circuit through the switch to engine ground. Magnetic Type The temperature indicating system is a magnetic type system, which consists only of the sending unit located in the engine block or cylinder head and a temperature gauge in the instrument cluster. The sending unit changes resistance according to the temperature of engine coolant, which varies the current flow through the gauge. The pointer position varies proportionally to the current flow. The sender resistance is high when coolant temperature is low, and low when coolant temperature is high. The pointer of the magnetic gauge remains in position when ignition is turned to the Off position. It will move to the correct indication whenever the ignition is turned back to On position. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics Thermostat: Technical Service Bulletins Cooling System - New System Diagnostics Article No. 93-24-8 11/24/93 ^ HESITATION - ROUGH IDLE - ENGINE COOLANT DOES NOT REACH NORMAL OPERATING TEMPERATURE - MEDIUM TRUCKS WITH 7.0L ENGINES ^ HESITATION/STALL DURING ACCELERATION OR DECELERATION ^ IDLE - ROUGH - ENGINE COOLANT DOES NOT REACH NORMAL OPERATING TEMPERATURE ^ HEATER/DEFROSTER - POOR HEATER OUTPUT - THERMOSTAT STUCK OPEN ^ COOLING SYSTEM - NEW DIAGNOSTICS FOR ENGINES THAT DO NOT REACH NORMAL OPERATING TEMPERATURE FORD: 1983-94 ESCORT 1984-87 EXP 1984-94 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1985-90 BRONCO II 1986-94 AEROSTAR 1988-94 F SUPER DUTY 1991-94 EXPLORER This TSB article is being republished in its entirety to include 1994 model year vehicles. ISSUE: Engine performance concerns such as hesitation or stall, rough idle, and/or poor fuel economy may be caused by the thermostat stuck in an open position or opening at a temperature lower than specified. ACTION: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics > Page 2401 Use the following "Cooling System Diagnosis" procedure to diagnose a cooling system that may not be reaching normal operating temperature. Follow the "Thermostat Diagnosis" procedure to determine if the thermostat may be at fault. Check the thermostat without removing it from the vehicle by using Rotunda Service Coolant Temperature Monitor Harness 007-00064. A new cooling system diagnosis procedure has been developed for engines that do not reach normal operating temperature. A new thermostat diagnosis procedure also has been developed, using a new service coolant temperature monitor harness. NOTE: THIS PROCEDURE WILL DIAGNOSE ONLY COOLING SYSTEMS THAT MAY NOT BE REACHING NORMAL OPERATING TEMPERATURE. IT WILL NOT DIAGNOSE A THERMOSTAT THAT CAUSES AN ENGINE OVERHEAT CONDITION. NOTE: THE ESCORT/TRACER SPECIFIC APPLICATION FOR THIS ARTICLE IS AS FOLLOWS: ^ 1983-1990 Escort 1.9L and 1.6L ^ 1991-1994 Escort 1.9L ^ 1991-1994 Tracer 1.9L Only THERMOSTAT DIAGNOSIS NOTE: DISCONNECTING THE POWERTRAIN CONTROL MODULE (PCM) TO ATTACH A BREAKOUT BOX OR AN EEC IV MONITOR WILL ERASE THE ADAPTIVE LEARNING FROM MEMORY AND MAY "HIDE" A DRIVE CONCERN TEMPORARILY UNTIL THE ADAPTIVE LEARNING IS RE-LEARNED. NOTE: THIS PROCEDURE IS MOST ACCURATE IF PERFORMED INDOORS AT LESS THAN 100~F (38~C) AMBIENT TEMPERATURE. THIS TEST MAY BE PERFORMED WITH OR WITHOUT THE HOOD OPEN AND WITH THE ENGINE WARM OR COLD. CAUTION: ALWAYS VENT THE EXHAUST TO THE OUTSIDE WHEN PERFORMING THIS TEST. 1. Check the coolant level in the radiator and coolant recovery reservoir. 2. With the key in the "off" position, proceed as follows: a. Remove the engine coolant temperature (ECT) sensor harness connector. b. Attach Rotunda Service Coolant Temperature Monitor Harness 007-00064 as a jumper between the PCM and the ECT. c. Attach Rotunda 73 Digital Multimeter 105-00051 or equivalent to the thermostat monitor harness. Voltage values (0-5vdc) may now be Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Cooling System - New System Diagnostics > Page 2402 monitored while the sensor retains its connection to the wiring harness. NOTE: A ROTUNDA NEW GENERATION STAR TESTER (NGS) 007-00500 OR THE ROTUNDA SERVICE BAY DIAGNOSTIC SYSTEM (SBDS) 001-00001 MAY BE USED TO MONITOR THE ECT ON VEHICLES EQUIPPED WITH DATA COMMUNICATIONS LINK (DCL). THE SBDS SEQUENCE TO USE FOR THE SCREEN IS "TOOLBOX - ELECTRONIC ENGINE CONTROL AND DCL - ITEM". 3. Vehicles equipped with electric engine cooling fan(s) must have a fan running during this test (high or low speed may be used). Two methods may be used to turn the fan(s) on: a. Disconnect the A/C compressor clutch power supply and turn the climate control to A/C "ON". Or b. Disconnect the power supply to the cooling fan and supply 12 volts direct to the fan connector from the battery. NOTE: A GROUND MAY BE REQUIRED FOR SOME APPLICATIONS. 4. Place transmission in "park" or "neutral". NOTE: RUNNING THIS TEST WITH THE VEHICLE IN GEAR OR WITH THE A/C COMPRESSOR CLUTCH ENGAGED (RUNNING) WILL CAUSE IMPROPER DIAGNOSIS 5. Start the engine and allow to idle throughout this test: a. Allow engine to run for 2 minutes, then record ECT voltage. b. From now on, record ECT voltage every 60 seconds. c. When the ECT voltage trend changes direction or changes only slightly (0.03 volts or less) from the previous reading, record this as the thermostat opening voltage. d. Use the "Voltage and Corresponding Temperature Chart" shown to obtain actual coolant temperatures. 6. If the opening voltage is GREATER than 0.75 volts (less than 18~ F/ 82~ C), or 0.85 volts (170~ F/ 77~ C) for 2.3L HSC engine only, replace the thermostat. Refer to the dealer Master Parts Catalog for correct thermostat usage. 7. If the thermostat opening voltage is LESS than 0.75 volts (greater than 180~ F/ 82~ C), or 0.85 volts (170~ F/ 77~ C) for 2.3L HSC engine only, the thermostat is good and should NOT be replaced. The "Cooling System Diagnosis Chart" should be referenced for further instructions. NOTE: The 10~ F opening temperature difference for the 2.3L HSC engine is due to the ECT sensor location. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-14-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208100, 402000, 608000, 608400, 609000, 609400, 611000, 611500, 622000, 690000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Page 2403 Thermostat: Specifications VIN C,R, Opening Temperature VIN C,R, Opening Temperature Thermostat Opening Temperature 197 F Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component Information > Technical Service Bulletins > Page 2404 Thermostat: Service and Repair 1. Partially drain cooling system. 2. Disconnect upper radiator hose at thermostat housing. 3. Remove two mounting bolts, housing and gaskets. 4. Reverse procedure to install. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair Water Pump: Service and Repair Water Pump Removal 1. Drain cooling system. 2. On EFI engines, remove fan shroud retaining screws. Remove fan/clutch assembly retaining bolts. 3. Remove fan/clutch assembly and shroud. 4. Rotate main accessory drive belt tensioner. Remove main drive belt and water pump pulley. 5. Remove power steering pump pulley and remove water pump to power steering pump brace. NOTE:On supercharged engines, it may be necessary to remove the intercooler to gain access to power steering pump pulley. Refer to Intercooler/Charge Air Cooler (CAC) Service and Repair. 6. On EFI engines, disconnect coolant bypass hoses at water pump. On supercharged engines, disconnect oil cooler tube and bypass hose. 7. Disconnect heater hose at water pump (EFI engines) and disconnect lower radiator hose. 8. Remove upper crankshaft sensor cover (supercharged engines). 9. Remove water pump retaining bolts and pump. Discard old gasket. CAUTION:If using a prying device to assist in water pump removal, be careful not to damage the mating surfaces. Installation NOTE:Lightly oil all bolt and stud threads before installation except those specifying special sealant. 1. Clean gasket surfaces on water pump and front cover. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information > Service and Repair > Page 2408 2. Position a new gasket on water pump sealing surface. NOTE:Gasket and Trim Adhesive D7AZ-1 9B508-AA (ES R-M 11 P17-A and ESE-M2G52-A) or equivalent is recommended to hold the gasket in position. 3. Position water pump on the front cover. Install retaining bolts. NOTE:The threads of the No.1 water pump retaining bolt must be coated with Pipe Sealant with Teflon© D8AZ-19554-A (ESG-M4G194-A) or equivalent before installing. Tighten retaining bolts to 20-30 N-m (15-22 lb-ft). 4. Install upper crankshaft sensor cover (supercharged engines). 5. Connect cooling bypass hose, heater hose, oil cooler hose and radiator lower hose to water pump. Tighten clamps securely. 6. Install water pump to power steering pump brace and install pump pulley. NOTE:If removed, install intercooler assembly. Refer to Intercooler/Charge Air Cooler (CAC) Service and Repair. 7. Position main accessory drive belt over the pulleys. 8. Install water pump pulley, fan/clutch assembly and fan shroud. Cross-tighten fan/clutch assembly retaining bolts to 16-24 N-m (12-18 lb-ft). 9. Rotate tensioner and install drive belt. 10. Fill cooling system with specified coolant. CAUTION:This engine has aluminum cylinder heads and requires a special corrosion inhibiting coolant formula to avoid cooling system damage. 11. Start engine and check for coolant leaks. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component Information > Testing and Inspection Catalytic Converter: Testing and Inspection Restricted Exhaust System Diagnosis A blocked or restricted exhaust system usually results in lack of power or popping through the carburetor. Check that the problem is not caused by ignition or timing conitions. Perform a visual inspection of the exhaust system. If the visual cannot locate the restriction, proceed with the following program: 1. Attach a vacuum gauge to intake manifold. Connect tachometer. Start engine and observe vacuum gauge. Gauge should indicated 16 to 21 inches of vacuum. 2. Increase engine speed to 2,000 rpm. Vacuum will drop when speed is increased rapidly, but should settle at 16 to 21 inches and remian steady. If vacuum drops below 16 inches, exhaust system is restricted. Stop engine. 3. Disconnect exhaust pipe at manifold. Start engine and increase speed to 2,000 rpm. a. If vacuum settles at 16 to 21 inches, restriction is in exhaust pipe, catalytic converter or muffler. If vehicle is equipped with a catalytic converter, reconnect exhaust pipe at manifold, remove muffler and check vacuum gauge. b. If vacuum drops below 16 inches, restriction is in the catalytic converter. If vacuum is normal, muffler is restricted. In the event of a converter failure, always check muffler to be sure converter debris has not entered muffler. 4. If the vacuum drops below 16 inches with exhaust pipe disconnected, exhaust manifold is restricted. a. On six-cylinder engines, remove exhaust manifold. On eight-cylinder engines, remove both exhaust manifolds. b. Inspect ports of exhaust manifold for casting flash by dropping a length of chain into each port. Don't use a wire or light to check ports. The restricted opening may be large enough for them to pass through but small enough to cause excessive back pressure at high engine rpm. c. Remove casting flash. If flash is at lower end of port, it can usually be chipped out. If flash cannot be removed, replace manifold. 5. Reassembly exhaust system and remove test equipment. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information > Specifications Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall Engine Control Module: Customer Interest Engine - Detonation/Hard Start/Rough Idle/Stall Article No. 91-9-5 05/01/91 ^ DETONATION - 3.8L (N/A) - DURING WIDE OPEN THROTTLE AT NORMAL ENGINE OPERATING TEMPERATURE ^ HARD START - 3.8L (N/A) - LONG CRANK TIME DURING INITIAL COLD START ^ IDLE - ROUGH - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START ^ STALL - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard/slow start may occur at the initial cold start followed by a rough idle during the first 30 seconds. Spark knock may also occur during wide open throttle operation at normal engine operating temperature. These conditions occur because of the operating strategy of the EEC IV processor. ACTION: Use the following procedure to determine if a new EEC IV processor is required. 1. Perform the diagnostic procedures in the 1989/90 Engine/Emission Diagnosis Shop Manual. Service as required. 2. If the conditions still exist, install a new EEC IV processor with a revised operating strategy. 3. Refer to the following Parts Block for correct parts usage. Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS F0PZ-12A650-GA EEC IV Processor (49 State) B F0PZ-12A650-FA EEC IV Processor (California) W OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910905A Perform Engine/Emissions 0.5 Hr. Diagnosis. 910905B Replace EEC IV Processor 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall > Page 2427 DRIVE J7 OASIS CODES: 602300, 607000, 608400, 615000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall Engine Control Module: All Technical Service Bulletins Engine - Detonation/Hard Start/Rough Idle/Stall Article No. 91-9-5 05/01/91 ^ DETONATION - 3.8L (N/A) - DURING WIDE OPEN THROTTLE AT NORMAL ENGINE OPERATING TEMPERATURE ^ HARD START - 3.8L (N/A) - LONG CRANK TIME DURING INITIAL COLD START ^ IDLE - ROUGH - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START ^ STALL - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard/slow start may occur at the initial cold start followed by a rough idle during the first 30 seconds. Spark knock may also occur during wide open throttle operation at normal engine operating temperature. These conditions occur because of the operating strategy of the EEC IV processor. ACTION: Use the following procedure to determine if a new EEC IV processor is required. 1. Perform the diagnostic procedures in the 1989/90 Engine/Emission Diagnosis Shop Manual. Service as required. 2. If the conditions still exist, install a new EEC IV processor with a revised operating strategy. 3. Refer to the following Parts Block for correct parts usage. Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS F0PZ-12A650-GA EEC IV Processor (49 State) B F0PZ-12A650-FA EEC IV Processor (California) W OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910905A Perform Engine/Emissions 0.5 Hr. Diagnosis. 910905B Replace EEC IV Processor 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall > Page 2433 DRIVE J7 OASIS CODES: 602300, 607000, 608400, 615000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding Precautions Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding Precautions Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 2443 Engine Control Module: Locations Body & Chassis Components Behind RH Shroud Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2446 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2447 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2448 Engine Control Module: Connector Views EEC-IV Module Connector Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2449 EEC-IV Module Connector Pin Usage Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Assembly (ECA) Engine Control Module: Description and Operation Electronic Control Assembly (ECA) Fig. 6 Electronic control assembly (ECA) The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration assembly, Fig. 6. The processor receives input signals from the various sensors. The information obtained is used by the processor to activate engine control systems to obtain optimum emission control and engine performance The calibration assembly is a permanent memory device that contains information. The processor applies the sensor inputs to the stored information to determine when and how long the various control systems should be applied. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Assembly (ECA) > Page 2452 Engine Control Module: Description and Operation Failure Mode Effects Management FMEM is an alternate system strategy in the ECA designed to allow improved vehicle drive should one or more sensor inputs fail. When a sensor input is perceived to be out-of-limits by the ECA, an alternative strategy will be initiated. The ECA will substitute a fixed in-limit sensor value and will continue to monitor the faulty sensor input. If the faulty sensor operates within limits, the ECA will return to the normal Engine Running mode (strategy). Code 98 will be displayed when FMEM is in effect. The MIL ``Check Engine'' light will remain ON when the FMEM is in effect. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 2453 Engine Control Module: Service and Repair The Electronic Control Assembly (ECA) is located behind the righthand kick panel. 1. Disconnect electrical connector from ECA. 2. Remove ECA lower leg-to-cowl side sheet metal attaching screw. 3. Remove ECA. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions Integrated Control Relay Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2458 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2459 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2460 Integrated Control Relay Module: Electrical Diagrams Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2461 Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Inside Power Distribution Box Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Page 2479 Fuel Pump Relay: Locations FUEL INJECTORS: The fuel injectors are mounted in the lower intake manifold. FUEL PRESSURE REGULATOR: The fuel pressure regulator is attached to the fuel supply manifold. FUEL FILTER: The filter is located downstream of the electric electric fuel pump and is mounted on the underbody. FUEL PUMP: The fuel pump is mounted on the fuel sender assembly inside of the fuel tank. FUEL PUMP RELAY: LH side of trunk, behind wheelwell. INERTIA SWITCH: The inertia switch is located on the LH side of trunk, behind wheelwell. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2482 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 2483 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description Fuel Pump Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2486 X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 - CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2487 Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2488 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2489 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2490 Fuel Pump Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2491 X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 - CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2492 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2493 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2494 Fig. 23 Integrated Controller Pinpoint Tests X13 & X14 (Part 4 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2495 Fig. 23 Integrated Controller Pinpoint Tests X15 (Part 5 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2496 Fig. 23 Integrated Controller Pinpoint Test X16 & X17 (Part 6 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2497 Fig. 23 Integrated Controller Pinpoint Tests X18, X19, X20 & X21 (Part 7 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2498 Fig. 23 Integrated Controller Pinpoint Test X22 (Part 8 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2499 Fig. 23 Integrated Controller Pinpoint Tests X23 & X25 (Part 9 Of 26) Fig. 23 Integrated Controller Pinpoint Tests X26, X27 & X30 (Part 10 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2500 Fig. 23 Integrated Controller Pinpoint Tests X31 & X32 (Part 11 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2501 Fig. 23 Integrated Controller Pinpoint Tests X33 & X35 (Part 12 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2502 Fig. 23 Integrated Controller Pinpoint Tests X36 & X37 (Part 13 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2503 Fig. 23 Integrated Controller Pinpoint Tests X40, X41, X42 & X43 (Part 14 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2504 Fig. 23 Integrated Controller Pinpoint Tests X44, X45 & X46 (Part 15 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2505 Fig. 23 Integrated Controller Pinpoint Tests X50, X51 & X52 (Part 16 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2506 Fig. 23 Integrated Controller Pinpoint Tests X53, X54 & X55 (Part 17 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2507 Fig. 23 Integrated Controller Pinpoint Tests X56, X57 & X58 (Part 18 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2508 Fig. 23 Integrated Controller Pinpoint Tests X59, X60 & X80 (Part 19 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2509 Fig. 23 Integrated Controller Pinpoint Tests X81, X82 & X83 (Part 20 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2510 Fig. 23 Integrated Controller Pinpoint Tests X84, X90 & X91 (Part 21 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2511 Fig. 23 Integrated Controller Pinpoint Tests X92, X93 & X94 (Part 22 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2512 Fig. 23 Integrated Controller Pinpoint Tests X95 & X96 (Part 23 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2513 Fig. 23 Integrated Controller Pinpoint Tests X100 & X101 (Part 24 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2514 Fig. 23 Integrated Controller Pinpoint Tests X102 & X103 (Part 25 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 2515 Fig. 23 Integrated Controller Pinpoint Test X104 (Part 26 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions Integrated Control Relay Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2520 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2521 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2522 Integrated Control Relay Module: Electrical Diagrams Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 2523 Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Inside Power Distribution Box Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Component Location - Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2531 Ignition Control Module: Description and Operation Module And Pin-Out The main function of the DIS module is to switch between ignition coils and cause these coils to spark. The module receives the PIP and CID signals as well as the SPOUT signal from the ECA. During normal operation, PIP is sent to the ECA to provide base timing and engine RPM information. The CID signal provides the DIS ignition module with the information required to synchronize the ignition coils so that they are fired in the proper order. The SPOUT signal contains the optimum spark timing and dwell information. The spark angle is determined by the rising edge of the SPOUT signal. The falling edge controls the ON or dwell time of the coil current. The dwell time is controlled by varying the duty cycle of the SPOUT signal. With the proper inputs from PIP, CID, and SPOUT the DIS module turns the coils On and Off in the proper order for spark control. PIN 1 VBAT (BATTERY VOLTAGE) PIN 2 CID PIN 3 NOT USED PIN 4 PIP IN PIN 5 SPOUT PIN 6 NOT USED PIN 7 IGND (MODULE GROUND) PIN 8 COIL 1 PIN 9 COIL 3 PIN 10 NOT USED PIN 11 COIL 2 PIN 12 IDM (IGNITION DIAGNOSTIC MODULE) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 2532 Ignition Control Module: Service and Repair Removal 1. Identify, then disconnect electrical connectors from DIS ignition module assembly by pushing down on the connector locking tabs. Tabs are marked PUSH. 2. Remove three retaining screws, then the ignition module from the lower intake manifold. Installation 1. Apply a 1/32 inch coat of silicone dielectric compound or equivalent to the mounting surface of the DIS module. 2. Mount the DIS module to the intake manifold. Torque bolts to 22-31 ft. lbs. 3. Connect electrical connectors to ignition module. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications Air Flow Meter/Sensor: Specifications Mass or Vane Airflow Sensor Engines with multi-port injection. 1.6L MFI, 1.9L MFI, 2.3L MFI: Vane Airflow Sensors, measured between second upper terminal (W/BK wire) and ground. 3.0L SHO, 3.8L Supercharged, 5.0L MFI H.O.: Mass Airflow Sensors, measured between terminal D (upper most) and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page 2538 Air Flow Meter/Sensor: Locations Engine Compartment Component Locations RH Front Of Engine Compartment, In Air Duct Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page 2539 Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart Barometric Pressure Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart Article No. 89-1-12 ^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART ^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS FORD: 1984-87 ALL CARLINES LINCOLN-MERCURY: 1984-89 ALL CARLINES LIGHT TRUCK: 1984-89 ALL TRUCKLINES This article is being republished in its entirety to include the MAP sensor application for the 2.3L HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine. ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP and BAP sensor application chart has been assembled to assist technicians in making sure the correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy, erratic engine idle or hesitation on acceleration may result. ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the correct service part applications. NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF THE FORD PARTS CATALOG. LIGHT TRUCK MAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE 1984-86 2.3L OHC All E6TZ-9F479-A MAP 1986-87 3.0L EFI All E6FZ-9F479-A MAP 1988-89 3.0L EFI All E7FZ-9F479-A MAP 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 4.9L EFI 5.0L EFI 7.5L EFI 1988-89 5.8L EFI All E7FZ-9F479-A MAP PASSENGER CAR MAP AND BAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE 1984-89 1.6L EFI All E7FZ-12A644-A BAP 1.9L EFI 2.3L Turbo 1989 3.0 "SHO" All E7FZ-12A644-A BAP 1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP (Mustang) 1989 5.0L Mass Air All E8FZ-12A644-A BAP 1984 2.3L HSC FBC All E6PZ-9F479-A MAP 1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP 2.5L HSC CFI 1984-85 3.8L CFI All E5SZ-9F479-A MAP 1984-85 5.0L CFI All E6TZ-9F479-A MAP 1986 2.3L OHC All E6FZ-9F479-A MAP Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart > Page 2544 3.0L EFI 3.8L CFI 5.0 SEFI 1984-85 2.3L OHC All E6FZ-9F479-A MAP 1987-89 1.9L CFI All E7DZ-9F479-A MAP 2.3L HSC CFI 2.5L HSC CFI 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI PART NUMBER PART NAME CLASS E7FZ-12A644-A BAP Sensor B E8FZ-12A644-A BAP Sensor B E6PZ-9F479-A MAP Sensor B E5SZ-9F479-A MAP Sensor AM E6TZ-9F479-A MAP Sensor BM E6FZ-9F479-A MAP Sensor B E7DZ-9F479-A MAP Sensor B E7FZ-9F479-A MAP Sensor B OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 620800, 631900, 640200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > Page 2545 Pinpoint Test DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP) Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation Fig. 15 Ignition barometric pressure switch This switch, Fig. 15, controls spark timing and/or other electrical devices according to altitude. Calibration resistors in the switch assembly cause the ignition module to vary the spark timing. Spark timing is advanced for vehicle operation above a predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some switch assemblies control both spark timing and another device while other switch assemblies control only one or the other. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing Fig. 33 Ignition barometric pressure switch resistance chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values in chart, Fig. 33. 3. Replace switch if resistance is not within specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair Camshaft Synchronizer Assembly: Service and Repair CAUTION: Prior to starting this procedure, set cylinder number one to 26 degrees After Top Dead Center (ATDC) of the compression stroke. Then note the position of the camshaft sensor electrical connector. The installation procedure requires that the connector be located in the same position. Removal 1. Disconnect negative battery cable. 2. Remove camshaft sensor assembly. 3. Remove synchronizer clamp (bolt and washer assembly). 4. Remove synchronizer from front engine cover assembly. NOTE: The intermediate oil pump driveshaft should be removed with the synchronizer assembly. Installation CAUTION: If the replacement synchronizer does not contain a plastic locator cover tool, a special service tool such as Syncro Positioner T89P-12200-A or equivalent must be obtained prior to installation of the replacement synchronizer. Failure to follow this procedure will result in improper synchronizer alignment. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. 1. If the plastic locator cover tool is not attached to the replacement synchronizer assembly, attach Syncro Positioner Tool T89P-12200-A or equivalent as follows: a. Engage synchronizer vane into the radial slot of the tool. b. Rotate tool on synchronizer base until tool boss engages the base notch. The cover tool should be square and in contact with entire top surface of synchronizer base. 2. Transfer intermediate oil pump driveshaft from old synchronizer to replacement synchronizer assembly. 3. Install synchronizer assembly so that gear engagement occurs when arrow on locator tool is pointed approximately 30 degrees counterclockwise from the front face of the engine block. This step will locate camshaft sensor electrical connector in the pre-removal position. 4. Install synchronizer base clamp (washer and bolt) and tighten bolt to 20-30 Nm (15-22 lb-ft). 5 Remove Syncro Positioner Tool T89P-12200-A or equivalent. 6. Install and connect camshaft sensor. CAUTION: If camshaft sensor electrical connector is not positioned properly (i.e. contacting the A/C bracket or forward of the supercharger drive belt), DO NOT reposition the connector by rotating the synchronizer base. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer and repeat installation procedure, beginning with Step 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair > Page 2555 7. Connect negative battery cable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Temperature Sensors 1.3L VAT: Measured between upper terminal (GN/BK wire) of airflow sensor and ground. 1.6L VAT: Measured between terminal 25 (upper terminal on airflow connector) and ground. 2.2L VAT: Measured between first (R wire) and fifth (LG/W wire) of airflow sensor. All others with EEC IV VAT: Measured between upper terminal (LG/P wire) of airflow sensor and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2560 Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2561 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Compartment. Top Front Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2562 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 4 Engine coolant temperature sensor The ECT, Fig. 8, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Top Front Of Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2568 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2569 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2570 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft timing sensor is a single Hall effect magnetic switch, actuated by three vanes on the crankshaft damper and pulley assembly. The signal generated by this sensor the Profile Ignition Pick-up (PIP). It provides base timing and RPM information to the DIS module and EEC IV module. Initial or base, timing is set at 10 degrees BTDC and is not adjustable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2571 Crankshaft Position Sensor: Adjustments INITIAL TIMING Initial timing is preset at 10~ plus or minus 2~ BTDC and is not adjustable. PIP SENSOR 1. Install Crankshaft Sensor Gauge T89P-AH or equivalent to outside surface of one vane of shutter. Gauge is magnetic and will conform to the shape of the vane. 2. Rotate crankshaft by HAND to align shutter vane with gauge into sensor air gap. Push sensor housing inward to contact gauge and tighten screws to 22-31 lb-in. CAUTION: Over tightening can cause damage to timing sensor. 3. Rotate crankshaft by HAND to position shutter vane with gauge outside of air gap. Remove magnetic gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2572 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect negative battery cable. 2. If necessary, loosen tensioner pulleys for A/C compressor and supercharger idler pulley belts, as well as removing belts from crankshaft pulley. 3. Disconnect sensor electrical connectors from engine wiring harness. 4. Raise vehicle and suitably support. Then remove upper and lower damper shield assemblies. 5. ON 89 MODELS: Remove crankshaft damper and pulley assembly using Universal Puller T67L-3600-A or equivalent. 6. Remove crankshaft sensor mounting screws and remove sensor. Installation 1. Position crankshaft sensor assembly on bracket. 2. Install two sensor attaching screws and tighten to 22-31 lb-in. 3. Install crankshaft damper and pulley assembly using crank gear and damper replacer T83T-6316-B or equivalent. Tighten pulley bolt to 103-132 lb-ft. 4. Install upper and lower damper shields and tighten fasteners to specification. Lower vehicle. 5. Route sensor wiring harness and connect both electrical connectors. Then install A/C and power steering belts and adjust to proper tension. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2577 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2578 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2579 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2580 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2581 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2582 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2583 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2584 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2585 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2586 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2587 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2588 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2589 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2590 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2591 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2592 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2593 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2594 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2595 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2596 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2597 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2598 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2599 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2600 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2601 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2602 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2603 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2604 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2605 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2606 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2607 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2608 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2609 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2610 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 2611 EGR Valve Position Sensor: Description and Operation EGR valve position sensor The EGR valve position sensor provides the EEC system with an EGR valve position signal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Temperature Sensors 1.3L VAT: Measured between upper terminal (GN/BK wire) of airflow sensor and ground. 1.6L VAT: Measured between terminal 25 (upper terminal on airflow connector) and ground. 2.2L VAT: Measured between first (R wire) and fifth (LG/W wire) of airflow sensor. All others with EEC IV VAT: Measured between upper terminal (LG/P wire) of airflow sensor and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2615 Intake Air Temperature Sensor: Locations Engine Compartment Component Locations Top Rear Of Engine Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2616 Intake Air Temperature Sensor: Description and Operation Fig. 1 Air charge temperature (ACT) sensor The ACT sensor, Fig. 1, used on EFI models, provides the EFI system mixture (air/fuel) temperature information. The ACT is used as both as a density corrector to air flow calculation and to proportion the cold enrichment fuel flow. This sensor is mounted on an intake manifold runner or on the air cleaner. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Rear Of Engine Lower RH Side Of Engine, Under Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2620 Knock Sensor: Description and Operation Knock Sensor The knock sensor is a piezoelectric accelerator accelerometer. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5 - 6 KHz). The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP Sensor - Pinpoint Test DF Manual Correction Article No. 89-5A-6 EEC IV - PINPOINT TEST "DF" - MAP SENSOR GRAPH - SHOP MANUAL CORRECTION FORD: 1989 ESCORT, MUSTANG, TEMPO, TAURUS, AND THUNDERBIRD LINCOLN-MERCURY: 1989 TOPAZ, SABLE, COUGAR, CONTINENTAL, MARK VII, LINCOLN TOWN CAR LIGHT TRUCK: 1989 RANGER, BRONCO, AEROSTAR, F-SERIES, ECONOLINE ISSUE: The MAP sensor graph and data table on page 17-67 of the 1989 Engine Emissions Diagnosis Manual, Volume H is incorrect. ACTION: If service is required, refer to this TSB for the correct graph and data. This information should be inserted into your 1989 Engine Emissions Diagnosis Manual, Volume H, Section 17-67 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-67 Manifold Absolute Pressure (MAP)/ Barometric Pressure (BP) Sensor Pinpoint Test DF Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 2625 MAP Sensor Graph NOTE: MAP sensor output frequency versus manifold vacuum data is based on 30.0 in-Hg barometric pressure. 1989 17-68 EEC-IV - Pinpoint Tests - All Vehicles Manifold Absolute Pressure (MAP)/ Barometric Pressure (BP) Sensor Pinpoint Test DF Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 2626 MAP/BP Sensor Graph (KOEO) NOTE: Frequency may vary plus or minus 3 Hz from the values given due to sensor variations. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 2627 Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart Article No. 89-1-12 ^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART ^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS FORD: 1984-87 ALL CARLINES LINCOLN-MERCURY: 1984-89 ALL CARLINES LIGHT TRUCK: 1984-89 ALL TRUCKLINES This article is being republished in its entirety to include the MAP sensor application for the 2.3L HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine. ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP and BAP sensor application chart has been assembled to assist technicians in making sure the correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy, erratic engine idle or hesitation on acceleration may result. ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the correct service part applications. NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF THE FORD PARTS CATALOG. LIGHT TRUCK MAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE 1984-86 2.3L OHC All E6TZ-9F479-A MAP 1986-87 3.0L EFI All E6FZ-9F479-A MAP 1988-89 3.0L EFI All E7FZ-9F479-A MAP 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 4.9L EFI 5.0L EFI 7.5L EFI 1988-89 5.8L EFI All E7FZ-9F479-A MAP PASSENGER CAR MAP AND BAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE 1984-89 1.6L EFI All E7FZ-12A644-A BAP 1.9L EFI 2.3L Turbo 1989 3.0 "SHO" All E7FZ-12A644-A BAP 1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP (Mustang) 1989 5.0L Mass Air All E8FZ-12A644-A BAP 1984 2.3L HSC FBC All E6PZ-9F479-A MAP 1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP 2.5L HSC CFI 1984-85 3.8L CFI All E5SZ-9F479-A MAP 1984-85 5.0L CFI All E6TZ-9F479-A MAP 1986 2.3L OHC All E6FZ-9F479-A MAP Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 2628 3.0L EFI 3.8L CFI 5.0 SEFI 1984-85 2.3L OHC All E6FZ-9F479-A MAP 1987-89 1.9L CFI All E7DZ-9F479-A MAP 2.3L HSC CFI 2.5L HSC CFI 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI PART NUMBER PART NAME CLASS E7FZ-12A644-A BAP Sensor B E8FZ-12A644-A BAP Sensor B E6PZ-9F479-A MAP Sensor B E5SZ-9F479-A MAP Sensor AM E6TZ-9F479-A MAP Sensor BM E6FZ-9F479-A MAP Sensor B E7DZ-9F479-A MAP Sensor B E7FZ-9F479-A MAP Sensor B OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 620800, 631900, 640200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 2629 Pinpoint Test DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP) Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 2630 Manifold Pressure/Vacuum Sensor: Locations Engine Compartment Component Locations RH Rear Of Engine Compartment Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 2635 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2636 Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2637 Oxygen Sensor: Locations Rear Of Engine In RH Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 2638 Oxygen Sensor: Description and Operation Fig. 9 Exhaust gas oxygen (EGO) sensor The EGO, Fig. 9, sensor supplies the ECA assembly with a rich or lean condition during engine operation. On 4-97.6 and 4-140 engines, the EGO sensor is threaded into the center of the exhaust manifold. On V6 engines, the EGO sensor is threaded into the rear portion of the left and right exhaust manifold assemblies. On V8 engines, the EGO sensor is threaded into the rear portion of the right exhaust manifold assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations I/P Components LH Side Of I/P, On Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Supercharger Removal/Assembly EGR Valve Installation The Pressure Feedback Electronic (PFE) Exhaust Gas Recirculation (EGR) Transducer is located at the Top Rear Center of the Engine. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2649 Technical Service Bulletin # 88265 Date: 881221 EEC IV Pinpoint - Test Manual Correction EEC IV - PINPOINT TESTS A, N AND P - 3.0L "SHO" AND 3.8L "SUPERCHARGED" ENGINES SHOP MANUAL CORRECTION Article No. 88-26-5 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: EEC IV pinpoint test "A" EEC IV No Start, "N" Ignition/Erratic and "P" Spark Timing Check are incorrect as published in the 1989 Engine/Emissions Diagnosis Manual, Section 17-5, 17-310 and 17-322. The Diagnostic schematics did not include the 3.0L "SHO" and 3.8L "Supercharged" crankshaft sensor connectors or the ignition coil connectors. ACTION: Use the pinpoint diagnostic information on pages 15 through 20 of this TSB article. This information should be inserted in your 1989 Engine/Emission Diagnosis Shop Manual, Section 17-5, 17-310 and 17-322 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODE: 680000 EEC-IV No Start EEC-IV-Pinpoint Tests - All Vehicles 1989 17-5 EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2650 Pinpoint Test Schematic 17-6 1989 EEC-IV-Pinpoint Tests - All Vehicles EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2651 WARNING STOP THIS TEST AT THE FIRST SIGN OF A FUEL LEAK AND SERVICE AS REQUIRED. CAUTION No open flame - No smoking during fuel delivery checks. Ignition/Erratic Diagnostic Monitor (IDM) EEC-IV - Pinpoint Tests - All Vehicles 1989 17-309 Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2652 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2653 Pinpoint Test Schematic 17-310 1989 EEC-IV - Pinpoint Tests - All Vehicles Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Spark Timing Check EEC-IV - Pinpoint Tests - All Vehicles 1989 17-321 Spark Timing Check Pinpoint P Note Test You should enter this Pinpoint Test only when directed here from Quick Test Step 4.0, when a Service Code 18 is received in Quick Test Step 5.0 or a code 49 is received in Quick Test Step 6.0. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2654 Remember To prevent the replacement of good components, be aware that the following non-EEC areas may be at fault: ^ Base Engine ^ Camshaft Sensor (CID) ^ Distributor ^ Single Hall Crankshaft Sensor (PIP) ^ TFI or DIS Module ^ Dual Hall Sensor This Pinpoint Test is intended to diagnose only the following: ^ Harness Spout Circuit ^ Base Timing ^ Processor Assembly (-12A650-) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2655 Pinpoint Test Schematic 17-322 1989 EEC-IV - Pinpoint Tests - All Vehicles Pinpoint Spark Timing Check Test P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications Throttle Position Sensor (TPS) Engines with EEC III: Turn ignition to RUN position and remove vacuum hose from throttle kicker as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV: Connect positive (+) probe of DVOM along the DG/LG wire of TPS. Connect negative (-) probe along the BK/W wire and turn ignition on but do not start engine. Adjust TPS to specified value. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2658 Throttle Position Sensor: Mechanical Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2659 Throttle Position Sensor: Description and Operation The throttle position sensor is used by the EEC computer to determine the operating mode (closed throttle, part throttle or wide open throttle) for selection of the proper air/fuel mixture, spark and EGR. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 2660 Throttle Position Sensor: Adjustments Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision Vehicle Speed Sensor: Technical Service Bulletins Speed Sensor Resistance Reading - Manual Revision ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1988-PAGE 19-109-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-PAGE 17-142-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1990-PAGE 17-146-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED Article No. 90-18B-1 FORD: 1988-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1988-90 COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1988-90 AEROSTAR ISSUE: The resistance reading of 10,000 ohm shown in the Vehicle Speed Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 2665 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 2666 Pinpoint Test DP on page 19-109 OF THE 1988 Engine/Emissions Diagnosis Shop Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 2667 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 2668 Manual, page 17-142 of the 1989 Engine/Emissions Diagnosis Shop Manual Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 2669 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 2670 and page 17-146 of the 1990 Engine/Emissions Diagnosis Shop Manual is incorrect. The correct reading is 500 ohms. ACTION: Refer to the pages following this TSB article for the revised test procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2671 Vehicle Speed Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2672 Vehicle Speed Sensor: Locations LH Rear Side Of Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 2673 Vehicle Speed Sensor: Service and Repair Fig. 26 Speed Sensor Replacement. Cougar, Crown Victoria, Town Car, Mark VII, Grand Marquis, & Thunderbird 1. Raise and support vehicle. 2. Remove bolt retaining the sensor attaching clip, then the sensor and driven gear from transmission, Fig. 26. 3. Disconnect sensor electrical connector. 4. Disconnect speedometer cable by pulling it out of speed sensor, Fig. 26. Do not attempt to remove spring retaining clip with speedometer cable in sensor. 5. Remove retainer, then separate sensor from driven gear. 6. Position sensor to driven gear and install retainer. 7. Connect electrical connector. 8. Ensure internal O-ring is properly seated in sensor housing. Snap speedometer cable into sensor housing. 9. Install sensor to transmission. 10. Lower vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2679 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2680 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2681 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2682 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2683 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2684 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2685 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2686 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2687 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2688 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2689 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2690 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2691 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2692 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2693 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2694 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2695 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2696 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2697 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2698 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2699 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2700 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2701 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2702 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2703 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2704 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2705 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2706 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2707 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2708 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2709 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2710 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2711 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2712 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 2713 EGR Valve Position Sensor: Description and Operation EGR valve position sensor The EGR valve position sensor provides the EEC system with an EGR valve position signal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Supercharger Removal/Assembly EGR Valve Installation The Pressure Feedback Electronic (PFE) Exhaust Gas Recirculation (EGR) Transducer is located at the Top Rear Center of the Engine. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications Air Flow Meter/Sensor: Specifications Mass or Vane Airflow Sensor Engines with multi-port injection. 1.6L MFI, 1.9L MFI, 2.3L MFI: Vane Airflow Sensors, measured between second upper terminal (W/BK wire) and ground. 3.0L SHO, 3.8L Supercharged, 5.0L MFI H.O.: Mass Airflow Sensors, measured between terminal D (upper most) and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 2721 Air Flow Meter/Sensor: Locations Engine Compartment Component Locations RH Front Of Engine Compartment, In Air Duct Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 2722 Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations FUEL INJECTORS: The fuel injectors are mounted in the lower intake manifold. FUEL PRESSURE REGULATOR: The fuel pressure regulator is attached to the fuel supply manifold. FUEL FILTER: The filter is located downstream of the electric electric fuel pump and is mounted on the underbody. FUEL PUMP: The fuel pump is mounted on the fuel sender assembly inside of the fuel tank. FUEL PUMP RELAY: LH side of trunk, behind wheelwell. INERTIA SWITCH: The inertia switch is located on the LH side of trunk, behind wheelwell. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 2728 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 2729 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 2730 Fuel Pump Inertia Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch PURPOSE The inertia switch is used to shut the fuel pump "Off" in the event of a collision. CONSTRUCTION The inertia switch consists of a steel ball held in place by a magnet. OPERATION When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate. This opens the electrical contacts of the switch and disrupts power to the electric fuel pump. The engine will quit running within a few seconds after the fuel pump loses power. The inertia switch must then be manually reset before the engine can be restarted. WARNING: DO NOT reset the inertia switch button if you see or smell fuel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2735 Technical Service Bulletin # 88265 Date: 881221 EEC IV Pinpoint - Test Manual Correction EEC IV - PINPOINT TESTS A, N AND P - 3.0L "SHO" AND 3.8L "SUPERCHARGED" ENGINES SHOP MANUAL CORRECTION Article No. 88-26-5 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: EEC IV pinpoint test "A" EEC IV No Start, "N" Ignition/Erratic and "P" Spark Timing Check are incorrect as published in the 1989 Engine/Emissions Diagnosis Manual, Section 17-5, 17-310 and 17-322. The Diagnostic schematics did not include the 3.0L "SHO" and 3.8L "Supercharged" crankshaft sensor connectors or the ignition coil connectors. ACTION: Use the pinpoint diagnostic information on pages 15 through 20 of this TSB article. This information should be inserted in your 1989 Engine/Emission Diagnosis Shop Manual, Section 17-5, 17-310 and 17-322 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODE: 680000 EEC-IV No Start EEC-IV-Pinpoint Tests - All Vehicles 1989 17-5 EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2736 Pinpoint Test Schematic 17-6 1989 EEC-IV-Pinpoint Tests - All Vehicles EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2737 WARNING STOP THIS TEST AT THE FIRST SIGN OF A FUEL LEAK AND SERVICE AS REQUIRED. CAUTION No open flame - No smoking during fuel delivery checks. Ignition/Erratic Diagnostic Monitor (IDM) EEC-IV - Pinpoint Tests - All Vehicles 1989 17-309 Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2738 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2739 Pinpoint Test Schematic 17-310 1989 EEC-IV - Pinpoint Tests - All Vehicles Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Spark Timing Check EEC-IV - Pinpoint Tests - All Vehicles 1989 17-321 Spark Timing Check Pinpoint P Note Test You should enter this Pinpoint Test only when directed here from Quick Test Step 4.0, when a Service Code 18 is received in Quick Test Step 5.0 or a code 49 is received in Quick Test Step 6.0. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2740 Remember To prevent the replacement of good components, be aware that the following non-EEC areas may be at fault: ^ Base Engine ^ Camshaft Sensor (CID) ^ Distributor ^ Single Hall Crankshaft Sensor (PIP) ^ TFI or DIS Module ^ Dual Hall Sensor This Pinpoint Test is intended to diagnose only the following: ^ Harness Spout Circuit ^ Base Timing ^ Processor Assembly (-12A650-) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 2741 Pinpoint Test Schematic 17-322 1989 EEC-IV - Pinpoint Tests - All Vehicles Pinpoint Spark Timing Check Test P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications Throttle Position Sensor (TPS) Engines with EEC III: Turn ignition to RUN position and remove vacuum hose from throttle kicker as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV: Connect positive (+) probe of DVOM along the DG/LG wire of TPS. Connect negative (-) probe along the BK/W wire and turn ignition on but do not start engine. Adjust TPS to specified value. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 2744 Throttle Position Sensor: Mechanical Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2745 Throttle Position Sensor: Description and Operation The throttle position sensor is used by the EEC computer to determine the operating mode (closed throttle, part throttle or wide open throttle) for selection of the proper air/fuel mixture, spark and EGR. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 2746 Throttle Position Sensor: Adjustments Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair Camshaft Synchronizer Assembly: Service and Repair CAUTION: Prior to starting this procedure, set cylinder number one to 26 degrees After Top Dead Center (ATDC) of the compression stroke. Then note the position of the camshaft sensor electrical connector. The installation procedure requires that the connector be located in the same position. Removal 1. Disconnect negative battery cable. 2. Remove camshaft sensor assembly. 3. Remove synchronizer clamp (bolt and washer assembly). 4. Remove synchronizer from front engine cover assembly. NOTE: The intermediate oil pump driveshaft should be removed with the synchronizer assembly. Installation CAUTION: If the replacement synchronizer does not contain a plastic locator cover tool, a special service tool such as Syncro Positioner T89P-12200-A or equivalent must be obtained prior to installation of the replacement synchronizer. Failure to follow this procedure will result in improper synchronizer alignment. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. 1. If the plastic locator cover tool is not attached to the replacement synchronizer assembly, attach Syncro Positioner Tool T89P-12200-A or equivalent as follows: a. Engage synchronizer vane into the radial slot of the tool. b. Rotate tool on synchronizer base until tool boss engages the base notch. The cover tool should be square and in contact with entire top surface of synchronizer base. 2. Transfer intermediate oil pump driveshaft from old synchronizer to replacement synchronizer assembly. 3. Install synchronizer assembly so that gear engagement occurs when arrow on locator tool is pointed approximately 30 degrees counterclockwise from the front face of the engine block. This step will locate camshaft sensor electrical connector in the pre-removal position. 4. Install synchronizer base clamp (washer and bolt) and tighten bolt to 20-30 Nm (15-22 lb-ft). 5 Remove Syncro Positioner Tool T89P-12200-A or equivalent. 6. Install and connect camshaft sensor. CAUTION: If camshaft sensor electrical connector is not positioned properly (i.e. contacting the A/C bracket or forward of the supercharger drive belt), DO NOT reposition the connector by rotating the synchronizer base. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer and repeat installation procedure, beginning with Step 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair > Page 2752 7. Connect negative battery cable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Top Front Of Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2758 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2759 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2760 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft timing sensor is a single Hall effect magnetic switch, actuated by three vanes on the crankshaft damper and pulley assembly. The signal generated by this sensor the Profile Ignition Pick-up (PIP). It provides base timing and RPM information to the DIS module and EEC IV module. Initial or base, timing is set at 10 degrees BTDC and is not adjustable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2761 Crankshaft Position Sensor: Adjustments INITIAL TIMING Initial timing is preset at 10~ plus or minus 2~ BTDC and is not adjustable. PIP SENSOR 1. Install Crankshaft Sensor Gauge T89P-AH or equivalent to outside surface of one vane of shutter. Gauge is magnetic and will conform to the shape of the vane. 2. Rotate crankshaft by HAND to align shutter vane with gauge into sensor air gap. Push sensor housing inward to contact gauge and tighten screws to 22-31 lb-in. CAUTION: Over tightening can cause damage to timing sensor. 3. Rotate crankshaft by HAND to position shutter vane with gauge outside of air gap. Remove magnetic gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2762 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect negative battery cable. 2. If necessary, loosen tensioner pulleys for A/C compressor and supercharger idler pulley belts, as well as removing belts from crankshaft pulley. 3. Disconnect sensor electrical connectors from engine wiring harness. 4. Raise vehicle and suitably support. Then remove upper and lower damper shield assemblies. 5. ON 89 MODELS: Remove crankshaft damper and pulley assembly using Universal Puller T67L-3600-A or equivalent. 6. Remove crankshaft sensor mounting screws and remove sensor. Installation 1. Position crankshaft sensor assembly on bracket. 2. Install two sensor attaching screws and tighten to 22-31 lb-in. 3. Install crankshaft damper and pulley assembly using crank gear and damper replacer T83T-6316-B or equivalent. Tighten pulley bolt to 103-132 lb-ft. 4. Install upper and lower damper shields and tighten fasteners to specification. Lower vehicle. 5. Route sensor wiring harness and connect both electrical connectors. Then install A/C and power steering belts and adjust to proper tension. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: Customer Interest Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Rear Of Engine Lower RH Side Of Engine, Under Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2780 Knock Sensor: Description and Operation Knock Sensor The knock sensor is a piezoelectric accelerator accelerometer. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5 - 6 KHz). The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections Fuel Pressure: Technical Service Bulletins Fuel Pressure Specification - Corrections ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-SECTION 11-SPECIFICATION CORRECTIONS ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-SECTION 17-SPECIFICATION CORRECTIONS Article No. 89-12A-25 FORD: 1989 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1989 AEROSTAR, BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER ISSUE: The pressure values shown for the 2.5L CFI engine in both "Key on engine off" and "running" conditions are incorrectly shown in the Electric Fuel Delivery System (EFD) on page 11-14 and the Fuel Control Pinpoint Test H on page 17-185. The 1988 date in the chart titles for both Passenger Car Engines and Light Truck Engines is incorrect on page 17-185. The 3.0L SHO SEFI "Key on engine off" value in the chart on page 11-14 is incorrect. ACTION: Refer to the pages following this TSB article for the corrected charts. This information should be inserted in your 1989 Engine Emissions Diagnosis Manual, pages 11-14 and 17-185. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 Fuel Delivery Systems 1989 11-13 Electric Fuel Delivery System EFD Electrical Schematic VEHICLE APPLICATION E Series 1988 and later model years, EFI F Series 1986 and later model years, EFI 11-14 1989 Fuel Delivery Systems Electric Fuel Delivery System EFD Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 2786 FUEL PRESSURE SPECIFICATION TABLE EEC-IV - Pinpoint Tests - All Vehicles 1989 17-185 Fuel Control Pinpoint Test GH Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 2787 FUEL PRESSURE SPECIFICATION TABLE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 2788 17-186 1989 EEC-IV-Pinpoint Tests-All Vehicles Fuel Control Pinpoint Test H Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 2789 Fuel Pressure: Specifications Key On Engine Off 35 - 40 psi Key On Engine Running 30 - 40 psi Engine Running Vacuum Hose Disconnected From Fuel Pressure Regulator 35 - 40 psi Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > System Information > Technical Service Bulletins > Page 2790 Fuel Pressure: Testing and Inspection STO Connector STATIC PRESSURE TEST 1. Check for adequate fuel supply. 2. Turn key OFF 3. Install fuel pressure gauge to test port on fuel rail. 4. Install test lead to fuel pump lead of STO test connector. 5. Turn Key ON Engine OFF (KOEO). 6. Ground test lead to run fuel pump. 7. Check to determine if fuel pressure is within acceptable limits. a. If pressure is low but greater than 3 psi (indicates fuel pump is running but not enough pressure) check for: ^ Plugged fuel filter ^ Kinked fuel line ^ Low voltage to pump (should be within 0.5 volts of battery voltage at connector). ^ Disconnect the fuel return line and note if fuel is being returned during this low pressure condition. If fuel is being returned, replace the fuel pressure regulator. Reconnect the fuel return line. b. If pressure is less than 3 psi (pump not running) check for: ^ Defective fuse link ^ Inertia switch open ^ Wiring at fuel pump/tank connector loose or open ^ Fuel pump ground connection at chassis loose or defective ^ Improper fuel pump relay operation If fuel supply and return lines are OK, and electrical supply and ground are OK, and fuel pressure is still low, replace fuel pump. DYNAMIC PRESSURE TEST 1. Disconnect and plug the vacuum line to the pressure regulator. 2. Start engine and run at idle. Check to determine if fuel pressure is within acceptable limits. Refer to SPECIFICATIONS. a. If pressure is low check for: ^ Plugged fuel filter ^ Restricted fuel line ^ Low voltage to pump (should be within 0.5 volts of battery voltage at connector). 3. Reconnect the vacuum line to the regulator. If fuel supply and return lines are OK, and electrical supply and ground is OK, and fuel pressure is still low, replace fuel pump. LEAKAGE TEST 1. Momentarily activate fuel pump by grounding test lead. Raise pressure to approximate operating pressure. 2. Remove ground from test lead and note pressure on gauge. Pressure should remain within 2 psi for 3 minutes after lead is ungrounded. a. If pressure is not maintained check for leaking fuel ^ Lines ^ Connectors ^ Injectors b. Disconnect fuel return line and plug engine side. Momentarily activate fuel pump by grounding test lead. Raise pressure to approximate operating pressure. If pressure holds replace regulator and retest. Reconnect the fuel return line. If pressure is not maintained replace fuel pump. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2799 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2800 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2801 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2802 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2803 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2804 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2805 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2806 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2807 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2808 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2809 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2810 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2811 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2812 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2813 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2814 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2815 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2821 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2822 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2823 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2824 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2825 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2826 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2827 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2828 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2829 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2830 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2831 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2832 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2833 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2834 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2835 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2836 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 2837 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2838 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2839 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2840 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2841 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2842 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2843 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2844 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2845 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2846 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2847 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2848 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2849 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2850 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2851 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2852 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2853 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2854 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2855 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2856 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2857 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2858 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2859 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2860 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2861 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2862 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2863 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2864 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2865 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2866 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2867 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2868 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2869 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2870 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2871 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 2872 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 2873 Fuel injected Model, Idle Speed Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System Information > Technical Service Bulletins > Page 2874 Idle Speed: Adjustments IDLE SPEED 1. Place automatic transmission in PARK. 2. Engine OFF, back out throttle plate stop screw clear off the throttle lever pad. 3. With a .010 in. feeler gauge between the throttle plate stop screw and throttle lever pad turn the screw in until contact is made then turn it an additional 1.5 turns. 4. Start engine and stabilize for 2 minutes then goose the engine and let it return to idle, lightly depress and release the accelerator and let engine idle. If idle problem still exists check for other possible causes. 5. On Automatic Overdrive Transmission (AOD) applications or Automatic Transaxle (AXOD) application check Throttle Valve (TV) adjustment. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when fueling vehicle or when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. NOTE: Methanol and ethanol are not interchangeable. Methanol fuel can be used only in vehicles designed for methanol fuels. Ethanol fuel can be used only in vehicles designed for ethanol fuels. WARNING: The fuel tubes leading from the fuel tank to the engine are under pressure during vehicle operation. When fuel injected engines are turned off, the fuel in the fuel tubes remains pressurized for long periods of time to provide quick start-ups. Special procedures for servicing these pressurized fuel systems are outlined in this section. These procedures should be followed to prevent accidental spraying of fuel, causing personal injury or a fire hazard. WARNING: Do not swallow fuel of any kind. Fuels such as methanol or fuel ethanol and gasoline or mixtures of these fuels are highly toxic and if swallowed can cause death or permanent injury. Swallowing methanol can also cause blindness. Immediately seek medical attention from a physician or poison control center to treat anyone who has swallowed fuel. Be aware that if fuel is swallowed, the onset of potential ill health effects may be delayed 12-24 hours. AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR OF ANY KIND CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY. AVOID GETTING FUEL LIQUID IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. ALLOWING ANY FUEL TO GET IN YOUR EYES WILL CAUSE SEVERE IRRITATION. FAILURE TO SEEK PROPER MEDICAL ATTENTION FOR FUEL CONTACT WITH THE EYES COULD LEAD TO PERMANENT INJURY. IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. MAKE SURE YOU WASH YOUR HANDS BEFORE HANDLING FOOD. FUELS CONTAINING GASOLINE SUCH AS FUEL METHANOL AND FUEL ETHANOL MAY CONTAIN BENZENE, WHICH IS A CANCER-CAUSING AGENT. IF YOU ARE TAKING MEDICATION FOR THE TREATMENT OF ALCOHOLISM, SUCH AS ANTABUSE OR OTHER FORMS OF DISULFIRAM, SKIN CONTACT WITH FUEL METHANOL, FUEL ETHANOL OR BREATHING THEIR VAPORS CAN CAUSE THE SAME KIND OF ADVERSE REACTION AS DRINKING ALCOHOLIC BEVERAGES. IN SENSITIVE INDIVIDUALS, SERIOUS PERSONAL INJURY OR SICKNESS COULD RESULT. IF YOU ARE TAKING SUCH MEDICATION, YOU SHOULD TAKE EXTRA CARE TO AVOID SKIN CONTACT WITH FUEL AND TO AVOID BREATHING ITS VAPORS. IF YOU DO GET FUEL ON YOUR SKIN, WASH IT OFF IMMEDIATELY. CONSULT A PHYSICIAN PROMPTLY IF YOU EXPERIENCE AN ADVERSE REACTION. WARNING: Do not modify the fuel system configuration or components or replace components with parts not especially designed for use with fuel methanol. Ford motor company has specially-designed the materials, components and system configuration for methanol-fueled vehicles and each particular system is precisely calibrated for efficient operation. Ford ethanol vehicles require the same parts as the methanol-fueled vehicles, but are calibrated specifically for gasoline/ethanol-blended fuels. The use of different parts or materials could produce an untested configuration that could result in fire, personal injury or cause engine damage. WARNING: Do not operate engine or smoke while refueling. WARNING: Use of the incorrect fuel or blending of fuels can result in severe engine damage. Refer to fuel filler door for vehicle-specific fuel usage. WARNING: It is important that your flexible fuel vehicle be properly maintained by ford flexible fuel trained personnel. If a problem occurs, it is important that properly trained personnel diagnose the cause. If the problem relates to the fuel system, proper part replacement is imperative to keep your vehicle operating at normal performance. Flexible fuel components and standard fuel components are not interchangeable. If your vehicle is not serviced in accordance with flexible fuel vehicle procedures, damage may occur and your warranty may be invalidated. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 2879 Fuel Pressure Release: Service and Repair WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube. Release pressure from fuel system at the fuel pressure relief valve using tool No. T80L-9974-B or equivalent. When relieving fuel pressure, crank engine with fuel pump electrical connector disconnected. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order > Component Information > Specifications Firing Order: Specifications V6 Firing Order: 1 4 2 5 3 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures Technical Service Bulletin # 9111B6 Date: 910614 Octane Adjust Shorting Bar - Revised Procedures Article No. 91-11B-6 ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1989 - PAGE 17-289 - PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1990 - PAGE 17-329 - PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1991 - PAGE 5-22 - EEC-IV QUICK TEST STEP 12.0 - CAR DIAGNOSIS BY SYMPTOM CHART REVISED ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1991 - PAGES 6-305 THROUGH 6-307 PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR FORD: 1989-91 TAURUS, THUNDERBIRD 1991 ESCORT, MUSTANG LINCOLN-MERCURY: 1989-90 COUGAR 1991 TRACER LIGHT TRUCK: 1989-91 RANGER 1991 AEROSTAR, EXPLORER ISSUE: Additional information regarding removal of the Octane Adjust Shorting Bar is required to assure compliance with Federal (EPA) Emission Standards. The following Manuals are affected on the pages indicated: ^ 1989 Engine/Emissions Diagnosis Page 17-289 ^ 1990 Engine/Emissions Diagnosis Page 17-329 ^ 1991 Engine/Emissions Diagnosis Page 5-22 and Pages 6-305 through 307 ACTION: Refer to the pages in this TSB article for the additional information. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 2888 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 2889 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 2890 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 2891 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 2892 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 2893 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 2894 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Locations > Component Locations Ignition Timing Connector: Component Locations Engine Compartment Component Locations RH Front Of Engine Compartment, Below VIP Test Connector Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Ignition Timing Connector > Component Information > Locations > Component Locations > Page 2897 Component Location - Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Mark 3.8L Supercharged Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams Component Location Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 2907 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable > Component Information > Diagrams > Page 2908 Ignition Cable: Service and Repair When removing spark plug wires from plugs, use spark plug wire remover T74P-6666-A or equivalent. Grasp and twist the boot back and forth on the plug until boot is loose. Remove boot and wire from plug. Pull on boot only. Do not pull on wire. When removing wires from the ignition coil, squeeze the locking tabs of coil wire retainer by hand. Twist and pull on boot until free. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Description and Operation > TFI IV Distributor: Description and Operation TFI IV Distributor (Typical) - Exploded View This distributor directs high voltage to the spark plugs and supplies crankshaft position and frequency information to the control module using a Profile Ignition Pick-up. Hall Effect Device The universal distributor operates by using a Hall Effect vane switch assembly, which causes the ignition coil to be switched off and on by the EEC IV and TFI-IV modules. The vane switch consists of a Hall Sensor on one side and a permanent magnet on the other. Rotary Vane Cup A rotary vane cup is used to trigger the signal off and on. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Description and Operation > TFI IV > Page 2913 Figure 7 - Magnetic Flux Field When the window of the vane cup is between the magnet and the Hall Effect device, a magnetic field is completed from the magnet through the Hall Effect device and back to the magnet. Hall Effect Device Response To Vane As the vane passes through this opening, the flux lines are shunted through the vane and back to the magnet. At this time, a voltage is produced as the vane passes through the opening. When the vane clears the opening, the window edge causes the signal to go to zero volts. The signal is then used by the EEC system for Crankshaft position Sensing and the Desired Spark Advance based on engine demand and calibration. The spark advance and voltage distribution is accomplished through a conventional rotor, cap and ignition wires. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Distributor, Ignition > Component Information > Description and Operation > TFI IV > Page 2914 Distributor: Description and Operation TFI Octane Rod Distributor (Typical) - Exploded View The octane rod adds a provision for a fixed octane adjustment. The adjustment is done by replacing the standard zero-degree rod located in the distributor bowl with a three degree or six degree retard rod. This is done only if the engine is experiencing a pinging or engine knocking condition and can not be repaired with the conventional methods (timing adjusted, proper operating temperature, higher gasoline octane rating....etc). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUG Tightening Torque ............................................................................................................................... .................................................................... 5-11 ft lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations Valve Clearance: Locations FRONT TO REAR Right Bank.............................................................................................................. .................................................................................................I-E-I-E-I-E Left Bank............................ .............................................................................................................................................................. .......................E-I-E-I-E-I Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance > System Information > Locations > Page 2921 Valve Clearance: Adjustments Fig. 5 Compressing Lifter To Check Valve Clearance Correct valve clearance is .09-.19 inch. A .060 inch longer or a .060 inch shorter pushrod is available to compensate for dimensional changes in the valve train. If clearance is less than specified, the .060 inch shorter pushrod should be used. If clearance is more than the maximum specified, the .060 inch longer pushrod should be used. Using an auxiliary starter switch crankshaft until No. 1 cylinder is at TDC compression stroke, then compress valve lifter using tool T82C-6500-A or equivalent, Fig. 5. At this point, the following valves can be checked: intake Nos. 1, 3 and 6; exhaust Nos. 1, 2 and 4. After clearance on these valves has been checked, rotate crankshaft until No. 5 cylinder is at TDC compression stroke (1 revolution of crankshaft), and then compress valve lifter using tool No. T82C-6500-A or equivalent, Fig. 5, and check the following valves: intake Nos. 2, 4 and 5; exhaust Nos. 3, 5 and 6. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications Air Flow Meter/Sensor: Specifications Mass or Vane Airflow Sensor Engines with multi-port injection. 1.6L MFI, 1.9L MFI, 2.3L MFI: Vane Airflow Sensors, measured between second upper terminal (W/BK wire) and ground. 3.0L SHO, 3.8L Supercharged, 5.0L MFI H.O.: Mass Airflow Sensors, measured between terminal D (upper most) and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page 2926 Air Flow Meter/Sensor: Locations Engine Compartment Component Locations RH Front Of Engine Compartment, In Air Duct Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page 2927 Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Temperature Sensors 1.3L VAT: Measured between upper terminal (GN/BK wire) of airflow sensor and ground. 1.6L VAT: Measured between terminal 25 (upper terminal on airflow connector) and ground. 2.2L VAT: Measured between first (R wire) and fifth (LG/W wire) of airflow sensor. All others with EEC IV VAT: Measured between upper terminal (LG/P wire) of airflow sensor and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2931 Intake Air Temperature Sensor: Locations Engine Compartment Component Locations Top Rear Of Engine Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 2932 Intake Air Temperature Sensor: Description and Operation Fig. 1 Air charge temperature (ACT) sensor The ACT sensor, Fig. 1, used on EFI models, provides the EFI system mixture (air/fuel) temperature information. The ACT is used as both as a density corrector to air flow calculation and to proportion the cold enrichment fuel flow. This sensor is mounted on an intake manifold runner or on the air cleaner. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > EEC IV Pinpoint Test Step KE15 - Revised Auxiliary Air Valve (Idle Speed): Technical Service Bulletins EEC IV Pinpoint Test Step KE15 Revised Article No. 89-25A-8 12/15/89 ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL, VOLUME H - PAGE 17-266 - PINPOINT TEST STEP KE15 REVISED FORD: 1989 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1989 AEROSTAR, BRONCO II, BRONCO, ECONOLINE, F SUPER DUTY, F-150, F-250, F-350, RANGER ISSUE: The Pinpoint Test Step KE15 on Page 17-266 of the 1989 Engine/Emission Shop Manual, Volume H, has incorrect direction if a NO answer is received. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > EEC IV Pinpoint Test Step KE15 - Revised > Page 2937 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > EEC IV Pinpoint Test Step KE15 - Revised > Page 2938 ACTION: Refer to the pages in this TSB for the revised information showing KE6 changed to KE16. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart Barometric Pressure Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart Article No. 89-1-12 ^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART ^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS FORD: 1984-87 ALL CARLINES LINCOLN-MERCURY: 1984-89 ALL CARLINES LIGHT TRUCK: 1984-89 ALL TRUCKLINES This article is being republished in its entirety to include the MAP sensor application for the 2.3L HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine. ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP and BAP sensor application chart has been assembled to assist technicians in making sure the correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy, erratic engine idle or hesitation on acceleration may result. ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the correct service part applications. NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF THE FORD PARTS CATALOG. LIGHT TRUCK MAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE 1984-86 2.3L OHC All E6TZ-9F479-A MAP 1986-87 3.0L EFI All E6FZ-9F479-A MAP 1988-89 3.0L EFI All E7FZ-9F479-A MAP 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 4.9L EFI 5.0L EFI 7.5L EFI 1988-89 5.8L EFI All E7FZ-9F479-A MAP PASSENGER CAR MAP AND BAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE 1984-89 1.6L EFI All E7FZ-12A644-A BAP 1.9L EFI 2.3L Turbo 1989 3.0 "SHO" All E7FZ-12A644-A BAP 1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP (Mustang) 1989 5.0L Mass Air All E8FZ-12A644-A BAP 1984 2.3L HSC FBC All E6PZ-9F479-A MAP 1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP 2.5L HSC CFI 1984-85 3.8L CFI All E5SZ-9F479-A MAP 1984-85 5.0L CFI All E6TZ-9F479-A MAP 1986 2.3L OHC All E6FZ-9F479-A MAP Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart > Page 2943 3.0L EFI 3.8L CFI 5.0 SEFI 1984-85 2.3L OHC All E6FZ-9F479-A MAP 1987-89 1.9L CFI All E7DZ-9F479-A MAP 2.3L HSC CFI 2.5L HSC CFI 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI PART NUMBER PART NAME CLASS E7FZ-12A644-A BAP Sensor B E8FZ-12A644-A BAP Sensor B E6PZ-9F479-A MAP Sensor B E5SZ-9F479-A MAP Sensor AM E6TZ-9F479-A MAP Sensor BM E6FZ-9F479-A MAP Sensor B E7DZ-9F479-A MAP Sensor B E7FZ-9F479-A MAP Sensor B OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 620800, 631900, 640200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > Page 2944 Pinpoint Test DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP) Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation Fig. 15 Ignition barometric pressure switch This switch, Fig. 15, controls spark timing and/or other electrical devices according to altitude. Calibration resistors in the switch assembly cause the ignition module to vary the spark timing. Spark timing is advanced for vehicle operation above a predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some switch assemblies control both spark timing and another device while other switch assemblies control only one or the other. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing Fig. 33 Ignition barometric pressure switch resistance chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values in chart, Fig. 33. 3. Replace switch if resistance is not within specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair Camshaft Synchronizer Assembly: Service and Repair CAUTION: Prior to starting this procedure, set cylinder number one to 26 degrees After Top Dead Center (ATDC) of the compression stroke. Then note the position of the camshaft sensor electrical connector. The installation procedure requires that the connector be located in the same position. Removal 1. Disconnect negative battery cable. 2. Remove camshaft sensor assembly. 3. Remove synchronizer clamp (bolt and washer assembly). 4. Remove synchronizer from front engine cover assembly. NOTE: The intermediate oil pump driveshaft should be removed with the synchronizer assembly. Installation CAUTION: If the replacement synchronizer does not contain a plastic locator cover tool, a special service tool such as Syncro Positioner T89P-12200-A or equivalent must be obtained prior to installation of the replacement synchronizer. Failure to follow this procedure will result in improper synchronizer alignment. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. 1. If the plastic locator cover tool is not attached to the replacement synchronizer assembly, attach Syncro Positioner Tool T89P-12200-A or equivalent as follows: a. Engage synchronizer vane into the radial slot of the tool. b. Rotate tool on synchronizer base until tool boss engages the base notch. The cover tool should be square and in contact with entire top surface of synchronizer base. 2. Transfer intermediate oil pump driveshaft from old synchronizer to replacement synchronizer assembly. 3. Install synchronizer assembly so that gear engagement occurs when arrow on locator tool is pointed approximately 30 degrees counterclockwise from the front face of the engine block. This step will locate camshaft sensor electrical connector in the pre-removal position. 4. Install synchronizer base clamp (washer and bolt) and tighten bolt to 20-30 Nm (15-22 lb-ft). 5 Remove Syncro Positioner Tool T89P-12200-A or equivalent. 6. Install and connect camshaft sensor. CAUTION: If camshaft sensor electrical connector is not positioned properly (i.e. contacting the A/C bracket or forward of the supercharger drive belt), DO NOT reposition the connector by rotating the synchronizer base. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer and repeat installation procedure, beginning with Step 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair > Page 2954 7. Connect negative battery cable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Temperature Sensors 1.3L VAT: Measured between upper terminal (GN/BK wire) of airflow sensor and ground. 1.6L VAT: Measured between terminal 25 (upper terminal on airflow connector) and ground. 2.2L VAT: Measured between first (R wire) and fifth (LG/W wire) of airflow sensor. All others with EEC IV VAT: Measured between upper terminal (LG/P wire) of airflow sensor and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 2959 Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2960 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Compartment. Top Front Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 2961 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 4 Engine coolant temperature sensor The ECT, Fig. 8, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Top Front Of Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2967 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 2968 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2969 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft timing sensor is a single Hall effect magnetic switch, actuated by three vanes on the crankshaft damper and pulley assembly. The signal generated by this sensor the Profile Ignition Pick-up (PIP). It provides base timing and RPM information to the DIS module and EEC IV module. Initial or base, timing is set at 10 degrees BTDC and is not adjustable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2970 Crankshaft Position Sensor: Adjustments INITIAL TIMING Initial timing is preset at 10~ plus or minus 2~ BTDC and is not adjustable. PIP SENSOR 1. Install Crankshaft Sensor Gauge T89P-AH or equivalent to outside surface of one vane of shutter. Gauge is magnetic and will conform to the shape of the vane. 2. Rotate crankshaft by HAND to align shutter vane with gauge into sensor air gap. Push sensor housing inward to contact gauge and tighten screws to 22-31 lb-in. CAUTION: Over tightening can cause damage to timing sensor. 3. Rotate crankshaft by HAND to position shutter vane with gauge outside of air gap. Remove magnetic gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 2971 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect negative battery cable. 2. If necessary, loosen tensioner pulleys for A/C compressor and supercharger idler pulley belts, as well as removing belts from crankshaft pulley. 3. Disconnect sensor electrical connectors from engine wiring harness. 4. Raise vehicle and suitably support. Then remove upper and lower damper shield assemblies. 5. ON 89 MODELS: Remove crankshaft damper and pulley assembly using Universal Puller T67L-3600-A or equivalent. 6. Remove crankshaft sensor mounting screws and remove sensor. Installation 1. Position crankshaft sensor assembly on bracket. 2. Install two sensor attaching screws and tighten to 22-31 lb-in. 3. Install crankshaft damper and pulley assembly using crank gear and damper replacer T83T-6316-B or equivalent. Tighten pulley bolt to 103-132 lb-ft. 4. Install upper and lower damper shields and tighten fasteners to specification. Lower vehicle. 5. Route sensor wiring harness and connect both electrical connectors. Then install A/C and power steering belts and adjust to proper tension. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer > Component Information > Technical Service Bulletins > EGR Transducer Sensor - Condensation EGR Backpressure Transducer: Technical Service Bulletins EGR Transducer Sensor Condensation EEC IV - PRESSURE FEEDBACK ELECTRONIC (PFE) EGR TRANSDUCER SENSOR CONDENSATION (WATER) Article No. 88-26-6 FORD: 1988-89 ESCORT, EXP, TEMPO, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1988-89 TOPAZ, SABLE, COUGAR, CONTINENTAL MERKUR: 1988-89 SCORPIO ISSUE: The pressure feedback electronic (PFE) EGR transducer sensor changes an exhaust pressure signal into analog voltage. The EEC IV processor uses this to control EGR flow. Condensation (water) is a natural by-product of combustion and may collect in the PFE sensor port or the PFE sensor silicon hose. Water in the PFE sensor port or PFE hose does not indicate an abnormal operating condition or failed sensor. The water in the PFE sensor port or PFE hose will drain back into the EGR tube because of the downward slope of the hose. Refer to the application chart of this TSB article for the affected vehicles. FIGURE 6 ACTION: Before replacing a PFE sensor for water in the sensor port or silicon tube, perform an EEC IV self test. If no service codes are found indicating a faulty PFE sensor, do not replace the sensor, Figure 6. PFE SENSOR APPLICATION CHART MODEL YEAR VEHICLE ENGINE REGION 1988-89 Escort-Exp 1.9L CFI 50 State 1988-89 Tempo/Topaz 2.3L HSC 50 State 1988-89 Thunderbird/ Cougar 3.8L 50 State 1988-89 Taurus/Sable 3.0L California 1988-89 Taurus/Sable 3.8L 50 State 1988-89 Continental 3.8L 50 State 1988-89 Scorpio 2.9L 50 State OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2980 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2981 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2982 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2983 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2984 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2985 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2986 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2987 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2988 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2989 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2990 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2991 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2992 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2993 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2994 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2995 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2996 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2997 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2998 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 2999 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3000 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3001 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3002 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3003 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3004 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3005 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3006 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3007 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3008 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3009 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3010 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3011 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3012 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3013 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 3014 EGR Valve Position Sensor: Description and Operation EGR valve position sensor The EGR valve position sensor provides the EEC system with an EGR valve position signal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9195 > May > 91 > Engine Detonation/Hard Start/Rough Idle/Stall Engine Control Module: All Technical Service Bulletins Engine - Detonation/Hard Start/Rough Idle/Stall Article No. 91-9-5 05/01/91 ^ DETONATION - 3.8L (N/A) - DURING WIDE OPEN THROTTLE AT NORMAL ENGINE OPERATING TEMPERATURE ^ HARD START - 3.8L (N/A) - LONG CRANK TIME DURING INITIAL COLD START ^ IDLE - ROUGH - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START ^ STALL - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard/slow start may occur at the initial cold start followed by a rough idle during the first 30 seconds. Spark knock may also occur during wide open throttle operation at normal engine operating temperature. These conditions occur because of the operating strategy of the EEC IV processor. ACTION: Use the following procedure to determine if a new EEC IV processor is required. 1. Perform the diagnostic procedures in the 1989/90 Engine/Emission Diagnosis Shop Manual. Service as required. 2. If the conditions still exist, install a new EEC IV processor with a revised operating strategy. 3. Refer to the following Parts Block for correct parts usage. Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS F0PZ-12A650-GA EEC IV Processor (49 State) B F0PZ-12A650-FA EEC IV Processor (California) W OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910905A Perform Engine/Emissions 0.5 Hr. Diagnosis. 910905B Replace EEC IV Processor 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9195 > May > 91 > Engine Detonation/Hard Start/Rough Idle/Stall > Page 3023 DRIVE J7 OASIS CODES: 602300, 607000, 608400, 615000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 90116 > May > 90 > Body/Frame Arc Welding Precautions Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall Engine Control Module: Customer Interest Engine - Detonation/Hard Start/Rough Idle/Stall Article No. 91-9-5 05/01/91 ^ DETONATION - 3.8L (N/A) - DURING WIDE OPEN THROTTLE AT NORMAL ENGINE OPERATING TEMPERATURE ^ HARD START - 3.8L (N/A) - LONG CRANK TIME DURING INITIAL COLD START ^ IDLE - ROUGH - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START ^ STALL - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard/slow start may occur at the initial cold start followed by a rough idle during the first 30 seconds. Spark knock may also occur during wide open throttle operation at normal engine operating temperature. These conditions occur because of the operating strategy of the EEC IV processor. ACTION: Use the following procedure to determine if a new EEC IV processor is required. 1. Perform the diagnostic procedures in the 1989/90 Engine/Emission Diagnosis Shop Manual. Service as required. 2. If the conditions still exist, install a new EEC IV processor with a revised operating strategy. 3. Refer to the following Parts Block for correct parts usage. Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS F0PZ-12A650-GA EEC IV Processor (49 State) B F0PZ-12A650-FA EEC IV Processor (California) W OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910905A Perform Engine/Emissions 0.5 Hr. Diagnosis. 910905B Replace EEC IV Processor 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall > Page 3033 DRIVE J7 OASIS CODES: 602300, 607000, 608400, 615000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work Multiple Junction Connector: All Technical Service Bulletins Vehicle - No Start Condition/Accessories Don't Work Article No. 89-6-6 ^ NO START - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE ^ POWER ACCESSORIES - INOPERATIVE - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A no start condition or power accessories that do not work may be caused by a loose or disconnected wire at the ground buss connector. The wire leads from the ground buss connectors may be looped under the carpet at the lower edge of the cowl trim panel. This type of routing allows the occupants feet to apply enough downward pressure on the carpet to pull one or more ground terminals from the ground buss connector. Accessories and systems that could be affected are in the 1989 Electrical Vacuum Troubleshooting Manual (EVTM), pages 16 through 19. A partial list of these accessories and systems are: ^ Power door locks ^ Power windows ^ Power seats ^ Keyless entry ^ Luggage compartment remote release ^ Interior courtesy lamps ^ Passive restraints ACTION: Inspect the driver's side ground buss connector (G-300) and the passenger's side ground buss connector (G-301) for loose or disconnected ground wires. Refer to the following procedure for service details. FIGURE 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work > Page 3039 FIGURE 2 1. Using the 1989 Thunderbird/Cougar EVTM, pages 16 through 19, determine which ground buss connector (G-300 or G-301) requires service, Figure 1 and 2. 2. Remove the cowl trim panel. 3. Detach the ground buss connector from the cowl. 4. Inspect each terminal for a proper connection. NOTE: THE TERMINALS ARE EASILY SEEN THROUGH THE WHITE PLASTIC COVER OF THE GROUND BUSS CONNECTOR. 5. If a wire(s) is loose or pulled out of a terminal(s), remove the terminal(s) from the ground buss connector and solder the wire(s) to the terminal(s). 6. Reinstall the repaired terminal(s) in the ground buss connector. 7. Reposition the ground buss connector. Rotate the ground buss connector either forward or rearward to allow the ground wire leads to be as close to the cowl as possible. 8. Install a 4-6 inch piece of body tape on the wire harness to hold it to the cowl panel, Figures 1 and 2. 9. Reinstall the cowl trim panel. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 890606A Inspect & Repair Ground 0.6 Hr. Buss (one side) 890606B Inspect & repair Ground 1.0 Hr. Buss (both sides) DEALER CODING BASIC PART NO. CONDITION CODE 14A488 44 OASIS CODES: 2100, 2150, 2700, 2770, 2900, 610200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work > Page 3045 FIGURE 2 1. Using the 1989 Thunderbird/Cougar EVTM, pages 16 through 19, determine which ground buss connector (G-300 or G-301) requires service, Figure 1 and 2. 2. Remove the cowl trim panel. 3. Detach the ground buss connector from the cowl. 4. Inspect each terminal for a proper connection. NOTE: THE TERMINALS ARE EASILY SEEN THROUGH THE WHITE PLASTIC COVER OF THE GROUND BUSS CONNECTOR. 5. If a wire(s) is loose or pulled out of a terminal(s), remove the terminal(s) from the ground buss connector and solder the wire(s) to the terminal(s). 6. Reinstall the repaired terminal(s) in the ground buss connector. 7. Reposition the ground buss connector. Rotate the ground buss connector either forward or rearward to allow the ground wire leads to be as close to the cowl as possible. 8. Install a 4-6 inch piece of body tape on the wire harness to hold it to the cowl panel, Figures 1 and 2. 9. Reinstall the cowl trim panel. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 890606A Inspect & Repair Ground 0.6 Hr. Buss (one side) 890606B Inspect & repair Ground 1.0 Hr. Buss (both sides) DEALER CODING BASIC PART NO. CONDITION CODE 14A488 44 OASIS CODES: 2100, 2150, 2700, 2770, 2900, 610200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3046 Engine Control Module: Locations Body & Chassis Components Behind RH Shroud Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3049 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3050 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3051 Engine Control Module: Connector Views EEC-IV Module Connector Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3052 EEC-IV Module Connector Pin Usage Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Assembly (ECA) Engine Control Module: Description and Operation Electronic Control Assembly (ECA) Fig. 6 Electronic control assembly (ECA) The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration assembly, Fig. 6. The processor receives input signals from the various sensors. The information obtained is used by the processor to activate engine control systems to obtain optimum emission control and engine performance The calibration assembly is a permanent memory device that contains information. The processor applies the sensor inputs to the stored information to determine when and how long the various control systems should be applied. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Assembly (ECA) > Page 3055 Engine Control Module: Description and Operation Failure Mode Effects Management FMEM is an alternate system strategy in the ECA designed to allow improved vehicle drive should one or more sensor inputs fail. When a sensor input is perceived to be out-of-limits by the ECA, an alternative strategy will be initiated. The ECA will substitute a fixed in-limit sensor value and will continue to monitor the faulty sensor input. If the faulty sensor operates within limits, the ECA will return to the normal Engine Running mode (strategy). Code 98 will be displayed when FMEM is in effect. The MIL ``Check Engine'' light will remain ON when the FMEM is in effect. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3056 Engine Control Module: Service and Repair The Electronic Control Assembly (ECA) is located behind the righthand kick panel. 1. Disconnect electrical connector from ECA. 2. Remove ECA lower leg-to-cowl side sheet metal attaching screw. 3. Remove ECA. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3065 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3066 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3067 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3068 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3069 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3070 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3071 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3072 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3073 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3074 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3075 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3076 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3077 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3078 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3079 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3080 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3081 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 89138 > Jun > 89 > Air By Pass Valve Cleaning/Replacement Service Tips Idle Speed Control Bypass Air (ISC-BPA) Valve: All Technical Service Bulletins Air By Pass Valve Cleaning/Replacement Service Tips FUEL SYSTEM-3.8L EFI-AIR BY-PASS VALVECLEANING AND REPLACEMENT SERVICE TIPS Article No. 89-13-8 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, SABLE ISSUE: Two different types of air by-pass valves have been released for use on 3.8L EFI engines. One type of valve has a silver metal housing and the other type has a black plastic housing. Both of the valves function in the same manner. Air by-pass valves that have a black plastic housing cannot be cleaned, they must be replaced. Valves that have silver metal housings can be cleaned. ACTION: If cleaning or replacement of an air by-pass valve is required, refer to the following supplemental service information. Also refer to the appropriate Car Shop Manual, Section 24-11 for service details. Figure 1 Figure 2 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 89138 > Jun > 89 > Air By Pass Valve Cleaning/Replacement Service Tips > Page 3086 Figure 3 1. Do not clean the black plastic air by-pass valve, Figure 1. This valve cannot be cleaned with carburetor cleaner because it can damage the valve's internal components. CAUTION: IF THE BLACK PLASTIC AIR BY-PASS VALVE REQUIRES SERVICE, IT MUST BE REPLACED. 2. The silver metal air by-pass valve can be cleaned. Use carburetor cleaner (D9AZ-19579-BA) to clean it. 3. Mount the black plastic air by-pass valve with the electrical connector on the in-board side of the throttle body, Figure 3. Do NOT mount it on the rocker cover side of the throttle body. 4. Reinstall the silver metal air by-pass valve in the same position as it was originally installed. PART NUMBER PART NAME CLASS D9AZ-19579-BA Carburetor Cleaner - Pkg. of 12 B E9SZ-9F715-E Air By-Pass Valve - Black B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4600 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3092 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3093 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3094 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3095 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3096 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3097 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3098 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3099 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3100 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3101 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3102 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3103 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3104 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3105 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3106 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3107 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3108 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 89138 > Jun > 89 > Air By Pass Valve Cleaning/Replacement Service Tips Idle Speed Control Bypass Air (ISC-BPA) Valve: All Technical Service Bulletins Air By Pass Valve Cleaning/Replacement Service Tips FUEL SYSTEM-3.8L EFI-AIR BY-PASS VALVECLEANING AND REPLACEMENT SERVICE TIPS Article No. 89-13-8 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, SABLE ISSUE: Two different types of air by-pass valves have been released for use on 3.8L EFI engines. One type of valve has a silver metal housing and the other type has a black plastic housing. Both of the valves function in the same manner. Air by-pass valves that have a black plastic housing cannot be cleaned, they must be replaced. Valves that have silver metal housings can be cleaned. ACTION: If cleaning or replacement of an air by-pass valve is required, refer to the following supplemental service information. Also refer to the appropriate Car Shop Manual, Section 24-11 for service details. Figure 1 Figure 2 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 89138 > Jun > 89 > Air By Pass Valve Cleaning/Replacement Service Tips > Page 3114 Figure 3 1. Do not clean the black plastic air by-pass valve, Figure 1. This valve cannot be cleaned with carburetor cleaner because it can damage the valve's internal components. CAUTION: IF THE BLACK PLASTIC AIR BY-PASS VALVE REQUIRES SERVICE, IT MUST BE REPLACED. 2. The silver metal air by-pass valve can be cleaned. Use carburetor cleaner (D9AZ-19579-BA) to clean it. 3. Mount the black plastic air by-pass valve with the electrical connector on the in-board side of the throttle body, Figure 3. Do NOT mount it on the rocker cover side of the throttle body. 4. Reinstall the silver metal air by-pass valve in the same position as it was originally installed. PART NUMBER PART NAME CLASS D9AZ-19579-BA Carburetor Cleaner - Pkg. of 12 B E9SZ-9F715-E Air By-Pass Valve - Black B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4600 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Electrical Specifications IDLE SPEED CONTROL - FI ENGINES W/ISC. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Electrical Specifications > Page 3117 Idle Speed Control Bypass Air (ISC-BPA) Valve: Mechanical Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3118 Idle Speed Control Bypass Air (ISC-BPA) Valve: Locations Engine Compartment. Top Center Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 3119 Idle Speed Control Bypass Air (ISC-BPA) Valve: Description and Operation The idle speed control/bypass air valve controls idle speed by regulating air that bypasses the throttle plate. There are two parts to the (ISC-BPA). The bypass air valve (BPA) and the idle speed control solenoid (ISC). The BPA valve is thermally controlled and functions only during cold engine conditions (below 140 degrees F). The ISC valve is controlled by the electronic control assembly and operates under all engine speed and temperature conditions. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Service and Repair > Procedures Idle Speed Control Bypass Air (ISC-BPA) Valve: Procedures WITH SPECIAL TOOLS CAUTION: DO NOT use the following procedure on a Nippondenso ISC-BPA valve (black plastic), as damage may result. Nippondenso valves are serviced by replacement only. Use only spray carburetor cleaner (Ford D9AZ-19579-BA, or equivalent). DO NOT spray directly on on throttle plates or use any type of scrubbing method. If the vehicle is equipped with a Mass Air Flow (MAF) sensor, do not run the engine while cleaning the Idle Speed Control By-Pass Air ISC-BPA valve. 1. Remove the throttle inlet air duct. 2. Disconnect the ISC-BPA valve connector. 3. Connect the ISC-BPA actuator (Rotunda 113-00009, or equivalent) and the injector tester/cleaner (Rotunda 113-00001, or equivalent) to the vehicle. 4. START the actuator and then START the engine (non MAF engines only). 5. Spray carburetor cleaner (Ford D9AZ-19579-BA, or equivalent) into the ISC-BPA valve for five seconds while actuator is operating. 6. Turn OFF the actuator and STOP the engine (if running). Allow the solvent to soak for 15 minutes. 7. Turn ON the actuator and START the engine (non MAF engines only). 8. Spray carburetor cleaner into the idle ISC-BPA for up to 6 seconds (MAF equipped) or 1 minute (non MAF equipped). 9. Turn OFF the actuator and shut OFF the engine (if running). 10. Install the throttle inlet air duct and START the engine, allowing to run for 1 minute. 11. Disconnect the actuator from the ISC-BPA valve. Connect the ISC-BPA connector. 12. START the engine and check for proper operation. WITH OUT SPECIAL TOOLS Fig. 1 Air bypass valve solenoid CAUTION: DO NOT use the following procedure on a Nippondenso ISC-BPA valve (black plastic), as damage may result. Nippondenso valves are serviced by replacement only. 1. Remove the Idle Speed Control By-Pass Air ISC-BPA valve from the throttle body. 2. Remove the electrical solenoid assembly from the mechanical portion of the ISC-BPA valve by removing the two screws, then sliding the mechanical portion away from the solenoid. 3. Soak the mechanical portion of the ISC-BPA in carburetor cleaner (Ford D9AZ-19579-BA, or equivalent) for up to 3 minutes. CAUTION: DO NOT exceed 3 minutes soaking time and DO NOT use choke cleaner, as internal damage may occur. 4. With the mechanical portion completely submerged, shake in all directions (up, down, right, and left). Push in the on the rod that mates with the solenoid assembly and again shake in all directions with the rod pushed in as far as possible. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Service and Repair > Procedures > Page 3122 5. Remove the valve from the cleaning fluid and dry it out with compressed air. 6. Reassemble the ISC-BPA valve and install on the vehicle, torquing the bolts to 71-102 lb. in. (8-11 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Service and Repair > Procedures > Page 3123 Idle Speed Control Bypass Air (ISC-BPA) Valve: Removal and Replacement Intake Manifold - Exploded View REMOVAL 1. Disconnect wiring harness connector from idle air by-pass valve assembly. 2. Remove the two retaining screws. 3. Remove valve and gasket. 4. Clean gasket mating surfaces. NOTE: If scraping is necessary, use care not to damage valve or throttle body gasket surfaces, or drop material into the throttle body. INSTALLATION 1. Install gasket and valve on throttle body. 2. Install the retaining screws. Torque to 87 in lbs (10 Nm). 3. Connect electrical wiring harness connector. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions Integrated Control Relay Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3128 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3129 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3130 Integrated Control Relay Module: Electrical Diagrams Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3131 Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Rear Of Engine Lower RH Side Of Engine, Under Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3135 Knock Sensor: Description and Operation Knock Sensor The knock sensor is a piezoelectric accelerator accelerometer. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5 - 6 KHz). The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Inside Power Distribution Box Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Malfunction Indicator Lamp: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3143 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3144 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3145 Malfunction Indicator Lamp: Electrical Diagrams Warning Indicators Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3146 Warning Indicators Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 3147 Warning Indicators Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Malfunction Indicator Lamp > Component Information > Diagrams > Page 3148 Malfunction Indicator Lamp: Description and Operation The MIL light is intended to alert the driver of certain malfunctions in the engine control system. If such a fault occurs, the EEC-IV processor will substitute a value or values and continue operating. In some cases this action may result in a slight change in vehicle driveability. On 1988 models, the check engine light can be used to read codes. The check engine light on the front dash panel will remain on when a hard fault is present. During the Self-test sequence, a service code is reported by the check engine light. It will represent itself as a flash on the check engine light display on the dash panel. A single digit number of three will be reported by three flashes. However, as previously stated, a service code is represented by a two digit number, such as 2-3. As a result, the Self-test service code of 2-3 will appear on the check engine light display as two flashes, then after a two second pause, the light will flash three times. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP Sensor - Pinpoint Test DF Manual Correction Article No. 89-5A-6 EEC IV - PINPOINT TEST "DF" - MAP SENSOR GRAPH - SHOP MANUAL CORRECTION FORD: 1989 ESCORT, MUSTANG, TEMPO, TAURUS, AND THUNDERBIRD LINCOLN-MERCURY: 1989 TOPAZ, SABLE, COUGAR, CONTINENTAL, MARK VII, LINCOLN TOWN CAR LIGHT TRUCK: 1989 RANGER, BRONCO, AEROSTAR, F-SERIES, ECONOLINE ISSUE: The MAP sensor graph and data table on page 17-67 of the 1989 Engine Emissions Diagnosis Manual, Volume H is incorrect. ACTION: If service is required, refer to this TSB for the correct graph and data. This information should be inserted into your 1989 Engine Emissions Diagnosis Manual, Volume H, Section 17-67 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-67 Manifold Absolute Pressure (MAP)/ Barometric Pressure (BP) Sensor Pinpoint Test DF Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 3153 MAP Sensor Graph NOTE: MAP sensor output frequency versus manifold vacuum data is based on 30.0 in-Hg barometric pressure. 1989 17-68 EEC-IV - Pinpoint Tests - All Vehicles Manifold Absolute Pressure (MAP)/ Barometric Pressure (BP) Sensor Pinpoint Test DF Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 3154 MAP/BP Sensor Graph (KOEO) NOTE: Frequency may vary plus or minus 3 Hz from the values given due to sensor variations. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 3155 Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart Article No. 89-1-12 ^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART ^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS FORD: 1984-87 ALL CARLINES LINCOLN-MERCURY: 1984-89 ALL CARLINES LIGHT TRUCK: 1984-89 ALL TRUCKLINES This article is being republished in its entirety to include the MAP sensor application for the 2.3L HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine. ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP and BAP sensor application chart has been assembled to assist technicians in making sure the correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy, erratic engine idle or hesitation on acceleration may result. ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the correct service part applications. NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF THE FORD PARTS CATALOG. LIGHT TRUCK MAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE 1984-86 2.3L OHC All E6TZ-9F479-A MAP 1986-87 3.0L EFI All E6FZ-9F479-A MAP 1988-89 3.0L EFI All E7FZ-9F479-A MAP 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 4.9L EFI 5.0L EFI 7.5L EFI 1988-89 5.8L EFI All E7FZ-9F479-A MAP PASSENGER CAR MAP AND BAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE 1984-89 1.6L EFI All E7FZ-12A644-A BAP 1.9L EFI 2.3L Turbo 1989 3.0 "SHO" All E7FZ-12A644-A BAP 1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP (Mustang) 1989 5.0L Mass Air All E8FZ-12A644-A BAP 1984 2.3L HSC FBC All E6PZ-9F479-A MAP 1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP 2.5L HSC CFI 1984-85 3.8L CFI All E5SZ-9F479-A MAP 1984-85 5.0L CFI All E6TZ-9F479-A MAP 1986 2.3L OHC All E6FZ-9F479-A MAP Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 3156 3.0L EFI 3.8L CFI 5.0 SEFI 1984-85 2.3L OHC All E6FZ-9F479-A MAP 1987-89 1.9L CFI All E7DZ-9F479-A MAP 2.3L HSC CFI 2.5L HSC CFI 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI PART NUMBER PART NAME CLASS E7FZ-12A644-A BAP Sensor B E8FZ-12A644-A BAP Sensor B E6PZ-9F479-A MAP Sensor B E5SZ-9F479-A MAP Sensor AM E6TZ-9F479-A MAP Sensor BM E6FZ-9F479-A MAP Sensor B E7DZ-9F479-A MAP Sensor B E7FZ-9F479-A MAP Sensor B OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 620800, 631900, 640200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 3157 Pinpoint Test DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP) Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 3158 Manifold Pressure/Vacuum Sensor: Locations Engine Compartment Component Locations RH Rear Of Engine Compartment Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 3163 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3164 Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3165 Oxygen Sensor: Locations Rear Of Engine In RH Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3166 Oxygen Sensor: Description and Operation Fig. 9 Exhaust gas oxygen (EGO) sensor The EGO, Fig. 9, sensor supplies the ECA assembly with a rich or lean condition during engine operation. On 4-97.6 and 4-140 engines, the EGO sensor is threaded into the center of the exhaust manifold. On V6 engines, the EGO sensor is threaded into the rear portion of the left and right exhaust manifold assemblies. On V8 engines, the EGO sensor is threaded into the rear portion of the right exhaust manifold assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations I/P Components LH Side Of I/P, On Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Supercharger Removal/Assembly EGR Valve Installation The Pressure Feedback Electronic (PFE) Exhaust Gas Recirculation (EGR) Transducer is located at the Top Rear Center of the Engine. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall Engine Control Module: Customer Interest Engine - Detonation/Hard Start/Rough Idle/Stall Article No. 91-9-5 05/01/91 ^ DETONATION - 3.8L (N/A) - DURING WIDE OPEN THROTTLE AT NORMAL ENGINE OPERATING TEMPERATURE ^ HARD START - 3.8L (N/A) - LONG CRANK TIME DURING INITIAL COLD START ^ IDLE - ROUGH - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START ^ STALL - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard/slow start may occur at the initial cold start followed by a rough idle during the first 30 seconds. Spark knock may also occur during wide open throttle operation at normal engine operating temperature. These conditions occur because of the operating strategy of the EEC IV processor. ACTION: Use the following procedure to determine if a new EEC IV processor is required. 1. Perform the diagnostic procedures in the 1989/90 Engine/Emission Diagnosis Shop Manual. Service as required. 2. If the conditions still exist, install a new EEC IV processor with a revised operating strategy. 3. Refer to the following Parts Block for correct parts usage. Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS F0PZ-12A650-GA EEC IV Processor (49 State) B F0PZ-12A650-FA EEC IV Processor (California) W OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910905A Perform Engine/Emissions 0.5 Hr. Diagnosis. 910905B Replace EEC IV Processor 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall > Page 3182 DRIVE J7 OASIS CODES: 602300, 607000, 608400, 615000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall Engine Control Module: All Technical Service Bulletins Engine - Detonation/Hard Start/Rough Idle/Stall Article No. 91-9-5 05/01/91 ^ DETONATION - 3.8L (N/A) - DURING WIDE OPEN THROTTLE AT NORMAL ENGINE OPERATING TEMPERATURE ^ HARD START - 3.8L (N/A) - LONG CRANK TIME DURING INITIAL COLD START ^ IDLE - ROUGH - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START ^ STALL - 3.8L (N/A) - DURING FIRST 30 SECONDS OF COLD START FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard/slow start may occur at the initial cold start followed by a rough idle during the first 30 seconds. Spark knock may also occur during wide open throttle operation at normal engine operating temperature. These conditions occur because of the operating strategy of the EEC IV processor. ACTION: Use the following procedure to determine if a new EEC IV processor is required. 1. Perform the diagnostic procedures in the 1989/90 Engine/Emission Diagnosis Shop Manual. Service as required. 2. If the conditions still exist, install a new EEC IV processor with a revised operating strategy. 3. Refer to the following Parts Block for correct parts usage. Obtain an Authorized Modifications Decal and list the date, dealer number, and summary of alterations performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield. PART NUMBER PART NAME CLASS F0PZ-12A650-GA EEC IV Processor (49 State) B F0PZ-12A650-FA EEC IV Processor (California) W OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910905A Perform Engine/Emissions 0.5 Hr. Diagnosis. 910905B Replace EEC IV Processor 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 9195 > May > 91 > Engine - Detonation/Hard Start/Rough Idle/Stall > Page 3188 DRIVE J7 OASIS CODES: 602300, 607000, 608400, 615000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding Precautions Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Engine Control Module: > 90116 > May > 90 > Body/Frame - Arc Welding Precautions Engine Control Module: All Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Technical Service Bulletins > Page 3198 Engine Control Module: Locations Body & Chassis Components Behind RH Shroud Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions Engine Control Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3201 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3202 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3203 Engine Control Module: Connector Views EEC-IV Module Connector Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3204 EEC-IV Module Connector Pin Usage Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Assembly (ECA) Engine Control Module: Description and Operation Electronic Control Assembly (ECA) Fig. 6 Electronic control assembly (ECA) The ECA is the brain of the EEC-IV system and is comprised of a processor and calibration assembly, Fig. 6. The processor receives input signals from the various sensors. The information obtained is used by the processor to activate engine control systems to obtain optimum emission control and engine performance The calibration assembly is a permanent memory device that contains information. The processor applies the sensor inputs to the stored information to determine when and how long the various control systems should be applied. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Electronic Control Assembly (ECA) > Page 3207 Engine Control Module: Description and Operation Failure Mode Effects Management FMEM is an alternate system strategy in the ECA designed to allow improved vehicle drive should one or more sensor inputs fail. When a sensor input is perceived to be out-of-limits by the ECA, an alternative strategy will be initiated. The ECA will substitute a fixed in-limit sensor value and will continue to monitor the faulty sensor input. If the faulty sensor operates within limits, the ECA will return to the normal Engine Running mode (strategy). Code 98 will be displayed when FMEM is in effect. The MIL ``Check Engine'' light will remain ON when the FMEM is in effect. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Engine Control Module > Component Information > Description and Operation > Page 3208 Engine Control Module: Service and Repair The Electronic Control Assembly (ECA) is located behind the righthand kick panel. 1. Disconnect electrical connector from ECA. 2. Remove ECA lower leg-to-cowl side sheet metal attaching screw. 3. Remove ECA. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions Integrated Control Relay Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3213 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3214 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3215 Integrated Control Relay Module: Electrical Diagrams Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 3216 Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules - Computers and Control Systems > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Inside Power Distribution Box Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications Air Flow Meter/Sensor: Specifications Mass or Vane Airflow Sensor Engines with multi-port injection. 1.6L MFI, 1.9L MFI, 2.3L MFI: Vane Airflow Sensors, measured between second upper terminal (W/BK wire) and ground. 3.0L SHO, 3.8L Supercharged, 5.0L MFI H.O.: Mass Airflow Sensors, measured between terminal D (upper most) and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page 3224 Air Flow Meter/Sensor: Locations Engine Compartment Component Locations RH Front Of Engine Compartment, In Air Duct Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Air Flow Meter/Sensor > Component Information > Specifications > Page 3225 Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart Barometric Pressure Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart Article No. 89-1-12 ^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART ^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS FORD: 1984-87 ALL CARLINES LINCOLN-MERCURY: 1984-89 ALL CARLINES LIGHT TRUCK: 1984-89 ALL TRUCKLINES This article is being republished in its entirety to include the MAP sensor application for the 2.3L HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine. ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP and BAP sensor application chart has been assembled to assist technicians in making sure the correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy, erratic engine idle or hesitation on acceleration may result. ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the correct service part applications. NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF THE FORD PARTS CATALOG. LIGHT TRUCK MAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE 1984-86 2.3L OHC All E6TZ-9F479-A MAP 1986-87 3.0L EFI All E6FZ-9F479-A MAP 1988-89 3.0L EFI All E7FZ-9F479-A MAP 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 4.9L EFI 5.0L EFI 7.5L EFI 1988-89 5.8L EFI All E7FZ-9F479-A MAP PASSENGER CAR MAP AND BAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE 1984-89 1.6L EFI All E7FZ-12A644-A BAP 1.9L EFI 2.3L Turbo 1989 3.0 "SHO" All E7FZ-12A644-A BAP 1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP (Mustang) 1989 5.0L Mass Air All E8FZ-12A644-A BAP 1984 2.3L HSC FBC All E6PZ-9F479-A MAP 1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP 2.5L HSC CFI 1984-85 3.8L CFI All E5SZ-9F479-A MAP 1984-85 5.0L CFI All E6TZ-9F479-A MAP 1986 2.3L OHC All E6FZ-9F479-A MAP Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > MAP and BAP Sensor - Application Chart > Page 3230 3.0L EFI 3.8L CFI 5.0 SEFI 1984-85 2.3L OHC All E6FZ-9F479-A MAP 1987-89 1.9L CFI All E7DZ-9F479-A MAP 2.3L HSC CFI 2.5L HSC CFI 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI PART NUMBER PART NAME CLASS E7FZ-12A644-A BAP Sensor B E8FZ-12A644-A BAP Sensor B E6PZ-9F479-A MAP Sensor B E5SZ-9F479-A MAP Sensor AM E6TZ-9F479-A MAP Sensor BM E6FZ-9F479-A MAP Sensor B E7DZ-9F479-A MAP Sensor B E7FZ-9F479-A MAP Sensor B OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 620800, 631900, 640200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Sensor > Component Information > Technical Service Bulletins > Page 3231 Pinpoint Test DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP) Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Switch > Component Information > Description and Operation Barometric Pressure Switch: Description and Operation Fig. 15 Ignition barometric pressure switch This switch, Fig. 15, controls spark timing and/or other electrical devices according to altitude. Calibration resistors in the switch assembly cause the ignition module to vary the spark timing. Spark timing is advanced for vehicle operation above a predetermined altitude and retarded for vehicle operation below a predetermined altitude. Some switch assemblies control both spark timing and another device while other switch assemblies control only one or the other. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Barometric Pressure Switch > Component Information > Testing and Inspection > Component Testing Barometric Pressure Switch: Testing and Inspection Component Testing Fig. 33 Ignition barometric pressure switch resistance chart 1. Disconnect switch from ignition module. 2. Connect suitable ohmmeter across switch terminals and compare resistance measured to values in chart, Fig. 33. 3. Replace switch if resistance is not within specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair Camshaft Synchronizer Assembly: Service and Repair CAUTION: Prior to starting this procedure, set cylinder number one to 26 degrees After Top Dead Center (ATDC) of the compression stroke. Then note the position of the camshaft sensor electrical connector. The installation procedure requires that the connector be located in the same position. Removal 1. Disconnect negative battery cable. 2. Remove camshaft sensor assembly. 3. Remove synchronizer clamp (bolt and washer assembly). 4. Remove synchronizer from front engine cover assembly. NOTE: The intermediate oil pump driveshaft should be removed with the synchronizer assembly. Installation CAUTION: If the replacement synchronizer does not contain a plastic locator cover tool, a special service tool such as Syncro Positioner T89P-12200-A or equivalent must be obtained prior to installation of the replacement synchronizer. Failure to follow this procedure will result in improper synchronizer alignment. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. 1. If the plastic locator cover tool is not attached to the replacement synchronizer assembly, attach Syncro Positioner Tool T89P-12200-A or equivalent as follows: a. Engage synchronizer vane into the radial slot of the tool. b. Rotate tool on synchronizer base until tool boss engages the base notch. The cover tool should be square and in contact with entire top surface of synchronizer base. 2. Transfer intermediate oil pump driveshaft from old synchronizer to replacement synchronizer assembly. 3. Install synchronizer assembly so that gear engagement occurs when arrow on locator tool is pointed approximately 30 degrees counterclockwise from the front face of the engine block. This step will locate camshaft sensor electrical connector in the pre-removal position. 4. Install synchronizer base clamp (washer and bolt) and tighten bolt to 20-30 Nm (15-22 lb-ft). 5 Remove Syncro Positioner Tool T89P-12200-A or equivalent. 6. Install and connect camshaft sensor. CAUTION: If camshaft sensor electrical connector is not positioned properly (i.e. contacting the A/C bracket or forward of the supercharger drive belt), DO NOT reposition the connector by rotating the synchronizer base. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer and repeat installation procedure, beginning with Step 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair > Page 3241 7. Connect negative battery cable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications Coolant Temperature Sensor/Switch (For Computer): Electrical Specifications Temperature Sensors 1.3L VAT: Measured between upper terminal (GN/BK wire) of airflow sensor and ground. 1.6L VAT: Measured between terminal 25 (upper terminal on airflow connector) and ground. 2.2L VAT: Measured between first (R wire) and fifth (LG/W wire) of airflow sensor. All others with EEC IV VAT: Measured between upper terminal (LG/P wire) of airflow sensor and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Electrical Specifications > Page 3246 Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3247 Coolant Temperature Sensor/Switch (For Computer): Locations Engine Compartment. Top Front Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page 3248 Coolant Temperature Sensor/Switch (For Computer): Description and Operation Fig. 4 Engine coolant temperature sensor The ECT, Fig. 8, sensor detects the temperature of engine coolant and supplies information to the ECA assembly. The ECT sensor is threaded into the heater outlet fitting on the engine. For engine control applications, the ECT signal is used to modify ignition timing, EGR flow and air/fuel mixture. On models with an electronic instrument cluster, the ECT output is used to control the coolant temperature indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Top Front Of Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3254 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 3255 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3256 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft timing sensor is a single Hall effect magnetic switch, actuated by three vanes on the crankshaft damper and pulley assembly. The signal generated by this sensor the Profile Ignition Pick-up (PIP). It provides base timing and RPM information to the DIS module and EEC IV module. Initial or base, timing is set at 10 degrees BTDC and is not adjustable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3257 Crankshaft Position Sensor: Adjustments INITIAL TIMING Initial timing is preset at 10~ plus or minus 2~ BTDC and is not adjustable. PIP SENSOR 1. Install Crankshaft Sensor Gauge T89P-AH or equivalent to outside surface of one vane of shutter. Gauge is magnetic and will conform to the shape of the vane. 2. Rotate crankshaft by HAND to align shutter vane with gauge into sensor air gap. Push sensor housing inward to contact gauge and tighten screws to 22-31 lb-in. CAUTION: Over tightening can cause damage to timing sensor. 3. Rotate crankshaft by HAND to position shutter vane with gauge outside of air gap. Remove magnetic gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3258 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect negative battery cable. 2. If necessary, loosen tensioner pulleys for A/C compressor and supercharger idler pulley belts, as well as removing belts from crankshaft pulley. 3. Disconnect sensor electrical connectors from engine wiring harness. 4. Raise vehicle and suitably support. Then remove upper and lower damper shield assemblies. 5. ON 89 MODELS: Remove crankshaft damper and pulley assembly using Universal Puller T67L-3600-A or equivalent. 6. Remove crankshaft sensor mounting screws and remove sensor. Installation 1. Position crankshaft sensor assembly on bracket. 2. Install two sensor attaching screws and tighten to 22-31 lb-in. 3. Install crankshaft damper and pulley assembly using crank gear and damper replacer T83T-6316-B or equivalent. Tighten pulley bolt to 103-132 lb-ft. 4. Install upper and lower damper shields and tighten fasteners to specification. Lower vehicle. 5. Route sensor wiring harness and connect both electrical connectors. Then install A/C and power steering belts and adjust to proper tension. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3263 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3264 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3265 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3266 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3267 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3268 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3269 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3270 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3271 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3272 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3273 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3274 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3275 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3276 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3277 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3278 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3279 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3280 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3281 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3282 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3283 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3284 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3285 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3286 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3287 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3288 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3289 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3290 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3291 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3292 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3293 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3294 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3295 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3296 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 3297 EGR Valve Position Sensor: Description and Operation EGR valve position sensor The EGR valve position sensor provides the EEC system with an EGR valve position signal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications Intake Air Temperature Sensor: Specifications Temperature Sensors 1.3L VAT: Measured between upper terminal (GN/BK wire) of airflow sensor and ground. 1.6L VAT: Measured between terminal 25 (upper terminal on airflow connector) and ground. 2.2L VAT: Measured between first (R wire) and fifth (LG/W wire) of airflow sensor. All others with EEC IV VAT: Measured between upper terminal (LG/P wire) of airflow sensor and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3301 Intake Air Temperature Sensor: Locations Engine Compartment Component Locations Top Rear Of Engine Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Intake Air Temperature Sensor > Component Information > Specifications > Page 3302 Intake Air Temperature Sensor: Description and Operation Fig. 1 Air charge temperature (ACT) sensor The ACT sensor, Fig. 1, used on EFI models, provides the EFI system mixture (air/fuel) temperature information. The ACT is used as both as a density corrector to air flow calculation and to proportion the cold enrichment fuel flow. This sensor is mounted on an intake manifold runner or on the air cleaner. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations Knock Sensor: Locations Rear Of Engine Lower RH Side Of Engine, Under Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3306 Knock Sensor: Description and Operation Knock Sensor The knock sensor is a piezoelectric accelerator accelerometer. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5 - 6 KHz). The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP Sensor - Pinpoint Test DF Manual Correction Article No. 89-5A-6 EEC IV - PINPOINT TEST "DF" - MAP SENSOR GRAPH - SHOP MANUAL CORRECTION FORD: 1989 ESCORT, MUSTANG, TEMPO, TAURUS, AND THUNDERBIRD LINCOLN-MERCURY: 1989 TOPAZ, SABLE, COUGAR, CONTINENTAL, MARK VII, LINCOLN TOWN CAR LIGHT TRUCK: 1989 RANGER, BRONCO, AEROSTAR, F-SERIES, ECONOLINE ISSUE: The MAP sensor graph and data table on page 17-67 of the 1989 Engine Emissions Diagnosis Manual, Volume H is incorrect. ACTION: If service is required, refer to this TSB for the correct graph and data. This information should be inserted into your 1989 Engine Emissions Diagnosis Manual, Volume H, Section 17-67 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-67 Manifold Absolute Pressure (MAP)/ Barometric Pressure (BP) Sensor Pinpoint Test DF Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 3311 MAP Sensor Graph NOTE: MAP sensor output frequency versus manifold vacuum data is based on 30.0 in-Hg barometric pressure. 1989 17-68 EEC-IV - Pinpoint Tests - All Vehicles Manifold Absolute Pressure (MAP)/ Barometric Pressure (BP) Sensor Pinpoint Test DF Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 3312 MAP/BP Sensor Graph (KOEO) NOTE: Frequency may vary plus or minus 3 Hz from the values given due to sensor variations. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 3313 Manifold Pressure/Vacuum Sensor: Technical Service Bulletins MAP and BAP Sensor - Application Chart Article No. 89-1-12 ^ MAP SENSOR - 2.3L HSC CFI AND 2.5L HSC CFI NEW SERVICE PART ^ EEC IV - "MAP" AND "BAP" SENSOR APPLICATION CHART - SERVICE TIPS FORD: 1984-87 ALL CARLINES LINCOLN-MERCURY: 1984-89 ALL CARLINES LIGHT TRUCK: 1984-89 ALL TRUCKLINES This article is being republished in its entirety to include the MAP sensor application for the 2.3L HSC FBC engine and the BAP sensor application for the 3.0L "SHO" engine. ISSUE: A new MAP sensor is now available to service 1984-86 Tempo/Topaz vehicles with 2.3L HSC CFI engines and 1986 Taurus vehicles with 2.5L HSC CFI engines. A quick reference MAP and BAP sensor application chart has been assembled to assist technicians in making sure the correct service parts are used. If an incorrect MAP or BAP sensor is installed, poor fuel economy, erratic engine idle or hesitation on acceleration may result. ACTION: Use the following quick reference "MAP" and "BAP" sensor application chart for the correct service part applications. NOTE: FOR APPLICATIONS NOT LISTED, REFER TO THE CALIBRATION PARTS LIST OF THE FORD PARTS CATALOG. LIGHT TRUCK MAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PARTS SENSOR TYPE 1984-86 2.3L OHC All E6TZ-9F479-A MAP 1986-87 3.0L EFI All E6FZ-9F479-A MAP 1988-89 3.0L EFI All E7FZ-9F479-A MAP 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 4.9L EFI 5.0L EFI 7.5L EFI 1988-89 5.8L EFI All E7FZ-9F479-A MAP PASSENGER CAR MAP AND BAP APPLICATION CHART YEAR ENGINE CALIB. SERVICE PART SENSOR TYPE 1984-89 1.6L EFI All E7FZ-12A644-A BAP 1.9L EFI 2.3L Turbo 1989 3.0 "SHO" All E7FZ-12A644-A BAP 1988 5.0L Mass Air Calif. E8FZ-12A644-A BAP (Mustang) 1989 5.0L Mass Air All E8FZ-12A644-A BAP 1984 2.3L HSC FBC All E6PZ-9F479-A MAP 1984-86 2.3L HSC CFI All E6PZ-9F479-A MAP 2.5L HSC CFI 1984-85 3.8L CFI All E5SZ-9F479-A MAP 1984-85 5.0L CFI All E6TZ-9F479-A MAP 1986 2.3L OHC All E6FZ-9F479-A MAP Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > MAP Sensor - Pinpoint Test DF Manual Correction > Page 3314 3.0L EFI 3.8L CFI 5.0 SEFI 1984-85 2.3L OHC All E6FZ-9F479-A MAP 1987-89 1.9L CFI All E7DZ-9F479-A MAP 2.3L HSC CFI 2.5L HSC CFI 1987-89 2.3L OHC EFI All E7FZ-9F479-A MAP 2.3L HSC EFI 2.9L EFI 3.0L EFI 3.8L EFI 5.0L SEFI PART NUMBER PART NAME CLASS E7FZ-12A644-A BAP Sensor B E8FZ-12A644-A BAP Sensor B E6PZ-9F479-A MAP Sensor B E5SZ-9F479-A MAP Sensor AM E6TZ-9F479-A MAP Sensor BM E6FZ-9F479-A MAP Sensor B E7DZ-9F479-A MAP Sensor B E7FZ-9F479-A MAP Sensor B OTHER APPLICABLE ARTICLES: 88-23-14 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 620800, 631900, 640200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 3315 Pinpoint Test DF - Manifold Absolute Pressure (MAP)/Barometric Pressure (BP) Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Technical Service Bulletins > Page 3316 Manifold Pressure/Vacuum Sensor: Locations Engine Compartment Component Locations RH Rear Of Engine Compartment Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination Oxygen Sensor: Technical Service Bulletins EGO Sensors - Silicone Contamination Article No. 93-23-6 11/10/93 ^ EGO SENSORS - SILICONE CONTAMINATION ^ ENGINE - SEALANTS, LOW VOLATILITY SILICONE REQUIRED ^ EXHAUST SYSTEM - SILICONE CONTAMINATION OF EXHAUST GAS OXYGEN (EGO) SENSORS FORD: 1984-86 LTD 1984-88 EXP 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-94 TAURUS 1988-93 FESTIVA 1989-94 PROBE 1994 ASPIRE LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 CONTINENTAL, COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1991-94 CAPRI, TRACER 1993-94 MARK VIII MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1983-94 RANGER 1984-90 BRONCO II 1984-94 BRONCO, ECONOLINE, F-150-350 SERIES 1986-94 AEROSTAR 1988-94 F-47, F-53 1991-94 EXPLORER 1993-94 VILLAGER This TSB article is being republished in its entirety to update model applicability and to revise the part number of the Low Volatility Sealant. ISSUE: EGO sensors can be contaminated if volatile types of silicone are used when servicing the engine. Volatile silicones can migrate throughout the system during the first one hundred hours of service. They are commonly found in liquid "silicone rubber" sealants and gasket material. These products are commonly sold in tubes and caulking-type cartridges. ACTION: When service is performed on the engine, only use new low volatility silicone sealant (F1AZ-19662-A) where specified. Also replace the contaminated EGO sensor if required. CAUTION: DO NOT SUBSTITUTE CONVENTIONAL SILICONE RUBBER SEALANTS WHEN LOW VOLATILITY SILICONE SEALANT IS SPECIFIED. PART NUMBER PART NAME CLASS F1AZ-19662-A Low Volatility RTV Sealant B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-14-5 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > EGO Sensors - Silicone Contamination > Page 3321 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 403000, 490000, 499000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3322 Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3323 Oxygen Sensor: Locations Rear Of Engine In RH Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Technical Service Bulletins > Page 3324 Oxygen Sensor: Description and Operation Fig. 9 Exhaust gas oxygen (EGO) sensor The EGO, Fig. 9, sensor supplies the ECA assembly with a rich or lean condition during engine operation. On 4-97.6 and 4-140 engines, the EGO sensor is threaded into the center of the exhaust manifold. On V6 engines, the EGO sensor is threaded into the rear portion of the left and right exhaust manifold assemblies. On V8 engines, the EGO sensor is threaded into the rear portion of the right exhaust manifold assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations I/P Components LH Side Of I/P, On Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Supercharger Removal/Assembly EGR Valve Installation The Pressure Feedback Electronic (PFE) Exhaust Gas Recirculation (EGR) Transducer is located at the Top Rear Center of the Engine. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3335 Technical Service Bulletin # 88265 Date: 881221 EEC IV Pinpoint - Test Manual Correction EEC IV - PINPOINT TESTS A, N AND P - 3.0L "SHO" AND 3.8L "SUPERCHARGED" ENGINES SHOP MANUAL CORRECTION Article No. 88-26-5 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: EEC IV pinpoint test "A" EEC IV No Start, "N" Ignition/Erratic and "P" Spark Timing Check are incorrect as published in the 1989 Engine/Emissions Diagnosis Manual, Section 17-5, 17-310 and 17-322. The Diagnostic schematics did not include the 3.0L "SHO" and 3.8L "Supercharged" crankshaft sensor connectors or the ignition coil connectors. ACTION: Use the pinpoint diagnostic information on pages 15 through 20 of this TSB article. This information should be inserted in your 1989 Engine/Emission Diagnosis Shop Manual, Section 17-5, 17-310 and 17-322 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODE: 680000 EEC-IV No Start EEC-IV-Pinpoint Tests - All Vehicles 1989 17-5 EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3336 Pinpoint Test Schematic 17-6 1989 EEC-IV-Pinpoint Tests - All Vehicles EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3337 WARNING STOP THIS TEST AT THE FIRST SIGN OF A FUEL LEAK AND SERVICE AS REQUIRED. CAUTION No open flame - No smoking during fuel delivery checks. Ignition/Erratic Diagnostic Monitor (IDM) EEC-IV - Pinpoint Tests - All Vehicles 1989 17-309 Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3338 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3339 Pinpoint Test Schematic 17-310 1989 EEC-IV - Pinpoint Tests - All Vehicles Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Spark Timing Check EEC-IV - Pinpoint Tests - All Vehicles 1989 17-321 Spark Timing Check Pinpoint P Note Test You should enter this Pinpoint Test only when directed here from Quick Test Step 4.0, when a Service Code 18 is received in Quick Test Step 5.0 or a code 49 is received in Quick Test Step 6.0. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3340 Remember To prevent the replacement of good components, be aware that the following non-EEC areas may be at fault: ^ Base Engine ^ Camshaft Sensor (CID) ^ Distributor ^ Single Hall Crankshaft Sensor (PIP) ^ TFI or DIS Module ^ Dual Hall Sensor This Pinpoint Test is intended to diagnose only the following: ^ Harness Spout Circuit ^ Base Timing ^ Processor Assembly (-12A650-) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3341 Pinpoint Test Schematic 17-322 1989 EEC-IV - Pinpoint Tests - All Vehicles Pinpoint Spark Timing Check Test P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications Throttle Position Sensor (TPS) Engines with EEC III: Turn ignition to RUN position and remove vacuum hose from throttle kicker as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV: Connect positive (+) probe of DVOM along the DG/LG wire of TPS. Connect negative (-) probe along the BK/W wire and turn ignition on but do not start engine. Adjust TPS to specified value. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3344 Throttle Position Sensor: Mechanical Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3345 Throttle Position Sensor: Description and Operation The throttle position sensor is used by the EEC computer to determine the operating mode (closed throttle, part throttle or wide open throttle) for selection of the proper air/fuel mixture, spark and EGR. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3346 Throttle Position Sensor: Adjustments Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision Vehicle Speed Sensor: Technical Service Bulletins Speed Sensor Resistance Reading - Manual Revision ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1988-PAGE 19-109-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-PAGE 17-142-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1990-PAGE 17-146-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED Article No. 90-18B-1 FORD: 1988-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1988-90 COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1988-90 AEROSTAR ISSUE: The resistance reading of 10,000 ohm shown in the Vehicle Speed Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3351 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3352 Pinpoint Test DP on page 19-109 OF THE 1988 Engine/Emissions Diagnosis Shop Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3353 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3354 Manual, page 17-142 of the 1989 Engine/Emissions Diagnosis Shop Manual Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3355 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3356 and page 17-146 of the 1990 Engine/Emissions Diagnosis Shop Manual is incorrect. The correct reading is 500 ohms. ACTION: Refer to the pages following this TSB article for the revised test procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3357 Vehicle Speed Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3358 Vehicle Speed Sensor: Locations LH Rear Side Of Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3359 Vehicle Speed Sensor: Service and Repair Fig. 26 Speed Sensor Replacement. Cougar, Crown Victoria, Town Car, Mark VII, Grand Marquis, & Thunderbird 1. Raise and support vehicle. 2. Remove bolt retaining the sensor attaching clip, then the sensor and driven gear from transmission, Fig. 26. 3. Disconnect sensor electrical connector. 4. Disconnect speedometer cable by pulling it out of speed sensor, Fig. 26. Do not attempt to remove spring retaining clip with speedometer cable in sensor. 5. Remove retainer, then separate sensor from driven gear. 6. Position sensor to driven gear and install retainer. 7. Connect electrical connector. 8. Ensure internal O-ring is properly seated in sensor housing. Snap speedometer cable into sensor housing. 9. Install sensor to transmission. 10. Lower vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3364 Technical Service Bulletin # 88265 Date: 881221 EEC IV Pinpoint - Test Manual Correction EEC IV - PINPOINT TESTS A, N AND P - 3.0L "SHO" AND 3.8L "SUPERCHARGED" ENGINES SHOP MANUAL CORRECTION Article No. 88-26-5 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: EEC IV pinpoint test "A" EEC IV No Start, "N" Ignition/Erratic and "P" Spark Timing Check are incorrect as published in the 1989 Engine/Emissions Diagnosis Manual, Section 17-5, 17-310 and 17-322. The Diagnostic schematics did not include the 3.0L "SHO" and 3.8L "Supercharged" crankshaft sensor connectors or the ignition coil connectors. ACTION: Use the pinpoint diagnostic information on pages 15 through 20 of this TSB article. This information should be inserted in your 1989 Engine/Emission Diagnosis Shop Manual, Section 17-5, 17-310 and 17-322 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODE: 680000 EEC-IV No Start EEC-IV-Pinpoint Tests - All Vehicles 1989 17-5 EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3365 Pinpoint Test Schematic 17-6 1989 EEC-IV-Pinpoint Tests - All Vehicles EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3366 WARNING STOP THIS TEST AT THE FIRST SIGN OF A FUEL LEAK AND SERVICE AS REQUIRED. CAUTION No open flame - No smoking during fuel delivery checks. Ignition/Erratic Diagnostic Monitor (IDM) EEC-IV - Pinpoint Tests - All Vehicles 1989 17-309 Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3367 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3368 Pinpoint Test Schematic 17-310 1989 EEC-IV - Pinpoint Tests - All Vehicles Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Spark Timing Check EEC-IV - Pinpoint Tests - All Vehicles 1989 17-321 Spark Timing Check Pinpoint P Note Test You should enter this Pinpoint Test only when directed here from Quick Test Step 4.0, when a Service Code 18 is received in Quick Test Step 5.0 or a code 49 is received in Quick Test Step 6.0. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3369 Remember To prevent the replacement of good components, be aware that the following non-EEC areas may be at fault: ^ Base Engine ^ Camshaft Sensor (CID) ^ Distributor ^ Single Hall Crankshaft Sensor (PIP) ^ TFI or DIS Module ^ Dual Hall Sensor This Pinpoint Test is intended to diagnose only the following: ^ Harness Spout Circuit ^ Base Timing ^ Processor Assembly (-12A650-) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 3370 Pinpoint Test Schematic 17-322 1989 EEC-IV - Pinpoint Tests - All Vehicles Pinpoint Spark Timing Check Test P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications Throttle Position Sensor (TPS) Engines with EEC III: Turn ignition to RUN position and remove vacuum hose from throttle kicker as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV: Connect positive (+) probe of DVOM along the DG/LG wire of TPS. Connect negative (-) probe along the BK/W wire and turn ignition on but do not start engine. Adjust TPS to specified value. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 3373 Throttle Position Sensor: Mechanical Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3374 Throttle Position Sensor: Description and Operation The throttle position sensor is used by the EEC computer to determine the operating mode (closed throttle, part throttle or wide open throttle) for selection of the proper air/fuel mixture, spark and EGR. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor > Component Information > Specifications > Page 3375 Throttle Position Sensor: Adjustments Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision Vehicle Speed Sensor: Technical Service Bulletins Speed Sensor Resistance Reading - Manual Revision ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1988-PAGE 19-109-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-PAGE 17-142-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED ^ ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL- 1990-PAGE 17-146-VEHICLE SPEED SENSOR PINPOINT TEST PROCEDURE REVISED Article No. 90-18B-1 FORD: 1988-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1988-90 COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1988-90 AEROSTAR ISSUE: The resistance reading of 10,000 ohm shown in the Vehicle Speed Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3380 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3381 Pinpoint Test DP on page 19-109 OF THE 1988 Engine/Emissions Diagnosis Shop Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3382 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3383 Manual, page 17-142 of the 1989 Engine/Emissions Diagnosis Shop Manual Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3384 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Speed Sensor Resistance Reading - Manual Revision > Page 3385 and page 17-146 of the 1990 Engine/Emissions Diagnosis Shop Manual is incorrect. The correct reading is 500 ohms. ACTION: Refer to the pages following this TSB article for the revised test procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 490000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3386 Vehicle Speed Sensor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3387 Vehicle Speed Sensor: Locations LH Rear Side Of Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor > Component Information > Technical Service Bulletins > Page 3388 Vehicle Speed Sensor: Service and Repair Fig. 26 Speed Sensor Replacement. Cougar, Crown Victoria, Town Car, Mark VII, Grand Marquis, & Thunderbird 1. Raise and support vehicle. 2. Remove bolt retaining the sensor attaching clip, then the sensor and driven gear from transmission, Fig. 26. 3. Disconnect sensor electrical connector. 4. Disconnect speedometer cable by pulling it out of speed sensor, Fig. 26. Do not attempt to remove spring retaining clip with speedometer cable in sensor. 5. Remove retainer, then separate sensor from driven gear. 6. Position sensor to driven gear and install retainer. 7. Connect electrical connector. 8. Ensure internal O-ring is properly seated in sensor housing. Snap speedometer cable into sensor housing. 9. Install sensor to transmission. 10. Lower vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation > Air Bypass Valves Air Diverter Valve: Description and Operation Air Bypass Valves Fig. 57 Normally closed air bypass valves Normally Open Air Bypass Valves W/Vacuum Vents Fig. 59 Normally open air bypass valves without vacuum vents There are two general groups of bypass valves, normally open and normally closed. Both groups are available in both remote and pump-mounted versions. Normally closed valves, Fig. 57, supply air to the exhaust system with medium and high applied vacuum signals during normal modes (engine operating at normal operating temperature), short idles, and some accelerations. With low or no vacuum applied to pump, air is dumped through silencer ports of valve. Normally open valves with a vacuum vent, Fig. 58, provide a timed air dump during decelerations and also dump when a vacuum pressure difference Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation > Air Bypass Valves > Page 3395 is maintained between the signal port and the vent port. The signal port must have 3 inches Hg more vacuum than the vent port to hold the dump. This mode is used to protect the catalyst from overheating. Normally open valves without a vacuum vent, Fig. 59, provide a timed dump of air for 1.1 or 2.8 seconds when a sudden high vacuum of about 20 inches Hg is applied to the signal port. This prevents backfire during deceleration. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation > Air Bypass Valves > Page 3396 Air Diverter Valve: Description and Operation Combination Air Bypass/Air Control Valves Fig. 61 Normally open combination air bypass/air control valve less bleed Fig. 62 Normally closed combination air bypass/air control valve less bleed Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation > Air Bypass Valves > Page 3397 Combination Air Bypass Valve/Air Control Valve Assembly These valves, used on some vehicles, combine the function of the air bypass valve, and the air control valve. Three types of valves are used, a normally open valve, Fig. 61, a normally closed valve without bleed, Fig. 62, and a normally closed valve with bleed, Fig. 63. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation > Page 3398 Air Diverter Valve: Testing and Inspection Fig. 62 Normally closed combination air bypass/air control valve less bleed Combination Air Bypass Valve/Air Control Valve Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Diverter Valve > Component Information > Description and Operation > Page 3399 Normally Closed Valves 1. Disconnect hose from outlets A and B, Figs. 62 and 63. 2. Disconnect and plug vacuum line to port D. 3. Run engine at 1500 RPM. There should be air flow at bypass vents. 4. Reconnect vacuum line to port D and disconnect and plug vacuum line to port S, then ensure that vacuum is present in line to vacuum port D. 5. Run engine at 1500 RPM. There should be air flow at outlet B but no air flow at outlet A. 6. Apply 8---10 inches Hg vacuum to port S and run engine at 1500 RPM. There should be air flow at outlet A. 7. On bleed type valve, some lesser amount of air will flow from outlet A or B and the main discharge will change when vacuum is applied to port S. If there is a small air tap attached to the inlet tube from the air pump, air flow should be present during engine operation. Fig. 61 Normally open combination air bypass/air control valve less bleed Normally Open Valves 1. Disconnect hoses from outlets A and B, Fig. 61. 2. Disconnect and plug vacuum lines to ports D and S. 3. Run engine at 1500 RPM. There should be air flow at outlet B. 4. Apply 8---10 inches Hg vacuum to port S and run engine at 1500 RPM. There should be air flow at outlet A. 5. Reconnect vacuum line to port D and ensure that vacuum is present. 6. Run engine at 1500 RPM. Air should flow out of bypass vents. 7. Reconnect vacuum hoses to original positions. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Description and Operation Air Injection Bypass Valve: Description and Operation NOTE: Engine tune up should be checked whenever the air pump system seems to be malfunctioning, especially items affecting air/fuel ratio. 1. Start engine and allow to reach normal operating temperature with transmission in Park or Neutral and parking brake applied. 2. Stop engine and remove air check valve hoses at bypass valve. On engines with two check valves, disconnect both hoses connecting bypass valve to check valves. 3. Connect tachometer to engine. Accelerate engine to 1500 RPM. Check that air is flowing from air bypass valve hose connection(s) by placing hand over valve connection. Air should be heard and felt. 4. Disconnect vacuum hose from bypass valve and plug vacuum hose. With engine speed at 1500 RPM and hand placed over bypass valve connection, there should be very little air flow heard or felt. Air should be discharged through the exhaust vents in the end of the air bypass valve silencer cover. If air flow is felt or heard through the bypass valve connection, the valve is defective and should be replaced. 5. Stop engine. Remove plug from vacuum hose and connect hose to bypass valve sense vacuum nippled. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Bypass Valve > Component Information > Description and Operation > Page 3403 Air Injection Bypass Valve: Testing and Inspection Normally Closed 1. Disconnect air supply hose at valve outlet, then remove vacuum line and check if vacuum is present at vacuum nipple. 2. Remove any restrictors or delay valves in vacuum line. Before proceeding to step 3, ensure vacuum is present at vacuum nipple. 3. Reconnect vacuum line to nipple, then accelerate engine to 1500 RPM. 4. Air pump supply should be present at air bypass valve outlet. Disconnect vacuum line, air at outlet should stop and air pump supply air should be present at silencer port. 5. If above step proves incorrect, check air pump, then bypass valve. Normally Open With Vacuum Vents 1. Disconnect air pump supply line at outlet, then vacuum lines from vacuum nipple and vacuum vent. 2. Accelerate engine to 1500 RPM, air pump supply air should be present at outlet. 3. Using suitable vacuum hose, connect vacuum nipple to intake manifold vacuum. No air should be present at valve outlet, all air should bypass through silencer ports. 4. Using the same vacuum hose as above step, cap vacuum vent and accelerate engine to 2000 RPM. Air pump supply air should be interrupted when throttle is released. 5. If above steps prove incorrect, check air pump, then bypass valve. Normally Open Without Vacuum Vent 1. Disconnect air supply line at valve outlet, then vacuum line at vacuum nipple. 2. Accelerate engine to 1500 RPM, air pump supply air should be present at outlet. 3. Using suitable vacuum hose, connect vacuum nipple to intake manifold vacuum. Air at outlet should decrease or shut off. 4. Air pump supply air should be present at silencer ports. 5. If above steps prove incorrect, check air pump, then bypass valve. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Testing and Inspection Air Injection Check Valve: Testing and Inspection 1. Disconnect supply hose from air pump side of valve. 2. Observe valve pintle by looking into valve through disconnected port. 3. Accelerate engine to 3000 RPM, then release throttle. Pintle should be open and then close. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Check Valve > Component Information > Testing and Inspection > Page 3407 Air Injection Check Valve: Service and Repair 1. Disconnect air supply valve from hose and, using a 1.25 inch crow-foot wrench, remove check valve. 2. Clean threads on air manifold adapter using a wire brush, then install new check valve. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves Air Injection Control Valve: Description and Operation Air Supply Control Valves Fig. 60 Air control & shut off valve with orifice Air control & shut off valve. 1982 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 3412 Standard air control valve. Air control/shut off valve. These valves are used to direct air pump output to the exhaust manifold or downstream to the catalyst system depending on the engine control modes. Three types of valves are used on 1983 vehicles, the standard air control valve, Fig. 70, the air control/shut off valve, Fig. 71, and the air control/shut off valve with orifice, Fig. 68. All other vehicles use the standard air control valve, Fig. 60. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 3413 Air Injection Control Valve: Description and Operation Anti-Backfire Gulp Valve Fig. 64 Anti-backfire Gulp valve The anti-backfire gulp valve, used on some vehicles, routes a portion of thermactor air to the intake manifold and is activated by intake manifold vacuum signal, Fig. 64. This valve is located downstream from the air bypass valve and functions only during periods of sudden decrease in manifold pressure. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 3414 Air Injection Control Valve: Description and Operation Combination Air Bypass/Air Control Valves Fig. 61 Normally open combination air bypass/air control valve less bleed Fig. 62 Normally closed combination air bypass/air control valve less bleed Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 3415 Combination Air Bypass Valve/Air Control Valve Assembly These valves, used on some vehicles, combine the function of the air bypass valve, and the air control valve. Three types of valves are used, a normally open valve, Fig. 61, a normally closed valve without bleed, Fig. 62, and a normally closed valve with bleed, Fig. 63. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 3416 Air Injection Control Valve: Description and Operation Thermactor Vacuum Vent Valve Fig. 65 Thermactor vacuum vent valve Fig. 66 Thermactor vacuum vent valve schematic (typical) This valve, Figs. 65 and 66, is used on some engines equipped with variable venturi carburetor. It provides the air for the thermactor retard delay valve and air bypass valve during idle modes to deactivate the thermactor system after a controlled period of time. Application of vacuum from the carburetor to both ports of the thermactor vacuum vent causes the dump valve to seat and vacuum to be applied to the rest of the system. Removal of vacuum during idle modes results in unseating of the dump valve, opening of the vent and allowing air to enter the system to reduce the vacuum previously applied to the retard delay valve. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Air Supply Control Valves > Page 3417 Air Injection Control Valve: Description and Operation Vacuum Differential Valve (VDV) Fig. 67 Vacuum differential valve (VDV) On some vehicles with the Thermactor system and catalytic converters, a (VDV), Fig. 67, is used to control the operation of the air bypass valve. Under normal operation, vacuum applied through the VDV holds the valve upward, blocking the vent port and allowing Thermactor air flow. During acceleration or deceleration or in case of system failure, the VDV momentarily cuts off vacuum flow to the bypass valve, diverting the Thermactor air flow to atmosphere. In case of excessive pressure or system restriction, the excess pressure will unseat the valve in the lower part of the bypass valve, allowing a partial flow of air to atmosphere. At the same time, the valve in the upper part of the valve remains unseated allowing a partial flow of air to the exhaust manifold. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Control Valve > Component Information > Description and Operation > Page 3418 Air Injection Control Valve: Testing and Inspection Air Control/Shut-Off Valve 1. Start engine and run at idle, disconnect vacuum supply hose from vacuum nipple, and disconnect inlet hose from valve. Suction should be felt at valve opening. 2. Apply manifold vacuum to vacuum nipple. No suction should be felt at valve inlet opening. Fig. 60 Air control & shut off valve with orifice Air Control/Shut-Off Valve With Orifice 1. Disconnect valve inlet supply hose and ensure that there is air flow to valve inlet, Fig. 60, then reconnect air supply hose. 2. Run engine at 1500 RPM and disconnect air supply hose at valve outlet and the vacuum hose at vacuum nipple. There should be air flow at valve outlet. 3. Connect a direct vacuum line from any manifold fitting to valve vacuum nipple. There should be a noticeable increase in air flow at valve outlet. 4. Connect all vacuum hoses at original positions. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Filter > Component Information > Service and Repair Air Injection Filter: Service and Repair Fig. 68 Removing centrifugal type air pump filter 1. Remove drive pulley and outer disc from air pump. 2. Remove filter fan from pump, Fig. 68. Do not attempt to remove the metal drive hub. 3. Install new filter fan using the pulley and bolts. Alternately tighten bolts to draw fan down evenly. A slight interference between the fan and housing is normal. A new fan may make noise during initial operation, until its outer diameter sealing lip has worn in, after approximately 20---30 miles of operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Hose/Tube > Component Information > Service and Repair Air Injection Hose/Tube: Service and Repair The air supply tubes, or air nozzles, will normally be replaced during cylinder head overhaul, however, they may be replaced without removing the cylinder head by removing the air manifold and using a hooked tool to pull the tube. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Manifold Rails <--> [Air Injection Manifold] > Component Information > Service and Repair Air Manifold Rails: Service and Repair 1. Disconnect air supply hose from check valve and position hose aside. 2. Unscrew air manifold to cylinder head coupling nuts until free of the cylinder head, then remove air manifold. 3. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Testing and Inspection Air Pump: Testing and Inspection NOTE: Engine tune up should be checked whenever the air pump system seems to be malfunctioning, especially items affecting air/fuel ratio. 1. Remove air cleaner, then inspect all hoses and hose connections for leaks. Correct as necessary. Check belt tension and correct as necessary. 2. With transmission in Park or Neutral with parking brake applied, start engine and allow it to reach normal operating temperature. 3. Stop engine. Disconnect air supply hose(s) from air pump to air bypass valve. 4. Install suitable thermactor test gauge in end of hose disconnected from bypass valve. Secure hose with clamp to prevent it from blowing out. On side or cover mounted bypass valves, install an elbow and hose adapter, then install test gauge. Position air pump supply tester so that air blast emitted will be harmlessly dissipated. 5. Connect tachometer to engine and start engine. Slowly increase engine speed to 1000 RPM while observing pressure at gauge. Air pump pressure should be at least 2.25 psi. If thermactor test gauge is not used, increase engine speed to 1500 RPM and place hand over open hose. Air flow should be heard and felt. 6. If air pump output pressure is not at least 2.25 psi, or if air flow is not heard and felt, replace pump and repeat test. Air Manifold, Hose and Tube 1. Inspect all hoses and tubes for deterioration or cracks. 2. Check hose and tube routing as interference may cause wear. 3. Check all hose and tube connections. 4. Check the pressure side of the system for leaks with a soapy water solution. With the pump running, bubbles will form if a leak exists. 5. When replacing any hose or tube, note routing before removal. The hoses used with this system are made of special material to withstand high temperature. No other type should be used. Exhaust Check Valves 1. Check valves should be inspected whenever the hose is disconnected from the valve or check valve failure is suspected. Any indication of exhaust gases in the air pump indicates check valve failure. 2. Orally blow through the check valve (toward air manifold) then attempt to suck back. Flow should be toward air manifold only. 3. When replacing a check valve, be careful not to bend or twist the air manifold. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Pump <--> [Air Injection Pump] > Component Information > Testing and Inspection > Page 3431 Air Pump: Service and Repair 1. Disconnect air inlet and outlet hoses from air pump. 2. Remove drive belt and mounting bolts from pump and remove the pump. 3. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Relief Valve > Component Information > Service and Repair > Air Pump Relief Valve, Replace Air Injection Relief Valve: Service and Repair Air Pump Relief Valve, Replace The air pump does not have to be disassembled to replace the relief valve, however, it must be removed from the engine. 1. Install Tool T66L-9A486-D on air pump and remove relief valve using a suitable slide hammer. 2. To install relief valve, use Tool T66L- 9A486-B and lightly hammer the valve until it is seated. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Air Injection Relief Valve > Component Information > Service and Repair > Air Pump Relief Valve, Replace > Page 3436 Air Injection Relief Valve: Service and Repair Relief Valve Pressure Setting Plug, Replace 1. Compress shoulders of pressure setting plug together and pull plug out of relief valve. 2. Install new valve into relief valve hole by pressing against its center with a suitable tool. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Pulsed Secondary Air Injection > Component Information > Description and Operation Pulsed Secondary Air Injection: Description and Operation Fig. 69 Thermactor II system (typical) Fig. 70 Thermactor II pulse air valve operation Some vehicles are equipped with this type of exhaust air injection system, Fig. 69, which does not have an air pump. The system uses the natural pulses of the exhaust system to draw air into the exhaust manifold. The system is regulated by a pulse air valve. The valve, Fig. 70, is connected to the air cleaner with a hose and to the exhaust manifold with a metal tube. Some pulse air valves closely resemble the standard Thermactor check valves, but are not interchangeable with them. When pressure inside the exhaust manifold is more than the pressure in the air cleaner, the reed in the pulse air valve is closed. When pressure in the exhaust manifold is lower than in the air cleaner, the reed opens and allows air to be drawn into the exhaust manifold. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Pulsed Secondary Air Injection > Component Information > Description and Operation > Page 3440 Fig. 71 Thermactor II pulse air valve test TESTING 1. Check to see that air flows freely through air cleaner or silencer to pulse air valve. 2. Check all hoses, tubes, and pulse air valves for leaks. 3. Disconnect hose at air cleaner side of pulse air valve and connect tester T75L-9487-A or equilvalent to valve, Fig. 71. A 6 inch length of hose, clamped at either end, should be used between tester and valve. 4. Squeeze bulb as flat as possible, then release it. Bulb should remain flat for at least 8 seconds. If not, valve is defective. 5. If tester is not available, disconnect hose as in Step 3 and blow air through valve toward exhaust manifold side, then attempt to suck air back through valve, the valve is defective. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Pulsed Secondary Air Injection > Component Information > Description and Operation > Page 3441 Pulsed Secondary Air Injection: Testing and Inspection Fig. 69 Thermactor II system (typical) Fig. 70 Thermactor II pulse air valve operation Some vehicles are equipped with this type of exhaust air injection system, Fig. 69, which does not have an air pump. The system uses the natural pulses of the exhaust system to draw air into the exhaust manifold. The system is regulated by a pulse air valve. The valve, Fig. 70, is connected to the air cleaner with a hose and to the exhaust manifold with a metal tube. Some pulse air valves closely resemble the standard Thermactor check valves, but are not interchangeable with them. When pressure inside the exhaust manifold is more than the pressure in the air cleaner, the reed in the pulse air valve is closed. When pressure in the exhaust manifold is lower than in the air cleaner, the reed opens and allows air to be drawn into the exhaust manifold. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Pulsed Secondary Air Injection > Component Information > Description and Operation > Page 3442 Fig. 71 Thermactor II pulse air valve test TESTING 1. Check to see that air flows freely through air cleaner or silencer to pulse air valve. 2. Check all hoses, tubes, and pulse air valves for leaks. 3. Disconnect hose at air cleaner side of pulse air valve and connect tester T75L-9487-A or equilvalent to valve, Fig. 71. A 6 inch length of hose, clamped at either end, should be used between tester and valve. 4. Squeeze bulb as flat as possible, then release it. Bulb should remain flat for at least 8 seconds. If not, valve is defective. 5. If tester is not available, disconnect hose as in Step 3 and blow air through valve toward exhaust manifold side, then attempt to suck air back through valve, the valve is defective. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Thermal Vacuum Valve, Air Injection > Component Information > Description and Operation Thermal Vacuum Valve: Description and Operation Fig. 20 Temperature vacuum switch--TVS This switch, Fig. 20, has a bi-metal disc which locates itself in one of two positions, depending on its temperature. One position allows free air flow in the vacuum line; and the other blocks air flow by sealing itself against the O-ring. The switching temperature is below the range of normal engine operating temperature. The TVS may be used to control the vacuum signal to the thermactor dump valve, to reduce emissions. The normally open TVS may block the purge vacuum signal to provide satisfactory cold driveability and reduce cold engine emissions. It may be also used to hold off EGR operation during cold engine operation. The normally closed TVS may allow cold spark advance to provide satisfactory cold engine driveability. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Air Injection > Vacuum Delay Valve, Air Injection > Component Information > Description and Operation Vacuum Delay Valve: Description and Operation This delay valve, used on some vehicles, delays air bypass during periods of low engine manifold vacuum. During sudden drops in manifold vacuum, DVDV delays operation of vacuum differential valve (VDV). A sudden raise in manifold vacuum will open check in delay valve. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component Information > Testing and Inspection Catalytic Converter: Testing and Inspection Restricted Exhaust System Diagnosis A blocked or restricted exhaust system usually results in lack of power or popping through the carburetor. Check that the problem is not caused by ignition or timing conitions. Perform a visual inspection of the exhaust system. If the visual cannot locate the restriction, proceed with the following program: 1. Attach a vacuum gauge to intake manifold. Connect tachometer. Start engine and observe vacuum gauge. Gauge should indicated 16 to 21 inches of vacuum. 2. Increase engine speed to 2,000 rpm. Vacuum will drop when speed is increased rapidly, but should settle at 16 to 21 inches and remian steady. If vacuum drops below 16 inches, exhaust system is restricted. Stop engine. 3. Disconnect exhaust pipe at manifold. Start engine and increase speed to 2,000 rpm. a. If vacuum settles at 16 to 21 inches, restriction is in exhaust pipe, catalytic converter or muffler. If vehicle is equipped with a catalytic converter, reconnect exhaust pipe at manifold, remove muffler and check vacuum gauge. b. If vacuum drops below 16 inches, restriction is in the catalytic converter. If vacuum is normal, muffler is restricted. In the event of a converter failure, always check muffler to be sure converter debris has not entered muffler. 4. If the vacuum drops below 16 inches with exhaust pipe disconnected, exhaust manifold is restricted. a. On six-cylinder engines, remove exhaust manifold. On eight-cylinder engines, remove both exhaust manifolds. b. Inspect ports of exhaust manifold for casting flash by dropping a length of chain into each port. Don't use a wire or light to check ports. The restricted opening may be large enough for them to pass through but small enough to cause excessive back pressure at high engine rpm. c. Remove casting flash. If flash is at lower end of port, it can usually be chipped out. If flash cannot be removed, replace manifold. 5. Reassembly exhaust system and remove test equipment. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions Vehicle Maintenance Monitor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 3456 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 3457 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 3458 Vehicle Maintenance Monitor: Electrical Diagrams Vehicle Maintenance Monitor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 3459 Vehicle Maintenance Monitor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Solenoid > Component Information > Description and Operation Bowl Vent Solenoid: Description and Operation Fig. 9 Carburetor fuel bowl solenoid vent valve This valve, Fig. 9, is a normally open valve located in the fuel bowl vent line. When the engine is running, the valve closes off the fuel bowl vent line. When the engine is shut off, the vent line returns to the normally open position. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Solenoid > Component Information > Description and Operation > Page 3464 Bowl Vent Solenoid: Testing and Inspection 1. Apply 12 volts to valve and ensure valve closes to block air passage. 2. Replace valve if it does not close when energized. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation > Auxiliary Fuel Bowl Vent Tube Bowl Vent Valve: Description and Operation Auxiliary Fuel Bowl Vent Tube Fig. 44 Auxiliary fuel bowl vent tube Used on some vehicles, this auxiliary vent tube, Fig. 44, is teed into the primary fuel bowl vent tube to vent the fuel bowl when the internal vent is closed (external vent is closed) and the solenoid or thermal vent valves are closed. This tube is vented to the air cleaner. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation > Auxiliary Fuel Bowl Vent Tube > Page 3469 Bowl Vent Valve: Description and Operation Carburetor Fuel Bowl Thermal Vent Valve Fig. 10 Carburetor fuel bowl thermal vent valve The thermal vent valve, Fig. 10, used on some vehicles, is a temperature actuated on/off valve, that is inserted in the carburetor to carbon canister vent line. This valve is closed when the engine compartment is cold, preventing fuel tank vapors, generated when the fuel tank heats up before the engine compartment, from being vented through the carburetor bowl. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation > Auxiliary Fuel Bowl Vent Tube > Page 3470 Bowl Vent Valve: Description and Operation Vacuum Bowl Vent Valve Fig. 51 Vacuum bowl vent valve This valve, Fig. 51, used on some vehicles, is a vacuum operated on/off valve. This valve controls vapor flow from the carburetor bowl to the carbon canister. When the engine is running, manifold vacuum closes the flow path from the carburetor bowl to the carbon canister. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Bowl Vent Valve > Component Information > Description and Operation > Auxiliary Fuel Bowl Vent Tube > Page 3471 Bowl Vent Valve: Description and Operation Vacuum/Thermostatic Bowl Vent Valve Fig. 52 Vacuum/thermoststic bowl vent valve This valve, Fig. 52, used on some vehicles, is a vacuum/temperature operated on/off valve. This valve controls vapor flow from the carburetor bowl to the carbon canister. When the engine is running, manifold vacuum closes the flow path from the carburetor bowl to the carbon canister. This valve also closes the bowl to canister flow path when the temperature of the valve is less than 90° F even if there is no manifold vacuum. When the temperature of the valve exceeds 120° F, the valve is open except when closed by manifold vacuum. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Control Valve > Component Information > Description and Operation Canister Purge Control Valve: Description and Operation Fig. 48 Purge control valve This valve, Fig. 48, is installed inline with the carbon canister and controls the flow of fuel vapors during various engine operating modes. The control is provided by a vacuum signal from either the spark port, EGR port or intake manifold and opens or closes the valve accordingly. When the engine is off, the vapors from the fuel tank and carburetor fuel bowl are routed through the purge control valve and into the carbon canister for storage. During normal cruise conditions, spark port or EGR vacuum is strong enough to open the orifice in the purge control valve to allow fuel vapors to flow from the carburetor canister through the purge line to a connection in the PCV tube or into the carburetor spacer. At the same time, the vapors from the fuel tank are also directed into the purge line. At idle and low speed cruise conditions, spark port or EGR port vacuum is not strong enough to open the orifice in the purge control valve so that the fuel vapors are then routed to the carbon canister. On some vehicles fuel vapors are not purged during low engine speeds because the additional fuel vapors will affect the fuel air mixture, resulting in a reduction of idle quality and an increase in exhaust emissions. On vehicles not affected by this purging, manifold vacuum is used to actuate the purge control valve and control the purging of fuel vapors since spark port or EGR port vacuum is too weak. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations Canister Purge Solenoid: Locations Engine Compartment Component Locations Below RH Front Of Engine Compartment Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Canister Purge Solenoid > Component Information > Locations > Page 3478 Canister Purge Solenoid: Description and Operation Fig. 45 Canister purge solenoid This valve, Fig. 45 used on some vehicles, controls the flow of vapors from the carbon canister to the intake manifold during various engine operating modes. This is a normally closed valve that is opened by a signal from the electronic control assembly to control carbon canister purging. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Locations Taurus / Sable 3.8L Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Charcoal Canister <--> [Evaporative Emission Control Canister] > Component Information > Locations > Page 3482 Charcoal Canister: Description and Operation Fig. 46 Charcoal canister The carbon canister, Fig. 46, stores fuel vapors from the fuel tank and carburetor bowl until the engine is started. At this time, fuel vapors are purged from the canister into the engine for combustion. Depending on application, either a 925 ml or 1400 ml canister is used. On vehicles equipped with a dual canister system, two canisters are linked together and the second canister is used for ``spill over'' fuel vapors. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses Technical Service Bulletin # 92E22 Date: 920401 Recall - Disconnected Fuel Vapor Hoses RECALL NUMBER 92E22 Date: March, 1992 At Dealers By N/R 0% of Parts Direct Shipped to Dealers At PDC By__________________ Date in Owner Letter: April 1992 To: All Dealers SUBJECT: Emissions Recall 92E22 - Disconnected Fuel Vapor Hoses on Certain 1989-Model Thunderbirds and Cougars Equipped With 3.8L Engines AFFECTED CARS: 1989-Model Thunderbird and Cougar cars equipped with 3.8L engines and manufactured at the Lorain Assembly Plant. REASONS FOR RECALL: The fuel vapor hose between the vapor valve on the fuel tank and the metal tube leading to the carbon cannister may be disconnected and cause the affected cars to exceed evaporative emissions standards. SERVICE ACTION: Cars returned for service will be inspected and, if necessary, have vapor hoses connected. ATTACHMENTS: Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Administrative Information - Attachment I ATTACHMENT I Emissions Recall 92E22 ADMINISTRATIVE INFORMATION OASIS: YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS RECALL. PLEASE NOTE: CORRECT ALL CARS IN STOCK BEFORE DELIVERY PROMPTLY CORRECT: Affected cars on the enclosed list. Other eligible cars on hand or brought to your dealership Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3491 DEALER-OWNER CONTACT: Immediately contact any owner you know of whose name is not on the list. Give the owner a copy of the Owner Letter. DISTRICT CONTACT: Advise FPSD district office if: ^ An owner cannot be contacted. ^ An owner does not make a service date. FPSD CONTACT: Talk with your FPSD Service Zone Manager about recall concerns. REIMBURSEMENT: Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use an original repair order for your service record file. RECALL PROOF OF CORRECTION CERTIFICATE: The State of California requires that Vehicle Emission Recall - Proof of Correction certificates be issued to owners of California cars serviced by this recall. Please assure that certificates are provided according to instructions contained in All-Dealer letter dated 10/31/91. Labor and Parts Requirement - Attachment II ATTACHMENT II Emissions Recall 92E22 LABOR ALLOWANCE Inspect and, If Necessary, Connect the Vapor Hose between the Fuel Tank Vapor Valve and the Tube to the Carbon Cannister, Prepare and Attach an Authorized Modifications Decal. Provide Owners of California Cars With Vehicle Emission Recall - Proof of Correction Certificates. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS ALLOWANCE E1PZ-9324-C Hose, Vapor Return From bulk $ 1.00 (Use 3-inch length, if new hose is required) FPS-8262 Label, Authorized Modifications (Obtain by ordering on DOES II) Technical Info. - Attachment III Attachment III-1 Emissions Recall 92E22 VAPOR HOSE INSPECTION/INSTALLATION INSTRUCTIONS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3492 AFFECTED VEHICLES: 1989 Model Thunderbird/Cougar - 50 States with 3.8L Engines Inspection Procedure 1. Remove fuel filler cap and attach Fuel Tank Assembly Leak Tester 134-00003 or equivalent. 2. Locate vent tube near the filler on frame rail and separate vent tube from nylon connector. Plug vent tube going to tank. 3. Pump fuel tank assembly leak tester up to 15 inches of water. In 2 minutes, gauge should not drop more than 2 inches of water. If pressure check is OK, do nothing. Inspection is complete. Prepare and install Authorized Modifications Decal shown on Sheet 3. 4. If pressure check results in a failure proceed to reconnect hose. Reconnect Hose WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THE PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM. 1. Relieve fuel pressure as follows: * Disconnect inertia switch in luggage compartment. * Crank engine for 15-20 seconds to relieve pressure. 2. Fuel should be drained from the tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011 or equivalent. 3. Remove exhaust shield screws and remove cross-over support. 4. Loosen clamps from fuel fill and vent hoses connecting the filler pipe to tank (Figure 1). 5. Place safety support under fuel tank and remove four fuel tank support strap bolts and straps. 6. Lower fuel tank. 7. Remove hoses (Figure 1). 8. Connect the hose from the vapor line to the rollover valve (Figure 2). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3493 9. If necessary obtain and cut a new 3-inch piece of hose (E1PZ-9324-C). Connect hose to fuel vapor valve assembly and to vent tube line. Make sure that the rollover valve assembly and grommet are seated properly. CAUTION: While raising the tank into position, make sure that the fuel vent crossover hose is positioned above the vent retainer and is not contacting the drive shaft. (Figure 3). 10. Raise fuel tank. 11. Connect fuel tank hoses to fuel filler pipe (Figure 1). 12. Tighten clamps from hoses to fuel filler pipe. 13. Install fuel tank straps and four fuel tank strap bolts. Tighten bolts to 28-40 N-m (21-29 lb.ft.). 14. Install screws to exhaust shield. 15. fnstall cross-over support. 16. Prepare and install Authorized Modifications Decal. Modifications Decal AUTHORIZED MODIFICATIONS DECAL Insert your P & A Code, "Vapor Return Hose Inspected and, if necessary, Reconnected/Replaced", "Emissions Recall 92E22" and date and attach the Authorized Modifications Decal to a clean surface on the fan shroud. Place the clear overlay on the decal. EMISSIONS RECALL - PROOF OF CORRECTION CERTIFICATE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3494 Provide owners of California cars with "Emissions Recall - Proof of Correction" cenificates. Owner Letter Mr. John Sample April, 1992 123 Main Street California, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 92E22) certain 1989-Model California Thunderbirds and Cougars equipped with 3.8L engines. Your car may have a disconnected fuel vapor return hose and may be releasing air pollutants which exceed California standards. What the Dealer Will Do: At no cost to you, your dealer will inspect and, if necessary, connect the vapor return hose according to the instructions provided by Ford. This service should have little or no effect on your car except to reduce air pollutants. If you do not have this service done, ^ Your emissions warranty may be reduced, ^ Your car may not pass emissions or smog tests that may be required in your area, ^ The California Department of Motor Vehicles may not renew vehicle registration. How long will it take?: The time needed to repair your car is about one hour. However, due to service scheduling times, your dealer may need your car one full working day. Call your dealer: Call your dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Car?: If you have, please fill out the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center by calling toll-free 1-800-392-3673, (1-800-392-FORD). The State of California requires the completion of emissions recall repairs prior to vehicle registration renewal. Your car is subject to these requirements. When this recall repair is completed by your dealer, you will receive a Vehicle Emission Recall - Proof of Correction certificate. This certificate says that this emissions recall has been performed on your car. PLEASE MAKE SURE THAT YOU GET A CERTIFICATE FROM THE DEALER AND THAT YOU HAVE IT WHEN YOU RENEW YOUR CAR'S REGISTRATION. We regret any problem this recall may cause you. We are doing this so you will be satisfied with your Ford-built car. In order to ensure your full protection under the emission warranty provisions and to avoid any inconvenience whell renewing your registration, it is recommended that you have your car serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your car. Dealer Letter March, 1992 To: Selected NAAO Export Sales North American Ford and Lincoln-Mercury Product Dealers All NAAO Export Sales District Offices All Affiliated Ford Motor Companies - Service Managers Subject: Emissions Recall 92E22 - Disconnected Fuel Vapor Hoses on Certain 1989-Model Thunderbirds and Cougars Equipped with 3.8L Engines Enclosed are copies of FPSD's Emissions Recall 92E22 Bulletin applicable to the subject North American Ford-built vehicles. A sample copy of NAAO Export Sales' owner notification letter is attached. If your dealership/location is involved, the applicable VIN listing is included. If not, use the Bulletins Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Recalls: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3495 as information only. Please note that some details in the enclosed Bulletins such as parts ordering and claim submission procedures are applicible to U.S. dealers only. Therefore, please observe the following administrative procedures: 1. Parts Order Order the parts from FPSD-IDO, Windsor, Canada, using conventional parts ordering procedures. Parts will be reimbursed by submission of recall claim Form(s) 1864. 2. Reimbursement Only the Form 1864 will be accepted for reimbursement under this Recall. Upon completion of the required service, the Form 1864 must be completely filled out and signed by authorized dealer personnel. Dealers having Direct Warranty Entry (DWE) are to use that method of claims submission. PLEASE ENSURE THAT COPIES OF THIS RECALL ANNOUNCEMENT ARE ROUTED TO YOUR PARTS AND SERVICE PERSONNEL. Serial Number: April, 1992 Ford Motor Company is voluntarily recalling (Emissions Recall 92E22) certain 1989-Model Thunderbirds and Cougars equipped with 3.8L engines. Your car may have a disconnected fuel vapor return hose and may be releasing air pollutants which exceed U.S. Federal standards. What the Dealer Will Do: At no charge to you, your dealer will inspect and, if necessary, connect the vapor hose on your car according to instructions provided by Ford. This service should have little or no effect on your car except to reduce air polutants. If you do not have this service done, Your emissions warranty may be reduced, Your car may not pass emissions or smog tests that may be required in your area. Call Your Dealer: Call your dealer without delay. Ask for an appointment and ask if parts are in stock. If your dealer does not have the parts, they can be ordered before scheduling your service date. When you bring your car in, give the dealer the enclosed form. If you misplace the form, your dealer will still do the work, free of charge. Changed Address or Sold the Car?: If you have, please fill out Section 1 of the prepaid postcard and mail it to us. If the dealer does not make the repair promptly and without charge, please fill out Section 3 of the prepaid postcard and mail it to us. Please have your car serviced promptly to maintain full emission warranty coverage. We regret any inconvenience this recall may cause you. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > Customer Interest: > 93252 > Dec > 93 > A/C Evaporator Tube - Refrigerant Leaks Evaporative Emissions Hose: Customer Interest A/C Evaporator Tube - Refrigerant Leaks Article No. 93-25-2 12/08/93 ^ EMISSIONS CONTROL - CARBON CANISTER PURGE HOSE - HOLE WORN IN EVAPORATOR CORE TUBE BY CARBON CANISTER PURGE HOSE ^ AIR CONDITIONING - EVAPORATOR CORE TUBE WORN BY CARBON CANISTER HOSE ^ LEAKS - REFRIGERANT - HOLE WORN IN EVAPORATOR CORE TUBE BY CARBON CANISTER PURGE HOSE FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR This TSB article is being republished in its entirety to include 1992 and 1993 model year vehicles. ISSUE: A refrigerant leak may develop in the evaporator core tube near the spring lock coupling. The leak occurs because the carbon canister purge hose may be routed too close and rubs against one of the evaporator core tubes and eventually wears a hole in it. ACTION: Install a protective sleeve for each evaporator tube, using a 1" (25.2 mm) length of heater hose. Refer to the following procedure for service details. 1. Slit the heater hoses lengthwise and position one around each tube, close to the spring lock coupling. 2. Secure the two hoses in position with bundling straps, as required. 3. Be sure each sleeve is in the correct position to prevent the purge hose from rubbing against the core tubes. 4. Reroute the canister purge hose so that it is above the evaporator core tubes and not in contact with any other vacuum line or wiring harness. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-22-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 932502A Install Protective Sleeve 0.4 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 19860 30 OASIS CODES: 208200, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 93252 > Dec > 93 > A/C Evaporator Tube - Refrigerant Leaks Evaporative Emissions Hose: All Technical Service Bulletins A/C Evaporator Tube - Refrigerant Leaks Article No. 93-25-2 12/08/93 ^ EMISSIONS CONTROL - CARBON CANISTER PURGE HOSE - HOLE WORN IN EVAPORATOR CORE TUBE BY CARBON CANISTER PURGE HOSE ^ AIR CONDITIONING - EVAPORATOR CORE TUBE WORN BY CARBON CANISTER HOSE ^ LEAKS - REFRIGERANT - HOLE WORN IN EVAPORATOR CORE TUBE BY CARBON CANISTER PURGE HOSE FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR This TSB article is being republished in its entirety to include 1992 and 1993 model year vehicles. ISSUE: A refrigerant leak may develop in the evaporator core tube near the spring lock coupling. The leak occurs because the carbon canister purge hose may be routed too close and rubs against one of the evaporator core tubes and eventually wears a hole in it. ACTION: Install a protective sleeve for each evaporator tube, using a 1" (25.2 mm) length of heater hose. Refer to the following procedure for service details. 1. Slit the heater hoses lengthwise and position one around each tube, close to the spring lock coupling. 2. Secure the two hoses in position with bundling straps, as required. 3. Be sure each sleeve is in the correct position to prevent the purge hose from rubbing against the core tubes. 4. Reroute the canister purge hose so that it is above the evaporator core tubes and not in contact with any other vacuum line or wiring harness. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-22-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 932502A Install Protective Sleeve 0.4 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 19860 30 OASIS CODES: 208200, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses Technical Service Bulletin # 92E22 Date: 920401 Recall - Disconnected Fuel Vapor Hoses RECALL NUMBER 92E22 Date: March, 1992 At Dealers By N/R 0% of Parts Direct Shipped to Dealers At PDC By__________________ Date in Owner Letter: April 1992 To: All Dealers SUBJECT: Emissions Recall 92E22 - Disconnected Fuel Vapor Hoses on Certain 1989-Model Thunderbirds and Cougars Equipped With 3.8L Engines AFFECTED CARS: 1989-Model Thunderbird and Cougar cars equipped with 3.8L engines and manufactured at the Lorain Assembly Plant. REASONS FOR RECALL: The fuel vapor hose between the vapor valve on the fuel tank and the metal tube leading to the carbon cannister may be disconnected and cause the affected cars to exceed evaporative emissions standards. SERVICE ACTION: Cars returned for service will be inspected and, if necessary, have vapor hoses connected. ATTACHMENTS: Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Administrative Information - Attachment I ATTACHMENT I Emissions Recall 92E22 ADMINISTRATIVE INFORMATION OASIS: YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS RECALL. PLEASE NOTE: CORRECT ALL CARS IN STOCK BEFORE DELIVERY PROMPTLY CORRECT: Affected cars on the enclosed list. Other eligible cars on hand or brought to your dealership Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3510 DEALER-OWNER CONTACT: Immediately contact any owner you know of whose name is not on the list. Give the owner a copy of the Owner Letter. DISTRICT CONTACT: Advise FPSD district office if: ^ An owner cannot be contacted. ^ An owner does not make a service date. FPSD CONTACT: Talk with your FPSD Service Zone Manager about recall concerns. REIMBURSEMENT: Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use an original repair order for your service record file. RECALL PROOF OF CORRECTION CERTIFICATE: The State of California requires that Vehicle Emission Recall - Proof of Correction certificates be issued to owners of California cars serviced by this recall. Please assure that certificates are provided according to instructions contained in All-Dealer letter dated 10/31/91. Labor and Parts Requirement - Attachment II ATTACHMENT II Emissions Recall 92E22 LABOR ALLOWANCE Inspect and, If Necessary, Connect the Vapor Hose between the Fuel Tank Vapor Valve and the Tube to the Carbon Cannister, Prepare and Attach an Authorized Modifications Decal. Provide Owners of California Cars With Vehicle Emission Recall - Proof of Correction Certificates. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS ALLOWANCE E1PZ-9324-C Hose, Vapor Return From bulk $ 1.00 (Use 3-inch length, if new hose is required) FPS-8262 Label, Authorized Modifications (Obtain by ordering on DOES II) Technical Info. - Attachment III Attachment III-1 Emissions Recall 92E22 VAPOR HOSE INSPECTION/INSTALLATION INSTRUCTIONS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3511 AFFECTED VEHICLES: 1989 Model Thunderbird/Cougar - 50 States with 3.8L Engines Inspection Procedure 1. Remove fuel filler cap and attach Fuel Tank Assembly Leak Tester 134-00003 or equivalent. 2. Locate vent tube near the filler on frame rail and separate vent tube from nylon connector. Plug vent tube going to tank. 3. Pump fuel tank assembly leak tester up to 15 inches of water. In 2 minutes, gauge should not drop more than 2 inches of water. If pressure check is OK, do nothing. Inspection is complete. Prepare and install Authorized Modifications Decal shown on Sheet 3. 4. If pressure check results in a failure proceed to reconnect hose. Reconnect Hose WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THE PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM. 1. Relieve fuel pressure as follows: * Disconnect inertia switch in luggage compartment. * Crank engine for 15-20 seconds to relieve pressure. 2. Fuel should be drained from the tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011 or equivalent. 3. Remove exhaust shield screws and remove cross-over support. 4. Loosen clamps from fuel fill and vent hoses connecting the filler pipe to tank (Figure 1). 5. Place safety support under fuel tank and remove four fuel tank support strap bolts and straps. 6. Lower fuel tank. 7. Remove hoses (Figure 1). 8. Connect the hose from the vapor line to the rollover valve (Figure 2). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3512 9. If necessary obtain and cut a new 3-inch piece of hose (E1PZ-9324-C). Connect hose to fuel vapor valve assembly and to vent tube line. Make sure that the rollover valve assembly and grommet are seated properly. CAUTION: While raising the tank into position, make sure that the fuel vent crossover hose is positioned above the vent retainer and is not contacting the drive shaft. (Figure 3). 10. Raise fuel tank. 11. Connect fuel tank hoses to fuel filler pipe (Figure 1). 12. Tighten clamps from hoses to fuel filler pipe. 13. Install fuel tank straps and four fuel tank strap bolts. Tighten bolts to 28-40 N-m (21-29 lb.ft.). 14. Install screws to exhaust shield. 15. fnstall cross-over support. 16. Prepare and install Authorized Modifications Decal. Modifications Decal AUTHORIZED MODIFICATIONS DECAL Insert your P & A Code, "Vapor Return Hose Inspected and, if necessary, Reconnected/Replaced", "Emissions Recall 92E22" and date and attach the Authorized Modifications Decal to a clean surface on the fan shroud. Place the clear overlay on the decal. EMISSIONS RECALL - PROOF OF CORRECTION CERTIFICATE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3513 Provide owners of California cars with "Emissions Recall - Proof of Correction" cenificates. Owner Letter Mr. John Sample April, 1992 123 Main Street California, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 92E22) certain 1989-Model California Thunderbirds and Cougars equipped with 3.8L engines. Your car may have a disconnected fuel vapor return hose and may be releasing air pollutants which exceed California standards. What the Dealer Will Do: At no cost to you, your dealer will inspect and, if necessary, connect the vapor return hose according to the instructions provided by Ford. This service should have little or no effect on your car except to reduce air pollutants. If you do not have this service done, ^ Your emissions warranty may be reduced, ^ Your car may not pass emissions or smog tests that may be required in your area, ^ The California Department of Motor Vehicles may not renew vehicle registration. How long will it take?: The time needed to repair your car is about one hour. However, due to service scheduling times, your dealer may need your car one full working day. Call your dealer: Call your dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Car?: If you have, please fill out the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center by calling toll-free 1-800-392-3673, (1-800-392-FORD). The State of California requires the completion of emissions recall repairs prior to vehicle registration renewal. Your car is subject to these requirements. When this recall repair is completed by your dealer, you will receive a Vehicle Emission Recall - Proof of Correction certificate. This certificate says that this emissions recall has been performed on your car. PLEASE MAKE SURE THAT YOU GET A CERTIFICATE FROM THE DEALER AND THAT YOU HAVE IT WHEN YOU RENEW YOUR CAR'S REGISTRATION. We regret any problem this recall may cause you. We are doing this so you will be satisfied with your Ford-built car. In order to ensure your full protection under the emission warranty provisions and to avoid any inconvenience whell renewing your registration, it is recommended that you have your car serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your car. Dealer Letter March, 1992 To: Selected NAAO Export Sales North American Ford and Lincoln-Mercury Product Dealers All NAAO Export Sales District Offices All Affiliated Ford Motor Companies - Service Managers Subject: Emissions Recall 92E22 - Disconnected Fuel Vapor Hoses on Certain 1989-Model Thunderbirds and Cougars Equipped with 3.8L Engines Enclosed are copies of FPSD's Emissions Recall 92E22 Bulletin applicable to the subject North American Ford-built vehicles. A sample copy of NAAO Export Sales' owner notification letter is attached. If your dealership/location is involved, the applicable VIN listing is included. If not, use the Bulletins Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3514 as information only. Please note that some details in the enclosed Bulletins such as parts ordering and claim submission procedures are applicible to U.S. dealers only. Therefore, please observe the following administrative procedures: 1. Parts Order Order the parts from FPSD-IDO, Windsor, Canada, using conventional parts ordering procedures. Parts will be reimbursed by submission of recall claim Form(s) 1864. 2. Reimbursement Only the Form 1864 will be accepted for reimbursement under this Recall. Upon completion of the required service, the Form 1864 must be completely filled out and signed by authorized dealer personnel. Dealers having Direct Warranty Entry (DWE) are to use that method of claims submission. PLEASE ENSURE THAT COPIES OF THIS RECALL ANNOUNCEMENT ARE ROUTED TO YOUR PARTS AND SERVICE PERSONNEL. Serial Number: April, 1992 Ford Motor Company is voluntarily recalling (Emissions Recall 92E22) certain 1989-Model Thunderbirds and Cougars equipped with 3.8L engines. Your car may have a disconnected fuel vapor return hose and may be releasing air pollutants which exceed U.S. Federal standards. What the Dealer Will Do: At no charge to you, your dealer will inspect and, if necessary, connect the vapor hose on your car according to instructions provided by Ford. This service should have little or no effect on your car except to reduce air polutants. If you do not have this service done, Your emissions warranty may be reduced, Your car may not pass emissions or smog tests that may be required in your area. Call Your Dealer: Call your dealer without delay. Ask for an appointment and ask if parts are in stock. If your dealer does not have the parts, they can be ordered before scheduling your service date. When you bring your car in, give the dealer the enclosed form. If you misplace the form, your dealer will still do the work, free of charge. Changed Address or Sold the Car?: If you have, please fill out Section 1 of the prepaid postcard and mail it to us. If the dealer does not make the repair promptly and without charge, please fill out Section 3 of the prepaid postcard and mail it to us. Please have your car serviced promptly to maintain full emission warranty coverage. We regret any inconvenience this recall may cause you. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 93252 > Dec > 93 > A/C Evaporator Tube - Refrigerant Leaks Evaporative Emissions Hose: All Technical Service Bulletins A/C Evaporator Tube - Refrigerant Leaks Article No. 93-25-2 12/08/93 ^ EMISSIONS CONTROL - CARBON CANISTER PURGE HOSE - HOLE WORN IN EVAPORATOR CORE TUBE BY CARBON CANISTER PURGE HOSE ^ AIR CONDITIONING - EVAPORATOR CORE TUBE WORN BY CARBON CANISTER HOSE ^ LEAKS - REFRIGERANT - HOLE WORN IN EVAPORATOR CORE TUBE BY CARBON CANISTER PURGE HOSE FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR This TSB article is being republished in its entirety to include 1992 and 1993 model year vehicles. ISSUE: A refrigerant leak may develop in the evaporator core tube near the spring lock coupling. The leak occurs because the carbon canister purge hose may be routed too close and rubs against one of the evaporator core tubes and eventually wears a hole in it. ACTION: Install a protective sleeve for each evaporator tube, using a 1" (25.2 mm) length of heater hose. Refer to the following procedure for service details. 1. Slit the heater hoses lengthwise and position one around each tube, close to the spring lock coupling. 2. Secure the two hoses in position with bundling straps, as required. 3. Be sure each sleeve is in the correct position to prevent the purge hose from rubbing against the core tubes. 4. Reroute the canister purge hose so that it is above the evaporator core tubes and not in contact with any other vacuum line or wiring harness. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-22-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 932502A Install Protective Sleeve 0.4 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 19860 30 OASIS CODES: 208200, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses Technical Service Bulletin # 92E22 Date: 920401 Recall - Disconnected Fuel Vapor Hoses RECALL NUMBER 92E22 Date: March, 1992 At Dealers By N/R 0% of Parts Direct Shipped to Dealers At PDC By__________________ Date in Owner Letter: April 1992 To: All Dealers SUBJECT: Emissions Recall 92E22 - Disconnected Fuel Vapor Hoses on Certain 1989-Model Thunderbirds and Cougars Equipped With 3.8L Engines AFFECTED CARS: 1989-Model Thunderbird and Cougar cars equipped with 3.8L engines and manufactured at the Lorain Assembly Plant. REASONS FOR RECALL: The fuel vapor hose between the vapor valve on the fuel tank and the metal tube leading to the carbon cannister may be disconnected and cause the affected cars to exceed evaporative emissions standards. SERVICE ACTION: Cars returned for service will be inspected and, if necessary, have vapor hoses connected. ATTACHMENTS: Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Administrative Information - Attachment I ATTACHMENT I Emissions Recall 92E22 ADMINISTRATIVE INFORMATION OASIS: YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS RECALL. PLEASE NOTE: CORRECT ALL CARS IN STOCK BEFORE DELIVERY PROMPTLY CORRECT: Affected cars on the enclosed list. Other eligible cars on hand or brought to your dealership Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3525 DEALER-OWNER CONTACT: Immediately contact any owner you know of whose name is not on the list. Give the owner a copy of the Owner Letter. DISTRICT CONTACT: Advise FPSD district office if: ^ An owner cannot be contacted. ^ An owner does not make a service date. FPSD CONTACT: Talk with your FPSD Service Zone Manager about recall concerns. REIMBURSEMENT: Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use an original repair order for your service record file. RECALL PROOF OF CORRECTION CERTIFICATE: The State of California requires that Vehicle Emission Recall - Proof of Correction certificates be issued to owners of California cars serviced by this recall. Please assure that certificates are provided according to instructions contained in All-Dealer letter dated 10/31/91. Labor and Parts Requirement - Attachment II ATTACHMENT II Emissions Recall 92E22 LABOR ALLOWANCE Inspect and, If Necessary, Connect the Vapor Hose between the Fuel Tank Vapor Valve and the Tube to the Carbon Cannister, Prepare and Attach an Authorized Modifications Decal. Provide Owners of California Cars With Vehicle Emission Recall - Proof of Correction Certificates. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS ALLOWANCE E1PZ-9324-C Hose, Vapor Return From bulk $ 1.00 (Use 3-inch length, if new hose is required) FPS-8262 Label, Authorized Modifications (Obtain by ordering on DOES II) Technical Info. - Attachment III Attachment III-1 Emissions Recall 92E22 VAPOR HOSE INSPECTION/INSTALLATION INSTRUCTIONS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3526 AFFECTED VEHICLES: 1989 Model Thunderbird/Cougar - 50 States with 3.8L Engines Inspection Procedure 1. Remove fuel filler cap and attach Fuel Tank Assembly Leak Tester 134-00003 or equivalent. 2. Locate vent tube near the filler on frame rail and separate vent tube from nylon connector. Plug vent tube going to tank. 3. Pump fuel tank assembly leak tester up to 15 inches of water. In 2 minutes, gauge should not drop more than 2 inches of water. If pressure check is OK, do nothing. Inspection is complete. Prepare and install Authorized Modifications Decal shown on Sheet 3. 4. If pressure check results in a failure proceed to reconnect hose. Reconnect Hose WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THE PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM. 1. Relieve fuel pressure as follows: * Disconnect inertia switch in luggage compartment. * Crank engine for 15-20 seconds to relieve pressure. 2. Fuel should be drained from the tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011 or equivalent. 3. Remove exhaust shield screws and remove cross-over support. 4. Loosen clamps from fuel fill and vent hoses connecting the filler pipe to tank (Figure 1). 5. Place safety support under fuel tank and remove four fuel tank support strap bolts and straps. 6. Lower fuel tank. 7. Remove hoses (Figure 1). 8. Connect the hose from the vapor line to the rollover valve (Figure 2). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3527 9. If necessary obtain and cut a new 3-inch piece of hose (E1PZ-9324-C). Connect hose to fuel vapor valve assembly and to vent tube line. Make sure that the rollover valve assembly and grommet are seated properly. CAUTION: While raising the tank into position, make sure that the fuel vent crossover hose is positioned above the vent retainer and is not contacting the drive shaft. (Figure 3). 10. Raise fuel tank. 11. Connect fuel tank hoses to fuel filler pipe (Figure 1). 12. Tighten clamps from hoses to fuel filler pipe. 13. Install fuel tank straps and four fuel tank strap bolts. Tighten bolts to 28-40 N-m (21-29 lb.ft.). 14. Install screws to exhaust shield. 15. fnstall cross-over support. 16. Prepare and install Authorized Modifications Decal. Modifications Decal AUTHORIZED MODIFICATIONS DECAL Insert your P & A Code, "Vapor Return Hose Inspected and, if necessary, Reconnected/Replaced", "Emissions Recall 92E22" and date and attach the Authorized Modifications Decal to a clean surface on the fan shroud. Place the clear overlay on the decal. EMISSIONS RECALL - PROOF OF CORRECTION CERTIFICATE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3528 Provide owners of California cars with "Emissions Recall - Proof of Correction" cenificates. Owner Letter Mr. John Sample April, 1992 123 Main Street California, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 92E22) certain 1989-Model California Thunderbirds and Cougars equipped with 3.8L engines. Your car may have a disconnected fuel vapor return hose and may be releasing air pollutants which exceed California standards. What the Dealer Will Do: At no cost to you, your dealer will inspect and, if necessary, connect the vapor return hose according to the instructions provided by Ford. This service should have little or no effect on your car except to reduce air pollutants. If you do not have this service done, ^ Your emissions warranty may be reduced, ^ Your car may not pass emissions or smog tests that may be required in your area, ^ The California Department of Motor Vehicles may not renew vehicle registration. How long will it take?: The time needed to repair your car is about one hour. However, due to service scheduling times, your dealer may need your car one full working day. Call your dealer: Call your dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, present this letter to the dealer. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address or Sold the Car?: If you have, please fill out the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may contact the Ford Customer Assistance Center by calling toll-free 1-800-392-3673, (1-800-392-FORD). The State of California requires the completion of emissions recall repairs prior to vehicle registration renewal. Your car is subject to these requirements. When this recall repair is completed by your dealer, you will receive a Vehicle Emission Recall - Proof of Correction certificate. This certificate says that this emissions recall has been performed on your car. PLEASE MAKE SURE THAT YOU GET A CERTIFICATE FROM THE DEALER AND THAT YOU HAVE IT WHEN YOU RENEW YOUR CAR'S REGISTRATION. We regret any problem this recall may cause you. We are doing this so you will be satisfied with your Ford-built car. In order to ensure your full protection under the emission warranty provisions and to avoid any inconvenience whell renewing your registration, it is recommended that you have your car serviced as soon as possible. Failure to do so could be determined as lack of proper maintenance of your car. Dealer Letter March, 1992 To: Selected NAAO Export Sales North American Ford and Lincoln-Mercury Product Dealers All NAAO Export Sales District Offices All Affiliated Ford Motor Companies - Service Managers Subject: Emissions Recall 92E22 - Disconnected Fuel Vapor Hoses on Certain 1989-Model Thunderbirds and Cougars Equipped with 3.8L Engines Enclosed are copies of FPSD's Emissions Recall 92E22 Bulletin applicable to the subject North American Ford-built vehicles. A sample copy of NAAO Export Sales' owner notification letter is attached. If your dealership/location is involved, the applicable VIN listing is included. If not, use the Bulletins Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Emissions Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Emissions Hose: > 92E22 > Apr > 92 > Recall - Disconnected Fuel Vapor Hoses > Page 3529 as information only. Please note that some details in the enclosed Bulletins such as parts ordering and claim submission procedures are applicible to U.S. dealers only. Therefore, please observe the following administrative procedures: 1. Parts Order Order the parts from FPSD-IDO, Windsor, Canada, using conventional parts ordering procedures. Parts will be reimbursed by submission of recall claim Form(s) 1864. 2. Reimbursement Only the Form 1864 will be accepted for reimbursement under this Recall. Upon completion of the required service, the Form 1864 must be completely filled out and signed by authorized dealer personnel. Dealers having Direct Warranty Entry (DWE) are to use that method of claims submission. PLEASE ENSURE THAT COPIES OF THIS RECALL ANNOUNCEMENT ARE ROUTED TO YOUR PARTS AND SERVICE PERSONNEL. Serial Number: April, 1992 Ford Motor Company is voluntarily recalling (Emissions Recall 92E22) certain 1989-Model Thunderbirds and Cougars equipped with 3.8L engines. Your car may have a disconnected fuel vapor return hose and may be releasing air pollutants which exceed U.S. Federal standards. What the Dealer Will Do: At no charge to you, your dealer will inspect and, if necessary, connect the vapor hose on your car according to instructions provided by Ford. This service should have little or no effect on your car except to reduce air polutants. If you do not have this service done, Your emissions warranty may be reduced, Your car may not pass emissions or smog tests that may be required in your area. Call Your Dealer: Call your dealer without delay. Ask for an appointment and ask if parts are in stock. If your dealer does not have the parts, they can be ordered before scheduling your service date. When you bring your car in, give the dealer the enclosed form. If you misplace the form, your dealer will still do the work, free of charge. Changed Address or Sold the Car?: If you have, please fill out Section 1 of the prepaid postcard and mail it to us. If the dealer does not make the repair promptly and without charge, please fill out Section 3 of the prepaid postcard and mail it to us. Please have your car serviced promptly to maintain full emission warranty coverage. We regret any inconvenience this recall may cause you. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls: > 92E22S1 > May > 92 > Recall Supplement #1 - Disconnected Vapor Hose Technical Service Bulletin # 92E22S1 Date: 920501 Overview of Recall 92E22 Supplement # 1 TO: All Dealers May, 1992 SUBJECT: Emissions Recall 92E22 Supplement # 1 - Disconnected Fuel Vapor hoses on Certain 1989-Model Thunderbirds and Cougars Equipped With 3.8L Engines - Alternative Technical Instructions and Labor Times. REFERENCE: Dealer Bulletin Dated March, 1992, Subject: Emissions Recall 92E22. OASIS Message # 2682, Dated April 7, 1992 REASON FOR THIS SUPPLEMENT The technical instructions in this supplement have been developed as an alternative method of inspecting the cars involved in this recall. These instructions are in addition to the instructions contained in the referenced bulletin which requires the use of a Rotunda 9134-00003 (or equivalent) Fuel Tank Assembly Leak Tester. ALTERNATIVE METHOD TECHNICAL INSTRUCTIONS AND LABOR ALLOWANCE Attachment II, "Labor Allowances", and Attachment III, "Technical Instructions" are attached reflecting the alternative method of inspection. Please file this information with the referenced bulletin. Attachment II- Labor and Parts Information ATTACHMENT II Emissions Recall 92E22-S1 Alternative Method LABOR ALLOWANCE Inspect (Alternative Method) and, If Necessary, Connect the Vapor Hose between the Fuel Tank Vapor Valve and the Tube to the Carbon Canister, Prepare and Attach an Authorized Modifications Decal. Provide Owners of California Cars With Vehicle Emission Recall - Proof of Correction Certificates. 1.2 Hrs. - Insert in Box "C" on Form 1864 Note: Add 0.1 Hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. Attachment III - Technical Instructions VAPOR HOSE INSPECTION/INSTALLATION INSTRUCTIONS AFFECTED VEHICLES: 1989 Model Thunderbird/Cougar - 50 States with 3.8L Engines Inspection/Replacement Procedure WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THE PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls: > 92E22S1 > May > 92 > Recall Supplement #1 - Disconnected Vapor Hose > Page 3538 1. Relieve fuel pressure as follows: - Disconnect inertia switch in luggage compartment. - Crank engine for 15-20 seconds to relieve pressure. 2. Fuel should be drained from the tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011 or equivalent. 3. Remove exhaust shield screws and remove cross-over support. 4. Loosen clamps from fuel fill and vent hoses connecting the filler pipe to tank (Figure 1). 5. Place safety support under fuel tank and remove four fuel tank support strap bolts, and straps. 6. Lower fuel tank 6-8 inches to gain access to rollover valve. 7. Remove hoses (Figure 1). 8. If disconnected, connect the hose from the vapor line to the rollover valve (Figure 2). 9. If necessary obtain and cut a new 3-inch piece of hose (E1PZ-9324-C). Connect hose to fuel vapor valve assembly and to vent tube line. Make sure that the rollover valve assembly and grommet are seated properly. CAUTION: While raising the tank into position, make sure that the fuel vent crossover hose is positioned above the vent retainer and is not contacting the drive shaft (Figure 3). 10. Raise fuel tank. 11. Connect fuel tank hoses to fuel filler pipe (Figure 1). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls: > 92E22S1 > May > 92 > Recall Supplement #1 - Disconnected Vapor Hose > Page 3539 12. Tighten clamps from hoses to fuel filler pipe. 13. Install fuel tank straps and four fuel tank strap bolts. Tighten bolts to 28-40 N-m (21-29 lb.ft.). 14. Install screws to exhaust shield. 15. Install cross-over support. 16. Prepare and install Authorized Modifications Decal shown. AUTHORIZED MODIFICATIONS DECAL ^ Insert your P & A Code, "Vapor Return Hose Inspected and, if necessary, Reconnected/Replaced", "Emissions Recall 92E22" and date and attach the Authorized Modifications Decal to a clean surface on the fan shroud. ^ Place the clear overlay on the decal. EMISSIONS RECALL - PROOF OF CORRECTION CERTIFICATE Provide owners of California cars with "Emissions Recall - Proof of Correction" certificates. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected Technical Service Bulletin # RECALL92E22 Date: 920301 Recall - Fuel Vapor Hoses Disconnected At Dealers By: N/R 0 % of Parts Direct Shipped to Dealers At PDC By:____________ Date in Owner Letter: April, 1992 RECALL NUMBER 92E22 Date: March, 1992 To: All Dealers SUBJECT: Emissions Recall 92E22 - Disconnected Fuel Vapor Hoses on Certain 1989-Model Thunderbirds and Cougars Equipped With 3.8L Engines AFFECTED CARS 1989-Model Thunderbird and Cougar cars equipped with 3.8L engines and manufactured at the Lorain Assembly Plant. REASONS FOR RECALL The fuel vapor hose between the vapor valve on the fuel tank and the metal tube leading to the carbon cannister may be disconnected and cause the affected cars to exceed evaporative emissions standards. SERVICE ACTION Cars returned for service will be inspected and, if necessary, have vapor hoses connected. ATTACHMENTS Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Administrative Information Attachment I ATTACHMENT I Emissions Recall 92E22 ADMINISTRATIVE INFORMATION OASIS YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL CARS IN STOCK BEFORE DELIVERY PROMPTLY Affected cars on the enclosed list. CORRECT Other eligible cars on hand or brought to your dealership. DEALER-OWNER Immediately contact any owner you know of whose name CONTACT is not on the list. Give the owner a copy of the Owner Letter. DISTRICT Advise FPSD district office if: CONTACT ^ An owner cannot be contacted. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected > Page 3544 ^ An owner does not make a service date. FPSD CONTACT Talk with your FPSD Service Zone Manager about recall concerns. REIMBURSEMENT Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use an original repair order for your service record file. RECALL PROOF The State of California requires that Vehicle Emission OF CORRECTION Recall - Proof of Correction certificates be issued to CERTIFICATE owners of California cars serviced by this recall. Please assure that certificates are provided according to instructions contained in All-Dealer letter dated 10/31/91. Labor and Parts Info. Attachment II ATTACHMENT II Emissions Recall 92E22 LABOR ALLOWANCE Inspect and, If Necessary, Connect the Vapor Hose between the Fuel Tank Vapor Valve and the Tube to the Carbon Cannister, Prepare and Attach an Authorized Modifications Decal. Provide Owners of California Cars With Vehicle Emission Recall - Proof of Correction Certificates. INSPECTION ONLY 0.3 Hrs. - Insert in Box "A" on Form 1864 INSPECTION AND CONNECTION OF HOSE 1.5 Hrs. - Insert in Box "B" on Form 1864 Note: Add 0.1 Hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS ALLOWANCE E1PZ-9324-C Hose, Vapor Return From bulk $ 1.00 (Use 3-inch length, if new hose is required) FPS-8262 Label, Authorized Modifications (Obtain by ordering on DOES II) Technical Info. Attachment III Attachment III-1 VAPOR HOSE Emissions Recall 92E22 INSPECTION/INSTALLATION INSTRUCTIONS AFFECTED VEHICLES: 1989 Model Thunderbird/Cougar - 50 States with 3.8L Engines Inspection Procedure 1. Remove fuel filler cap and attach Fuel Tank Assembly Leak Tester 134-00003 or equivalent. 2. Locate vent tube near the filter on frame rail and separate vent tube from nylon connector. Plug vent tube going to tank. 3. Pump fuel tank assembly leak tester up to 15 inches of water. In 2 minutes, gauge should not drop more than 2 inches of water. If pressure check is OK, do nothing. Inspection is complete. Prepare and install Authorized Modifications Decal shown on Sheet 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected > Page 3545 4. If pressure check results in a failure proceed to reconnect hose. Reconnect Hose WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THE PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM. 1. Relieve fuel pressure as follows: Disconnect inertia switch in luggage compartment. - Crank engine for 15-20 seconds to relieve pressure. 2. Fuel should be drained from the tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011 or equivalent. 3. Remove exhaust shield screws and remove cross-over support. 4. Loosen clamps from fuel fill and vent hoses connecting the filler pipe to tank (Figure 1). 5. Place safety support under fuel tank and remove four fuel tank support strap bolts, and straps. 6. Lower fuel tank. 7. Remove hoses. 8. Connect the hose from the vapor line to the rollover valve (Figure 2). 9. If necessary obtain and cut a new 3-inch piece of hose (E1PZ-9324-C). Connect hose to fuel vapor valve assembly and to vent tube line. Make sure that the rollover valve assembly and grommet are seated properly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected > Page 3546 CAUTION: While raising the tank into position, make sure that the fuel vent crossover hose is positioned above the vent retainer and is not contacting the drive shaft (Figure 3). 10. Raise fuel tank. 11. Connect fuel tank hoses to fuel filler pipe. 12. Tighten clamps from hoses to fuel filler pipe. 13. Install fuel tank straps and four fuel tank strap bolts. Tighten bolts to 28-40 N-m (21-29 lb.ft). 14. Install screws to exhaust shield. 15. Install cross-over support. 16. Prepare and install Authorized Modifications Decal shown below. Authorized Modifications Decal ^ Insert your P & A Code, "Vapor Return Hose Inspected and, if necessary, Reconnected/Replaced", "Emissions Recall 92E22" and date and attach the Authorized Modifications Decal to a clean surface on the fan shroud. ^ Place the clear overlay on the decal. Dealer Letter March, 1992 To: Selected NAAO Export Sales North American Ford and LincolnMercury Product Dealers All NAAO Export Sales District Offices All Affiliated Ford Motor Companies - Service Managers Subject: Emissions Recall 92E22 - Disconnected Fuel Vapor Hoses on Certain 1989-Model Thunderbirds and Cougars Equipped with 3.8L Engines Enclosed are copies of FPSD's Emissions Recall 92E22 Bulletin applicable to the subject North American Ford-built vehicles. A sample copy of NAAO Export Sales' owner notification letter is attached. If your dealership/location is involved, the applicable VIN listing is included. If not, use the Bulletins Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected > Page 3547 as information only. Please note that some details in the enclosed Bulletins such as parts ordering and claim submission procedures are applicable to U.S. dealers only. Therefore, please observe the following administrative procedures: 1. Parts Order Order the parts directly from FPSD-IDO, Windsor, Canada, using conventional parts ordering procedures. Parts will be reimbursed by submission of recall claim Form(s) 1864. 2. Reimbursement Only the Form 1864 will be accepted for reimbursement under this Recall. Upon completion of the required service, the Form 1864 must be completely filled out and signed by authorized dealer personnel. Dealers having Direct Warranty Entry (DWE) are to use that method of claims submission. PLEASE ENSURE THAT COPIES OF THIS RECALL ANNOUNCEMENT ARE ROUTED TO YOUR PARTS AND SERVICE PERSONNEL. Serial Number: April, 1992 Ford Motor Company is voluntarily recalling (Emissions Recall 92E22) certain 1989-Model Thunderbirds and Cougars equipped with 3.8L engines. Your car may have a disconnected fuel vapor return hose and may be releasing air pollutants which exceed U. S. Federal standards. What the Dealer At no charge to you, your dealer will inspect and, if Will Do necessary, connect the vapor hose on your car according to instructions provided by Ford. This service should have little or no effect on your car except to reduce air pollutants. If you do not have this service done, ^ Your emissions warranty may be reduced, ^ Your car may not pass emissions or smog tests that may be required in your area. Call Your Dealer Call your dealer without delay. Ask for an appointment and ask if parts are in stock. If your dealer does not have the parts, they can be ordered before scheduling your service date. When you bring your car in, give the dealer the enclosed form. If you misplace the form, your dealer will still do the work, free of charge. Changed Address If you have, please fill out Section 1 of the prepaid or Sold the Car? postcard and mail it to us. If the dealer does not make the repair promptly and without charge, please fill out Section 3 of the prepaid postcard and mail it to us. Please have your car serviced promptly to maintain full emission warranty coverage. We regret any inconvenience this recall may cause you. Owner Letter Serial Number: 12345678901234567 April, 1992 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 92E22) certain 1989-Model Thunderbirds and Cougars equipped with 3.8L engines. Your car may have a disconnected fuel vapor return hose and may be releasing air pollutants which exceed Federal standards. What the Dealer At no charge to you, your dealer will Will Do inspect and, if necessary, connect the vapor hose on your car according to instructions provided by Ford. This service should have little or no effect on your car except to reduce air pollutants. If you do not have this service done, ^ Your emissions warranty may be reduced, ^ Your car may not pass emissions or smog tests that may be required in your area. How Long Will The time needed to repair your car Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > Recalls: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected > Page 3548 It Take? is about one hour. However, due to service scheduling times, your dealer may need your car for one full working day. Call Your Dealer Call your dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address If you have, please fill out the enclosed or Sold the prepaid postcard and mail it to us. Car? If the dealer does not make the repair promptly and without charge, you may contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360, Detroit, MI, 48243. Please have your car serviced promptly to maintain full emission warranty coverage. We regret any inconvenience this recall may cause you. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 92E22S1 > May > 92 > Recall Supplement #1 - Disconnected Vapor Hose Technical Service Bulletin # 92E22S1 Date: 920501 Overview of Recall 92E22 Supplement # 1 TO: All Dealers May, 1992 SUBJECT: Emissions Recall 92E22 Supplement # 1 - Disconnected Fuel Vapor hoses on Certain 1989-Model Thunderbirds and Cougars Equipped With 3.8L Engines - Alternative Technical Instructions and Labor Times. REFERENCE: Dealer Bulletin Dated March, 1992, Subject: Emissions Recall 92E22. OASIS Message # 2682, Dated April 7, 1992 REASON FOR THIS SUPPLEMENT The technical instructions in this supplement have been developed as an alternative method of inspecting the cars involved in this recall. These instructions are in addition to the instructions contained in the referenced bulletin which requires the use of a Rotunda 9134-00003 (or equivalent) Fuel Tank Assembly Leak Tester. ALTERNATIVE METHOD TECHNICAL INSTRUCTIONS AND LABOR ALLOWANCE Attachment II, "Labor Allowances", and Attachment III, "Technical Instructions" are attached reflecting the alternative method of inspection. Please file this information with the referenced bulletin. Attachment II- Labor and Parts Information ATTACHMENT II Emissions Recall 92E22-S1 Alternative Method LABOR ALLOWANCE Inspect (Alternative Method) and, If Necessary, Connect the Vapor Hose between the Fuel Tank Vapor Valve and the Tube to the Carbon Canister, Prepare and Attach an Authorized Modifications Decal. Provide Owners of California Cars With Vehicle Emission Recall - Proof of Correction Certificates. 1.2 Hrs. - Insert in Box "C" on Form 1864 Note: Add 0.1 Hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. Attachment III - Technical Instructions VAPOR HOSE INSPECTION/INSTALLATION INSTRUCTIONS AFFECTED VEHICLES: 1989 Model Thunderbird/Cougar - 50 States with 3.8L Engines Inspection/Replacement Procedure WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THE PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 92E22S1 > May > 92 > Recall Supplement #1 - Disconnected Vapor Hose > Page 3554 1. Relieve fuel pressure as follows: - Disconnect inertia switch in luggage compartment. - Crank engine for 15-20 seconds to relieve pressure. 2. Fuel should be drained from the tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011 or equivalent. 3. Remove exhaust shield screws and remove cross-over support. 4. Loosen clamps from fuel fill and vent hoses connecting the filler pipe to tank (Figure 1). 5. Place safety support under fuel tank and remove four fuel tank support strap bolts, and straps. 6. Lower fuel tank 6-8 inches to gain access to rollover valve. 7. Remove hoses (Figure 1). 8. If disconnected, connect the hose from the vapor line to the rollover valve (Figure 2). 9. If necessary obtain and cut a new 3-inch piece of hose (E1PZ-9324-C). Connect hose to fuel vapor valve assembly and to vent tube line. Make sure that the rollover valve assembly and grommet are seated properly. CAUTION: While raising the tank into position, make sure that the fuel vent crossover hose is positioned above the vent retainer and is not contacting the drive shaft (Figure 3). 10. Raise fuel tank. 11. Connect fuel tank hoses to fuel filler pipe (Figure 1). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 92E22S1 > May > 92 > Recall Supplement #1 - Disconnected Vapor Hose > Page 3555 12. Tighten clamps from hoses to fuel filler pipe. 13. Install fuel tank straps and four fuel tank strap bolts. Tighten bolts to 28-40 N-m (21-29 lb.ft.). 14. Install screws to exhaust shield. 15. Install cross-over support. 16. Prepare and install Authorized Modifications Decal shown. AUTHORIZED MODIFICATIONS DECAL ^ Insert your P & A Code, "Vapor Return Hose Inspected and, if necessary, Reconnected/Replaced", "Emissions Recall 92E22" and date and attach the Authorized Modifications Decal to a clean surface on the fan shroud. ^ Place the clear overlay on the decal. EMISSIONS RECALL - PROOF OF CORRECTION CERTIFICATE Provide owners of California cars with "Emissions Recall - Proof of Correction" certificates. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected Technical Service Bulletin # RECALL92E22 Date: 920301 Recall - Fuel Vapor Hoses Disconnected At Dealers By: N/R 0 % of Parts Direct Shipped to Dealers At PDC By:____________ Date in Owner Letter: April, 1992 RECALL NUMBER 92E22 Date: March, 1992 To: All Dealers SUBJECT: Emissions Recall 92E22 - Disconnected Fuel Vapor Hoses on Certain 1989-Model Thunderbirds and Cougars Equipped With 3.8L Engines AFFECTED CARS 1989-Model Thunderbird and Cougar cars equipped with 3.8L engines and manufactured at the Lorain Assembly Plant. REASONS FOR RECALL The fuel vapor hose between the vapor valve on the fuel tank and the metal tube leading to the carbon cannister may be disconnected and cause the affected cars to exceed evaporative emissions standards. SERVICE ACTION Cars returned for service will be inspected and, if necessary, have vapor hoses connected. ATTACHMENTS Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Requirements Attachment III ^ Technical Information Administrative Information Attachment I ATTACHMENT I Emissions Recall 92E22 ADMINISTRATIVE INFORMATION OASIS YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL CARS IN STOCK BEFORE DELIVERY PROMPTLY Affected cars on the enclosed list. CORRECT Other eligible cars on hand or brought to your dealership. DEALER-OWNER Immediately contact any owner you know of whose name CONTACT is not on the list. Give the owner a copy of the Owner Letter. DISTRICT Advise FPSD district office if: CONTACT ^ An owner cannot be contacted. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected > Page 3560 ^ An owner does not make a service date. FPSD CONTACT Talk with your FPSD Service Zone Manager about recall concerns. REIMBURSEMENT Submit claims using the 1864 format on the DWE screen. (Refer to your Warranty and Policy Manual Section 6.3 pages 5-8). Use an original repair order for your service record file. RECALL PROOF The State of California requires that Vehicle Emission OF CORRECTION Recall - Proof of Correction certificates be issued to CERTIFICATE owners of California cars serviced by this recall. Please assure that certificates are provided according to instructions contained in All-Dealer letter dated 10/31/91. Labor and Parts Info. Attachment II ATTACHMENT II Emissions Recall 92E22 LABOR ALLOWANCE Inspect and, If Necessary, Connect the Vapor Hose between the Fuel Tank Vapor Valve and the Tube to the Carbon Cannister, Prepare and Attach an Authorized Modifications Decal. Provide Owners of California Cars With Vehicle Emission Recall - Proof of Correction Certificates. INSPECTION ONLY 0.3 Hrs. - Insert in Box "A" on Form 1864 INSPECTION AND CONNECTION OF HOSE 1.5 Hrs. - Insert in Box "B" on Form 1864 Note: Add 0.1 Hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS ALLOWANCE E1PZ-9324-C Hose, Vapor Return From bulk $ 1.00 (Use 3-inch length, if new hose is required) FPS-8262 Label, Authorized Modifications (Obtain by ordering on DOES II) Technical Info. Attachment III Attachment III-1 VAPOR HOSE Emissions Recall 92E22 INSPECTION/INSTALLATION INSTRUCTIONS AFFECTED VEHICLES: 1989 Model Thunderbird/Cougar - 50 States with 3.8L Engines Inspection Procedure 1. Remove fuel filler cap and attach Fuel Tank Assembly Leak Tester 134-00003 or equivalent. 2. Locate vent tube near the filter on frame rail and separate vent tube from nylon connector. Plug vent tube going to tank. 3. Pump fuel tank assembly leak tester up to 15 inches of water. In 2 minutes, gauge should not drop more than 2 inches of water. If pressure check is OK, do nothing. Inspection is complete. Prepare and install Authorized Modifications Decal shown on Sheet 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected > Page 3561 4. If pressure check results in a failure proceed to reconnect hose. Reconnect Hose WARNING: FUEL SUPPLY LINES ON VEHICLES WITH FUEL INJECTED ENGINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THE PRESSURE MUST BE RELIEVED BEFORE SERVICING THE FUEL SYSTEM. 1. Relieve fuel pressure as follows: Disconnect inertia switch in luggage compartment. - Crank engine for 15-20 seconds to relieve pressure. 2. Fuel should be drained from the tank as completely as possible prior to tank removal. This is accomplished by siphoning or pumping the fuel out through the fuel filler pipe using Rotunda Fuel Storage Tanker 034-00002 and Adapter Hose 034-00011 or equivalent. 3. Remove exhaust shield screws and remove cross-over support. 4. Loosen clamps from fuel fill and vent hoses connecting the filler pipe to tank (Figure 1). 5. Place safety support under fuel tank and remove four fuel tank support strap bolts, and straps. 6. Lower fuel tank. 7. Remove hoses. 8. Connect the hose from the vapor line to the rollover valve (Figure 2). 9. If necessary obtain and cut a new 3-inch piece of hose (E1PZ-9324-C). Connect hose to fuel vapor valve assembly and to vent tube line. Make sure that the rollover valve assembly and grommet are seated properly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected > Page 3562 CAUTION: While raising the tank into position, make sure that the fuel vent crossover hose is positioned above the vent retainer and is not contacting the drive shaft (Figure 3). 10. Raise fuel tank. 11. Connect fuel tank hoses to fuel filler pipe. 12. Tighten clamps from hoses to fuel filler pipe. 13. Install fuel tank straps and four fuel tank strap bolts. Tighten bolts to 28-40 N-m (21-29 lb.ft). 14. Install screws to exhaust shield. 15. Install cross-over support. 16. Prepare and install Authorized Modifications Decal shown below. Authorized Modifications Decal ^ Insert your P & A Code, "Vapor Return Hose Inspected and, if necessary, Reconnected/Replaced", "Emissions Recall 92E22" and date and attach the Authorized Modifications Decal to a clean surface on the fan shroud. ^ Place the clear overlay on the decal. Dealer Letter March, 1992 To: Selected NAAO Export Sales North American Ford and LincolnMercury Product Dealers All NAAO Export Sales District Offices All Affiliated Ford Motor Companies - Service Managers Subject: Emissions Recall 92E22 - Disconnected Fuel Vapor Hoses on Certain 1989-Model Thunderbirds and Cougars Equipped with 3.8L Engines Enclosed are copies of FPSD's Emissions Recall 92E22 Bulletin applicable to the subject North American Ford-built vehicles. A sample copy of NAAO Export Sales' owner notification letter is attached. If your dealership/location is involved, the applicable VIN listing is included. If not, use the Bulletins Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected > Page 3563 as information only. Please note that some details in the enclosed Bulletins such as parts ordering and claim submission procedures are applicable to U.S. dealers only. Therefore, please observe the following administrative procedures: 1. Parts Order Order the parts directly from FPSD-IDO, Windsor, Canada, using conventional parts ordering procedures. Parts will be reimbursed by submission of recall claim Form(s) 1864. 2. Reimbursement Only the Form 1864 will be accepted for reimbursement under this Recall. Upon completion of the required service, the Form 1864 must be completely filled out and signed by authorized dealer personnel. Dealers having Direct Warranty Entry (DWE) are to use that method of claims submission. PLEASE ENSURE THAT COPIES OF THIS RECALL ANNOUNCEMENT ARE ROUTED TO YOUR PARTS AND SERVICE PERSONNEL. Serial Number: April, 1992 Ford Motor Company is voluntarily recalling (Emissions Recall 92E22) certain 1989-Model Thunderbirds and Cougars equipped with 3.8L engines. Your car may have a disconnected fuel vapor return hose and may be releasing air pollutants which exceed U. S. Federal standards. What the Dealer At no charge to you, your dealer will inspect and, if Will Do necessary, connect the vapor hose on your car according to instructions provided by Ford. This service should have little or no effect on your car except to reduce air pollutants. If you do not have this service done, ^ Your emissions warranty may be reduced, ^ Your car may not pass emissions or smog tests that may be required in your area. Call Your Dealer Call your dealer without delay. Ask for an appointment and ask if parts are in stock. If your dealer does not have the parts, they can be ordered before scheduling your service date. When you bring your car in, give the dealer the enclosed form. If you misplace the form, your dealer will still do the work, free of charge. Changed Address If you have, please fill out Section 1 of the prepaid or Sold the Car? postcard and mail it to us. If the dealer does not make the repair promptly and without charge, please fill out Section 3 of the prepaid postcard and mail it to us. Please have your car serviced promptly to maintain full emission warranty coverage. We regret any inconvenience this recall may cause you. Owner Letter Serial Number: 12345678901234567 April, 1992 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is voluntarily recalling (Emissions Recall 92E22) certain 1989-Model Thunderbirds and Cougars equipped with 3.8L engines. Your car may have a disconnected fuel vapor return hose and may be releasing air pollutants which exceed Federal standards. What the Dealer At no charge to you, your dealer will Will Do inspect and, if necessary, connect the vapor hose on your car according to instructions provided by Ford. This service should have little or no effect on your car except to reduce air pollutants. If you do not have this service done, ^ Your emissions warranty may be reduced, ^ Your car may not pass emissions or smog tests that may be required in your area. How Long Will The time needed to repair your car Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > RECALL92E22 > Mar > 92 > Recall - Fuel Vapor Hoses Disconnected > Page 3564 It Take? is about one hour. However, due to service scheduling times, your dealer may need your car for one full working day. Call Your Dealer Call your dealer without delay. Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. Changed Address If you have, please fill out the enclosed or Sold the prepaid postcard and mail it to us. Car? If the dealer does not make the repair promptly and without charge, you may contact the Ford Customer Assistance Center at 300 Renaissance Center, P.O. Box 43360, Detroit, MI, 48243. Please have your car serviced promptly to maintain full emission warranty coverage. We regret any inconvenience this recall may cause you. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporative Fuel Vapor Return Hose: > 8964 > Mar > 89 > Fuel Tank - Replacement Service Tips Evaporative Fuel Vapor Return Hose: All Technical Service Bulletins Fuel Tank - Replacement Service Tips FUEL SYSTEM - FUEL TANK REPLACEMENT AND SERVICE TIPS Article No. 89-6-4 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The fuel tank vapor vent hose that connects the right hand side and left hand side of the fuel tank requires some special attention when servicing or replacing the fuel tank. The fuel vapor vent hose must not be routed between the driveshaft and the subframe. FIGURE 1 ACTION: Route the fuel vapor vent hose over the subframe and over the fuel vapor vent hose retainer as shown in Figure 1. OTHER APPLICABLE ARTICLES: 89-5A-16 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4500, 4800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Evaporative Fuel Vapor Return Hose > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporative Fuel Vapor Return Hose: > 8964 > Mar > 89 > Fuel Tank - Replacement Service Tips Evaporative Fuel Vapor Return Hose: All Technical Service Bulletins Fuel Tank - Replacement Service Tips FUEL SYSTEM - FUEL TANK REPLACEMENT AND SERVICE TIPS Article No. 89-6-4 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The fuel tank vapor vent hose that connects the right hand side and left hand side of the fuel tank requires some special attention when servicing or replacing the fuel tank. The fuel vapor vent hose must not be routed between the driveshaft and the subframe. FIGURE 1 ACTION: Route the fuel vapor vent hose over the subframe and over the fuel vapor vent hose retainer as shown in Figure 1. OTHER APPLICABLE ARTICLES: 89-5A-16 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4500, 4800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Fuel Overflow Reservoir > Component Information > Description and Operation Fuel Overflow Reservoir: Description and Operation This system provides a vapor space above the gasoline surface in the fuel tank. This area is enough to permit breathing space for the tank vapor valve assembly under all static and most dynamic conditions. Horizontally mounted tanks accomplish this by a raised mounting section for the valve assembly which is centrally located on the upper surface of the tank. Vertically mounted tanks use a centrally mounted vapor valve assembly on the uppermost surface of the fuel tank. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Liquid Vapor Separator, Evaporative System > Component Information > Description and Operation Liquid Vapor Separator: Description and Operation Fig. 47 Fuel tank vapor valve All fuel tank vapor valves, Fig. 47, use a small orifice which allows only vapor and not fuel to pass into the line going to the vapor storage canister. This assembly is mounted on the fuel tank. Fuel vapors trapped in the sealed fuel tank are vented through the vapor valve assembly. The vapors leave the valve assembly through a single vapor line and continue to the charcoal canister for storage, until they are purged into the engine. On vehicles equipped with fuel/vapor return lines, vapors created in the fuel line is continuously vented back to the fuel tank. This prevents engine surging from fuel enrichment. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Thermal Vacuum Valve - EVAP > Component Information > Description and Operation Thermal Vacuum Valve - EVAP: Description and Operation Fig. 18 Ported vacuum switches--PVS These switches, Fig. 18, control vacuum to emission components during engine warm-up. The 2-port and 4-port types open when coolant temperature reaches a predetermined value. The 3-port type switches vacuum from the center to the top or bottom ports. Electrical switches can be opened or closed until the PVS is fully cycled. All PVS units are temperature-activated and have a specific opening and closing temperature. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Description and Operation > Cold Start Spark Hold (CSSH) Vacuum Delay Valve: Description and Operation Cold Start Spark Hold (CSSH) Fig. 11 Cold start hold system--CSSH This system, used on some vehicles, provides momentary spark advance hold during acceleration when the engine is cold, to provide improved cold engine acceleration. When engine coolant temperature is less than 128° F, the CSSH PVS is closed and the distributor vacuum signal travels through the restrictor, Fig. 11. When the engine is started cold, high vacuum acts on the vacuum advance unit to provide maximum advance. During acceleration, the high vacuum in the vacuum advance unit is slowly bled down through the restrictor, providing a modified vacuum advance during the initial stage of acceleration. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Description and Operation > Cold Start Spark Hold (CSSH) > Page 3587 Vacuum Delay Valve: Description and Operation Vacuum Delay Valves Types Of Vacuum Delay Valves This valve, Fig. 23, further reduces emissions by delaying the spark advance during rapid acceleration and by cutting off advance immediately upon deceleration. This is a one-way valve and will not operate if installed backwards. On all systems which employ the dual diaphragm distributor, the line which has high vacuum at idle (normal operating temperature) is connected to the secondary (retard) side of the distributor vacuum advance unit. This is the connection closest to the distributor cap. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Delay Vacuum Bypass (DVB) Vacuum Delay Valve: Testing and Inspection Delay Vacuum Bypass (DVB) 1. Remove air cleaner. 2. Remove spark delay valve. (Refer to Spark Delay Valve section for test procedure for this unit.) Replace spark delay valve with a connector. Remove vacuum line at distributor and install a T-fitting and a vacuum gauge. 3. With transmission in neutral and engine idling at normal operating temperature, open throttle to 1/2 open position. 4. Open and close throttle as noted in Step 3 while watching vacuum reading. A quick rise and fall should be noted. If vacuum is indicated, proceed to next step. If no vacuum is indicated, check the vacuum lines, evaporative canister purge valve, T-fitting, and carburetor vacuum port for blockage. Correct as necessary. 5. Turn off engine and replace the spark delay valve (tested before reinstalling as noted in Step 2). Remove vacuum gauge and T-fitting and replace vacuum hoses. 6. Remove vacuum check valve and test. (Refer to Spark Delay Valve section for test procedure for this unit). Replace if defective. Reinstall valve. 7. Install a T-fitting between the check valve and the PVS. Connect a vacuum gauge at this point. 8. With transmission in neutral and engine idling at normal operating temperature, open throttle to 1/2 position. Note vacuum reading at steady 1/2 throttle. If reading is 2 inches Hg or less, PVS unit is good. If more than 2 inches Hg is indicated, PVS is defective and must be replaced. 9. Remove vacuum gauge and return all vacuum lines to original location. Reinstall air cleaner assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Delay Vacuum Bypass (DVB) > Page 3590 Vacuum Delay Valve: Testing and Inspection Vacuum Delay Valve SDV & VDV valve color coding Refer to Fig. 35, for number value by color code. To perform the following procedure, an external vacuum source capable of maintaining a minimum constant 10 inches Hg is required. Vacuum & spark delay valve specifications chart Mono Delay Valve 1. Set external vacuum source to 10 inches Hg and connect black side of delay valve to vacuum source. 2. Connect a vacuum gauge with a 24 inch hose to colored side of delay valve. 3. Apply 10 inches Hg vacuum and observe time in seconds for gauge to read 0---8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg should be as shown in Fig. 36. Dual Delay Valve 1. Set external vacuum source to 10 inches Hg and connect vacuum gauge with a 24 inch hose to DIST nipple of delay valve. 2. Connect black side of delay valve and CARB nipple of delay valve to vacuum source. Avoid applying vacuum to CARB nipple while applying vacuum to black side of valve. 3. Apply 10 inches Hg of vacuum and observe time in seconds for gauge to read from 0---8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg should be as shown in Fig. 36. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Vacuum Delay Valve, EVAP > Component Information > Testing and Inspection > Delay Vacuum Bypass (DVB) > Page 3591 Retard Delay Valve 1. Set external vacuum source to 10 inches Hg and connect colored side of delay valve to vacuum source. 2. Connect a vacuum gauge with a 24 inch hose to white side of delay valve. 3. Apply 10 inches Hg of vacuum and observe time in seconds for gauge to read from 0---8 inches Hg. The minimum and maximum time for gauge to read 8 inches Hg should be as shown in Fig. 36. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Backpressure Transducer > Component Information > Technical Service Bulletins > EGR Transducer Sensor Condensation EGR Backpressure Transducer: Technical Service Bulletins EGR Transducer Sensor Condensation EEC IV - PRESSURE FEEDBACK ELECTRONIC (PFE) EGR TRANSDUCER SENSOR CONDENSATION (WATER) Article No. 88-26-6 FORD: 1988-89 ESCORT, EXP, TEMPO, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1988-89 TOPAZ, SABLE, COUGAR, CONTINENTAL MERKUR: 1988-89 SCORPIO ISSUE: The pressure feedback electronic (PFE) EGR transducer sensor changes an exhaust pressure signal into analog voltage. The EEC IV processor uses this to control EGR flow. Condensation (water) is a natural by-product of combustion and may collect in the PFE sensor port or the PFE sensor silicon hose. Water in the PFE sensor port or PFE hose does not indicate an abnormal operating condition or failed sensor. The water in the PFE sensor port or PFE hose will drain back into the EGR tube because of the downward slope of the hose. Refer to the application chart of this TSB article for the affected vehicles. FIGURE 6 ACTION: Before replacing a PFE sensor for water in the sensor port or silicon tube, perform an EEC IV self test. If no service codes are found indicating a faulty PFE sensor, do not replace the sensor, Figure 6. PFE SENSOR APPLICATION CHART MODEL YEAR VEHICLE ENGINE REGION 1988-89 Escort-Exp 1.9L CFI 50 State 1988-89 Tempo/Topaz 2.3L HSC 50 State 1988-89 Thunderbird/ Cougar 3.8L 50 State 1988-89 Taurus/Sable 3.0L California 1988-89 Taurus/Sable 3.8L 50 State 1988-89 Continental 3.8L 50 State 1988-89 Scorpio 2.9L 50 State OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Control Solenoid > Component Information > Description and Operation EGR Control Solenoid: Description and Operation EGR solenoid valve assembly (dithering type) The dual EGR solenoid valve assembly consists of two dithering solenoid valves. The first is a vacuum valve which supplies vacuum to the sonic EGR valve when energized. The second is a vent valve which vents the EGR valve to the atmosphere when de-energized. Both solenoid valves receive variable duty cycle signals from the EEC system according to EGR requirements. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Locations EGR Vacuum Regulator Solenoid: Locations Engine Compartment Component Locations RH Rear Of Engine Compartment Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Vacuum Regulator Solenoid <--> [EGR Electronic Vacuum Regulator Solenoid] > Component Information > Locations > Page 3603 EGR Vacuum Regulator Solenoid: Testing and Inspection 1. Disconnect vacuum line from output (middle) port, and connect a vacuum gauge to port. 2. With engine at idle, the vacuum gauge reading should average between 1.9 and 3.15 inches. The fluctuation of vacuum between the higher and lower limits is normal, but the average should be within specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3607 EGR Valve: Locations Supercharger Removal/Assembly EGR Valve Installation The Exhaust Gas Recirculation (EGR) Valve is located at the Top Rear Center of the Engine. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3608 EGR Valve: Description and Operation In this system the exhaust gases are metered through the EGR valve to a passage in the carburetor spacer thereby diluting the air fuel mixture entering the combustion chambers. Dilution of the incoming mixture lowers peak flame temperatures during combustion and thus limits the formation of nitrogen oxides (NOx). Fig. 39 EGR connections. 4 & 6 cyl. engines On four and six cylinder engines, the EGR system is basically the same as the Spacer Entry EGR System except that exhaust gas is routed directly from the exhaust manifold, Fig. 39. Two variables control the operation of the EGR system, 1) engine coolant temperature and 2) carburetor vacuum. When engine coolant temperature is below the specified level the EGR system is locked out by a temperature controlled vacuum switch. The vacuum switch is installed in series with the EGR valve. This valve receives vacuum from a port in the carburetor body. When the valve is closed due to lower coolant temperature, no vacuum is applied to the EGR valve and no exhaust gas is fed to the air-fuel mixture. When the engine coolant temperature reaches the specified level, the valve opens allowing vacuum to be applied to the EGR valve. Exhaust gas is then fed to the air-fuel mixture. The second factor controlling EGR operation is carburetor vacuum. The location of the EGR port in the carburetor determines at what point vacuum is sent to the EGR valve. Vacuum should be fed to the EGR vacuum control valve when the primary throttle plate reaches a position corresponding to a road speed of approximately 20 mph under light acceleration. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3609 Fig. 40 Venturi vacuum amplifier A Venturi Vacuum Amplifier, Fig. 40, uses a weak venturi-vacuum signal to produce a strong intake manifold vacuum to operate the EGR valve, thereby achieving an accurate, repeatable and almost exact proportion between venturi airflow and EGR flow. This assists in controlling oxides of nitrogen with minimal sacrifice in driveability. There are three basic types of EGR valves: the ported type, the back pressure type and the electronic-sonic type. The electronic-sonic type valve is used with the EEC system. Information on this valve can be found in the ``EEC'' section of this chapter. Fig. 41 Ported type EGR valves Ported type valves, Fig. 41, may be of the poppet or tapered stem design and can have base or side entry. The two passages connecting the exhaust system to intake manifold are blocked by a valve which is opened by vacuum and closed by spring pressure. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Specifications > Page 3610 Fig. 42 EGR valve with integral back pressure transducer Two types of back pressure valves are used. The integral back pressure transducer valve, Fig. 42, cannot be opened by vacuum until the bleed hole is closed by exhaust back pressure. When open, the valve oscillates at a level dependent on the exhaust back pressure flowing through the orifice. Valve opening increases as signal vacuum and exhaust back pressure increases. Fig. 43 EGR valve with remote back pressure transducer Some vehicles use an EGR valve with a remote back pressure transducer, Fig. 43. This assembly operates the same as the EGR valve with integral back pressure transducer valve and is serviced only as an assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > EGR Venturi Vacuum Amplifier EGR Valve: Testing and Inspection EGR Venturi Vacuum Amplifier Idle must be set to specifications, engine must be at normal operating temperature and manifold vacuum must be adequate for this test. 1. Connect a vacuum gauge hose at EGR valve (port O). The gauge may read as high as 2 inches Hg at idle. 2. Disconnect venturi hose at carburetor and increase engine speed to 2000 RPM on all except 4-97 and 4-140 engines, 4000 RPM on 4-97 engines and 3000 on 4-140 engines. 3. Connect venturi hose. Gauge should read 4 inches Hg. 4. Return engine to idle. Gauge should return to initial reading. 5. If operation is not as described previously, replace VVA. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > EGR Venturi Vacuum Amplifier > Page 3613 EGR Valve: Testing and Inspection With Back Pressure Transducer Signal Response Test 1. Check all system vacuum lines for proper routing and secure connections. 2. Inspect vacuum lines for wear or damage and replace as necessary. 3. Disconnect and plug vacuum line to EGR valve, then connect vacuum pump to valve. 4. Run engine at idle and apply 6 inches Hg vacuum to valve. 5. If vacuum holds and valve opens and stays open, replace valve. 6. Ensure that there is no vacuum to valve at idle. If there is, check hose routing. 7. Ensure that there is no vacuum to valve or valve operation when engine is cold. If there is, check ported vacuum switch and thermal vacuum switch, replacing as necessary. 8. Ensure that there is vacuum to valve at 3000 RPM on 4-140 engine, or kickdown RPM on all other engines, with engine at operating temperature. If there is no vacuum, trace system vacuum lines back from EGR valve and replace components as necessary. Refer to vehicle emission decal for kickdown RPM specification. Valve Function Test 1. Select drive socket wrench with O.D. of approximately 1/16 inch less than I.D. of tailpipe. 2. Cover drive socket hole and insert socket in tailpipe with open end facing out. Do not block tailpipe fully and do not run engine faster than idle or for prolonged periods of time. Be sure to remove socket from tailpipe at end of test. 3. Run engine at idle and gradually apply vacuum. Valve stem/diaphragm should move smoothly and engine should roughen. 4. Trap 6 inches Hg of vacuum and hold. Vacuum should drop more than 1 inch Hg in 30 seconds. 5. If valve stem/diaphragm moves smoothly but engine does not roughen, clean valve passages. 6. If conditions in steps 3 and/or 4 are not met, replace valve. 7. If valve is suspected of sticking, remove valve from engine and cycle valve by pressing carefully with fingers against lower transducer plate. 8. If valve sticks open when fingers are released, replace valve. 9. If valve does not stick, clean inlet and outlet ports with wire brush. Do not use sand blasting or gasoline to clean the valve. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve > Component Information > Testing and Inspection > EGR Venturi Vacuum Amplifier > Page 3614 EGR Valve: Testing and Inspection Without Back Pressure Transducer Single Response Tests 1. Check all system vacuum lines for proper routing and secure connections. 2. Inspect vacuum lines for wear or damage and replace as necessary. 3. Ensure there is no vacuum to valve at idle. Recheck hose routing if vacuum is present. 4. Ensure that there is vacuum at valve at 3000 RPM on 4-140 engine, or kickdown RPM on other engines, with engine at operating temperature. If there is no vacuum, trace system vacuum lines back from EGR valve and replace components as necessary. Refer to vehicle emission decal for kickdown RPM specification. Valve Function Test 1. Run engine at idle and apply 8 inches Hg vacuum to valve. Valve stem should move, opening valve, and engine should roughen. 2. If valve stem moves but engine does not roughen, remove valve and clean inlet and outlet ports with fine wire brush. Do not use sand blasting or gasoline to clean EGR valve. 3. Run engine at idle and trap and hold 4 inches Hg vacuum. 4. If vacuum drops more than 1 inch Hg vacuum in 30 seconds, replace valve. Seat Test This test should be performed when the valve is suspected of leaking, indicated by rough engine operation. 1. Install blocking gasket (no flow holes) between mounting and valve, then retighten valve. 2. Improved engine operation indicates a defective valve. Clean or replace as necessary. 3. Replace blocking gasket with conventional gasket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3619 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3620 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3621 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3622 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3623 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3624 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3625 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3626 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3627 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3628 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3629 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3630 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3631 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3632 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3633 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3634 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3635 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3636 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3637 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3638 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3639 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3640 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3641 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3642 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3643 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3644 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3645 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3646 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3647 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3648 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3649 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3650 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3651 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor - Manual Revision > Page 3652 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 3653 EGR Valve Position Sensor: Description and Operation EGR valve position sensor The EGR valve position sensor provides the EEC system with an EGR valve position signal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Supercharger Removal/Assembly EGR Valve Installation The Pressure Feedback Electronic (PFE) Exhaust Gas Recirculation (EGR) Transducer is located at the Top Rear Center of the Engine. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > Thermal Vacuum Valve, EGR > Component Information > Description and Operation Thermal Vacuum Valve: Description and Operation Fig. 18 Ported vacuum switches--PVS These switches, Fig. 18, control vacuum to emission components during engine warm-up. The 2-port and 4-port types open when coolant temperature reaches a predetermined value. The 3-port type switches vacuum from the center to the top or bottom ports. Electrical switches can be opened or closed until the PVS is fully cycled. All PVS units are temperature-activated and have a specific opening and closing temperature. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation Positive Crankcase Ventilation Valve: Description and Operation Fig. 55 Typical PCV system Fig. 56 PCV valve All engines produce small amounts of blow-by gases which seep past the piston rings and into the crankcase. These blow-by gases are the result of the high pressures developed within the combustion chamber during the combustion process, and contain undesirable pollutants. To prevent blow-by gases from entering the atmosphere while allowing proper crankcase ventilation, all engines use a PCV system, Fig. 55. The PCV system prevents blow-by gases from escaping by routing them through a vacuum controlled ventilating valve and a hose into the intake manifold. The blow-by gases mix with the air/fuel mixture and are burned in the combustion chambers. When the engine is running, fresh air is drawn into the crankcase through a tube or hose connected to the air cleaner housing. The PCV valve, Fig. 56, consists of a needle valve, spring and housing. When the engine is off, the spring holds the needle valve closed to stop vapors from entering the intake manifold. When the engine is running, manifold vacuum unseats the valve allowing crankcase vapors to enter the intake manifold. In case of a backfire in the intake manifold the valve closes, stopping the backflow and preventing ignition of fumes in the crankcase. During certain engine conditions, more blow-by gases are created than the ventilator valve can handle. The excess is returned through the air intake tube to the air cleaner and carburetor where it is burned in the engine. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation > Positive Crankcase Ventilation Valve > Component Information > Description and Operation > Page 3664 Positive Crankcase Ventilation Valve: Testing and Inspection Fig. 55 Typical PCV system Fig. 56 PCV valve All engines produce small amounts of blow-by gases which seep past the piston rings and into the crankcase. These blow-by gases are the result of the high pressures developed within the combustion chamber during the combustion process, and contain undesirable pollutants. To prevent blow-by gases from entering the atmosphere while allowing proper crankcase ventilation, all engines use a PCV system, Fig. 55. The PCV system prevents blow-by gases from escaping by routing them through a vacuum controlled ventilating valve and a hose into the intake manifold. The blow-by gases mix with the air/fuel mixture and are burned in the combustion chambers. When the engine is running, fresh air is drawn into the crankcase through a tube or hose connected to the air cleaner housing. The PCV valve, Fig. 56, consists of a needle valve, spring and housing. When the engine is off, the spring holds the needle valve closed to stop vapors from entering the intake manifold. When the engine is running, manifold vacuum unseats the valve allowing crankcase vapors to enter the intake manifold. In case of a backfire in the intake manifold the valve closes, stopping the backflow and preventing ignition of fumes in the crankcase. During certain engine conditions, more blow-by gases are created than the ventilator valve can handle. The excess is returned through the air intake tube to the air cleaner and carburetor where it is burned in the engine. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision Technical Service Bulletin # 8918A9 Date: 890915 EVP Sensor - Manual Revision ENGINE EMISSIONS DIAGNOSTIC MANUALS, VOLUME H - 1985 THROUGH 1989 - EGR VALVE POSITION SENSOR (EVP) DIAGNOSTIC PROCEDURES REVISED Article No. 89-18A-9 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-86 LTD 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS 1988-89 FESTIVA 1989 PROBE LINCOLN-MERCURY: 1985-86 CAPRI 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII 1985-86 MARQUIS 1985-89 TOPAZ, TOWN CAR 1986-89 SABLE 1987-89 TRACER MERKUR: 1986-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER 1986-89 AEROSTAR ISSUE: The EGR Valve Position Sensor (EVP) diagnostic procedures in 1985 through 1989 Engine Emissions Diagnosis Shop Manuals, Volume H, have been revised. EVP Sensors may exhibit internal wear problems that can cause driveability symptoms and display a Continuous Self-Test Code 32. This is not associated to correcting the problem using the existing diagnostic procedures. ACTION: Refer to the pages following this TSB article for the revised diagnostic procedures. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 1985 Pinpoint Tests - DM - EGR, EVP and EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3670 1985 EEC IV - Pinpoint Tests - All Vehicles 22-77 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint DM Test 1985 Pinpoint Tests - Fa - Neutral Drive Switch -A/C Input Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3671 1985 22-78 EEC IV - Pinpoint Tests - All Vehicles Neutral Drive Switch FA A/C Input PinpointTest 1986 (EGR) Systems Functional Diagnosis 1986 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3672 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1986 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3673 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed to the emission decal specification. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1986 Quick Test: Continuous Self-Test 6.0 EEC IV - Quick Test - All Engines 18-13 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3674 QUICK TEST: Continuous Self-Test 6.0 1986 18-14 EEC IV-Quick Test-All Engines QUICK TEST: Continuous Self-Test 6.0 Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3675 1986 EEC IV-Pinpoint Tests - All Vehicles 21-95 EGR Valve Position Sensor (EVP) PinpointTest DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3676 21-96 1986 EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3677 EEC IV-Pinpoint Tests-All Vehicles 1986 21-97A EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3678 1986 21-97B EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3679 1986 EEC IV-Pinpoint Tests-All Vehicles 21-98 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) 1987 (EGR) Systems - Functional Diagnosis 1987 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3680 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1987 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Disconnect the 9G428 EVP sensor electrical connector mounted on top of the 9H473 valve. 7. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 8. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 9. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. 10. Reconnect the idle air bypass valve electrical connector. 11. Unplug and reconnect the EGR vacuum supply hose. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3681 12. Reconnect the EVP sensor electrical connector. 13. The EGR valve is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continous Code 32 was not present, refer to the Diagnostic Routines in Section 2. 1987 Quick Test: Continuous Self-Test - 6.0 1987 EEC-IV Quick Test-All Engines 16-15 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3682 16-16 1987 EEC-IV Quick Test-All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR 1987 EEC IV - Pinpoint Tests - All Vehicles 19-91 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3683 EGR VALVE Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN 19-92A 1987 EEC IV Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, Pinpoint Test DN 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3684 1987 EEC IV-Pinpoint Tests-All Vehicles 19-92B EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car and 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3685 1987 19-93-A EEC IV-Pinpoint Tests-All Vehicles EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) - 2.3L HSC, 2.5L, 5.0L SEFI Passenger Car 4.9L and 5.0L Truck Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3686 EEC IV-Pinpoint Tests-All Vehicles 1987 19-94 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1988 Exhaust Gas Recirculation (EGR) Systems 6-11 Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3687 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, replace the EGR valve. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), replace the EGR valve. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 6-12 1988 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 2-1/2 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur, replace the valve: ^ Engine does not stall. ^ Idle speed does not drop more than 100 rpm. ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3688 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR is OK, REPLACE EVP sensor if the Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 1988 EEC-IV - Quick Test - All Engines 16-15 QUICK TEST: Continuous Self-Test 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3689 1988 16-16 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test Pinpoint Test - DN - EGR - EVP & EVR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3690 EEC-IV - Pinpoint Tests - All Vehicles 1988 19-101 EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3691 19-102 1988 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3692 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-102A EGR Valve Position Sensor (EVP) EGR Valve Regulator (EVR) Pinpoint Test DN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3693 1988 19-103 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3694 1988 EEC-IV - Pinpoint Tests - All Vehicles 19-104 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Valve Regulator (EVR) (EGR) Systems - Functional Diagnosis 1989 6-11 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3695 PORTED EGR VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is no vacuum to the EGR valve at idle with the engine at normal operating temperature. 3. Install a tachometer, Rotunda 059-00010 or equivalent. 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is fully applied to the EGR valve: ^ If idle speed drops more than 100 rpm or if engine stalls, perform the next step. Otherwise, for vacuum leak at EGR valve, replace the valve. ^ If EGR passages are blocked, clean the valve using Rotunda 021-80056 EGR valve cleaner. ^ Remove the vacuum from the EGR valve. If idle speed does not return to normal (+/- 25 rpm), check for contamination, clean the valve. ^ Make sure there is no sand left in the valve or pick-up tube. Replace the valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. 10. Unplug and reconnect the EGR vacuum supply hose. 11. The EGR system is OK, refer to the Diagnostic Routines in Section 2. 1989 6-12 Exhaust Gas Recirculation (EGR) Systems Functional Diagnosis ELECTRONIC EGR (EEGR) VALVE 1. Make certain that all vacuum hoses are correctly routed and securely attached. Replace cracked, crimped or broken hoses. 2. Make certain there is less than 2.5 in-Hg vacuum to the EGR valve at idle with the engine at normal operating temperature. NOTE: The EVR solenoid has a constant internal leak. You will notice a small vacuum signal. This signal should be less than 1.0 in-Hg at idle. 3. Install a tachometer, Rotunda 059-00010 or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3696 4. Disconnect the Idle Air Bypass Valve (9F715) electrical connector (1.9L EFI engines only). 5. Remove the vacuum supply hose from the EGR valve nipple. Plug the hose. 6. Start engine, idle with transmission in NEUTRAL, and observe the engine idle speed. If necessary, adjust idle speed according to Section 4. 7. Slowly apply 5-10 inches of mercury vacuum to the EGR valve vacuum nipple using a hand vacuum pump, Rotunda 021-00014 or equivalent. 8. When vacuum is applied to the EGR valve and any of the following occur: ^ Engine does not stall ^ Idle speed does not drop more than 100 rpm ^ Idle speed does not return to normal (+/- 25 rpm) after the vacuum is removed Then: ^ For vacuum leak at EGR valve, replace the valve. ^ Check for contamination, clean the EGR valve, using Rotunda 021-80056 EGR valve cleaner or equivalent. ^ Make sure there is no sand left in the valve. ^ Replace the EGR valve if necessary. 9. Reconnect the idle air bypass valve electrical connector. Unplug and reconnect the EGR vacuum supply hose. 10. If EGR valve is OK, REPLACE EVP sensor if Continuous Code 32 was present. If the Continuous Code 32 was not present, refer to the Diagnostic Routines in Section 2. Quick Test:Continuous Self-Test - 6.0 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3697 1989 EEC-IV - Quick Test - All Engines 14-17 QUICK TEST: Continuous 6.0 Self-Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3698 1989 14-18 EEC-IV - Quick Test - All Engines QUICK TEST: Continuous 6.0 Self-Test 1989 EEC-IV - Quick Test - All Engines 14-19 QUICK TEST: Continuous 6.0 Self-Test Quick Test:Diagnostic By Symptom - 7.0 1989 14-20 EEC-IV - Quick Test - All Engines QUICK TEST: Diagnostic By Symptom 7.0 A DIAGNOSTIC BY SYMPTOM SPECIAL NOTES: ^ Verify that a Pass Code 11 was received in Key On Engine Off, Engine Running and Continuous Self-Tests before continuing with this test. ^ If a symptom is present and the EEC system is suspected, Go to part B of Diagnostic By Symptom. If the EEC system is not suspected, GO to Section 2, Diagnostic Routines. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3699 Pinpoint Test - DN - EGR - EVP & EVR 1989 EEC-IV - Pinpoint Tests-All Vehicles 17-133 EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3700 1989 17-134 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3701 1989 EEC-IV-Pinpoint Tests - All Vehicles 17-134A Pinpoint Test DN EGR Valve Position Sensor (EVP) EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3702 1989 17-135 EEC-IV - Pinpoint Tests - All Vehicles EGR Valve Position Sensor (EVP) Pinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > EVP Sensor Manual Revision > Page 3703 1989 EEC-IV - Pinpoint Tests - All Vehicles 17-136A EGR Valve Position Sensor (EVP) 04GPinpoint Test DN EGR Vacuum Regulator Solenoid (EVR) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > EGR Valve Position Sensor > Component Information > Technical Service Bulletins > Page 3704 EGR Valve Position Sensor: Description and Operation EGR valve position sensor The EGR valve position sensor provides the EEC system with an EGR valve position signal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Sensors and Switches - Emission Control Systems > Pressure Feedback Exhaust Sensor, EGR > Component Information > Locations Pressure Feedback Exhaust Sensor: Locations Supercharger Removal/Assembly EGR Valve Installation The Pressure Feedback Electronic (PFE) Exhaust Gas Recirculation (EGR) Transducer is located at the Top Rear Center of the Engine. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Description and Operation > Cold Weather Modulator Thermostatic Air Cleaner Vacuum Switch: Description and Operation Cold Weather Modulator Fig. 3 Cold weather modulator This modulator, Fig. 3, is used on some models to prevent the air cleaner door from opening when outside air is below a predetermined temperature. At higher ambient temperatures, the modulator is inoperative. During acceleration, with outside air below the preset temperature, the modulator will close off the vacuum to the motor and hold the duct open. The modulator is located inline between the air temperature control sensor and the vacuum duct motor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Description and Operation > Cold Weather Modulator > Page 3713 Thermostatic Air Cleaner Vacuum Switch: Description and Operation Mechanically Controlled Thermostatic Fig. 1 Mechanically controlled thermostatic assembly Carburetor air temperature is thermostatically controlled by the air duct and valve assembly. Air from the engine compartment, or heated air from the shrouded exhaust manifold is supplied to the engine Fig. 1. During the engine warm-up period when the air temperature entering the air duct is less than 105° F, the thermostat is in the retracted position and the air valve is held in the closed position by the air valve spring, thus shutting off the air from the engine compartment. Air is then drawn from the shroud at the exhaust manifold. As the temperature of the air passing the thermostat unit rises, the thermostat starts to open and pulls the air valve down. This allows cooler air from the engine compartment to enter the air cleaner. When the temperature of the air reaches 130° F, the air valve is in the open position so that only engine compartment air is allowed to enter the air cleaner. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Description and Operation > Cold Weather Modulator > Page 3714 Thermostatic Air Cleaner Vacuum Switch: Description and Operation Vacuum Operated Thermostatic Fig. 2 Bi-metal switch A vacuum operated duct valve with a thermostatic bi-metal control, Fig. 2, is used. The valve in the duct assembly is in an open position when the engine is not operating. When the engine is operating at below 75° F, manifold vacuum is routed through the bi-metal switch to the vacuum motor to close the duct valve allowing only heated air to enter the air cleaner. When the engine reaches normal operating temperature the bi-metal switch opens an air-bleed which eliminates the vacuum and the duct valve opens allowing only cold air to enter the air cleaner. During periods of acceleration the duct valve will open regardless of temperature due to the loss of manifold vacuum. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Testing and Inspection > Air Cleaner Cold Weather Modulator Thermostatic Air Cleaner Vacuum Switch: Testing and Inspection Air Cleaner Cold Weather Modulator 1. Cool modulator to below the following temperatures by spraying with Refrigerant 12: black modulator, 20° F; blue modulator, 40° F; green modulator, 50° F; yellow modulator, 65° F. Allow sufficient time for modulator temperature to stabilize and modulator valve to close. Do not spray refrigerant with engine running, as any refrigerant drawn into the carburetor and burned in the engine will produce poisonous phosgene gas. Conduct test in well ventilated area. 2. Use a 24 inch length of 1/4 inch hose between cold weather modulator and vacuum gauge. Using an external vacuum source, apply at least 16 inches Hg vacuum to vacuum motor side of modulator and trap vacuum by pinching hose. The modulator must hold at least 5 inches Hg vacuum for 30 seconds. If not, replace modulator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Testing and Inspection > Air Cleaner Cold Weather Modulator > Page 3717 Thermostatic Air Cleaner Vacuum Switch: Testing and Inspection Mechanically Controlled Thermostatic Preferred Method 1. Remove air cleaner cover and components necessary to observe position of duct door. 2. With engine cold and ambient air temperature less than 105° F, the duct valve should be closed in the heat on position (closed). If duct valve is open, cool thermostat by spraying with Refrigerant 12. Do not spray refrigerant with engine running, as any refrigerant drawn into the carburetor and burned in the engine will produce poisonous phosgene gas. Conduct this procedure in well ventilated area. 3. Place a magnetic based thermometer (Rotunda T75L-9601-A or equivalent) as near as possible to the thermostat and reinstall air cleaner cover without wing nut. Start engine and allow to idle. 4. As engine warms up, observe duct valve door. When duct valve door opens (heat off position), remove air cleaner cover and note temperature reading. 5. Temperature reading should be about 130---150° F. If not, repair or replace components as necessary. Alternate Method 1. With duct assembly installed, engine cold and ambient temperature below 100° F, the valve plate should be in the heat on position. 2. If plate is not in the heat on position, check for interference of plate and duct which may cause plate to bind. 3. Remove duct and valve assembly. Immerse assembly in cool (below 75° F) water so that thermostat capsule is covered with water. 4. Raise water temperature to 100° F, allowing 5 minutes for stabilization, and observe valve position. The correct position should be in the heat on position. 5. Increase water temperature to 135° F, allowing 5 minutes for stabilization and observe valve plate. The plate should be in the heat off position. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Inlet Air Temperature Control <--> [Thermostatic Air Cleaner] > Thermostatic Air Cleaner Vacuum Switch > Component Information > Testing and Inspection > Air Cleaner Cold Weather Modulator > Page 3718 Thermostatic Air Cleaner Vacuum Switch: Testing and Inspection Vacuum Operated Thermostatic This test must be performed with ambient air temperature below 60° F. Do not immerse any part of the vacuum operated duct and valve assembly in water. 1. On systems with Cold Weather Modulator, bypass the modulator by connecting the two vacuum lines from the modulator. 2. Apply parking brake and block wheels, then remove air cleaner cover and element. Check heat riser tube and zip tube for proper installation or damage. Repair or replace as necessary. 3. Remove components necessary to observe position of duct door. On vacuum operated units, disconnect vacuum line at duct and valve. Check that duct door is in the open (fresh air side) position. If not, check for binding or sticking. Repair or replace as necessary. 4. Place a magnetic based thermometer as near as possible to temperature sensor on inlet side. If air cleaner housing is aluminum, use tape to secure thermometer. Do not allow magnet to touch temperature sensor. 5. Start engine. If duct door is in the heat on position, proceed to step 7. If duct door is in the heat off position, turn engine off. Cool sensor temperature by spraying with Refrigerant 12 for 20 seconds. Do not spray refrigerant with engine running, as any refrigerant drawn into the carburetor and burned in the engine will produce poisonous phosgene gas. Conduct this procedure in well ventilated area. 6. Restart engine. If duct door is in the heat off position during idle, check vacuum hoses. 7. Reinstall air cleaner cover without wing nut. With engine running, observe duct door. When door starts to open, remove air cleaner cover and note temperature reading on thermometer. Temperature reading should not exceed the following specifications: a. For brown color coded sensors, temperature should not exceed 75° F. b. For black or pink color coded sensors, temperature should not exceed 90° F. c. For blue or yellow or green color coded sensors, temperature should not exceed 105° F. d. If temperatures are greater than those specified above, replace sensor. 8. If duct door does not start to open within 5 minutes after performing step, remove air cleaner cover and note temperature. If temperature is less than specified above, the temperature is insufficient to operate the duct door. Reinstall air cleaner cover without wing nut and continue to run engine until specified temperature is reached. If duct door has not started to open by then, replace sensor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Emission Control Systems > Vacuum Restrictor > Component Information > Description and Operation Vacuum Restrictor: Description and Operation Fig. 29 Vacuum restrictor The orifice type flow restrictor, Fig. 29, is used on some systems to control the flow rate and or timing characteristics to the following systems: a. EGR valve timing (opening and closing). b. Part throttle spark advance. c. Purge system. d. Thermactor system. The flow rate through the restrictor is the same in both directions. If blocked, it should be replaced. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections Fuel Pressure: Technical Service Bulletins Fuel Pressure Specification - Corrections ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-SECTION 11-SPECIFICATION CORRECTIONS ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-SECTION 17-SPECIFICATION CORRECTIONS Article No. 89-12A-25 FORD: 1989 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1989 AEROSTAR, BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER ISSUE: The pressure values shown for the 2.5L CFI engine in both "Key on engine off" and "running" conditions are incorrectly shown in the Electric Fuel Delivery System (EFD) on page 11-14 and the Fuel Control Pinpoint Test H on page 17-185. The 1988 date in the chart titles for both Passenger Car Engines and Light Truck Engines is incorrect on page 17-185. The 3.0L SHO SEFI "Key on engine off" value in the chart on page 11-14 is incorrect. ACTION: Refer to the pages following this TSB article for the corrected charts. This information should be inserted in your 1989 Engine Emissions Diagnosis Manual, pages 11-14 and 17-185. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 Fuel Delivery Systems 1989 11-13 Electric Fuel Delivery System EFD Electrical Schematic VEHICLE APPLICATION E Series 1988 and later model years, EFI F Series 1986 and later model years, EFI 11-14 1989 Fuel Delivery Systems Electric Fuel Delivery System EFD Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 3727 FUEL PRESSURE SPECIFICATION TABLE EEC-IV - Pinpoint Tests - All Vehicles 1989 17-185 Fuel Control Pinpoint Test GH Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 3728 FUEL PRESSURE SPECIFICATION TABLE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 3729 17-186 1989 EEC-IV-Pinpoint Tests-All Vehicles Fuel Control Pinpoint Test H Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Page 3730 Fuel Pressure: Specifications Key On Engine Off 35 - 40 psi Key On Engine Running 30 - 40 psi Engine Running Vacuum Hose Disconnected From Fuel Pressure Regulator 35 - 40 psi Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > System Information > Technical Service Bulletins > Page 3731 Fuel Pressure: Testing and Inspection STO Connector STATIC PRESSURE TEST 1. Check for adequate fuel supply. 2. Turn key OFF 3. Install fuel pressure gauge to test port on fuel rail. 4. Install test lead to fuel pump lead of STO test connector. 5. Turn Key ON Engine OFF (KOEO). 6. Ground test lead to run fuel pump. 7. Check to determine if fuel pressure is within acceptable limits. a. If pressure is low but greater than 3 psi (indicates fuel pump is running but not enough pressure) check for: ^ Plugged fuel filter ^ Kinked fuel line ^ Low voltage to pump (should be within 0.5 volts of battery voltage at connector). ^ Disconnect the fuel return line and note if fuel is being returned during this low pressure condition. If fuel is being returned, replace the fuel pressure regulator. Reconnect the fuel return line. b. If pressure is less than 3 psi (pump not running) check for: ^ Defective fuse link ^ Inertia switch open ^ Wiring at fuel pump/tank connector loose or open ^ Fuel pump ground connection at chassis loose or defective ^ Improper fuel pump relay operation If fuel supply and return lines are OK, and electrical supply and ground are OK, and fuel pressure is still low, replace fuel pump. DYNAMIC PRESSURE TEST 1. Disconnect and plug the vacuum line to the pressure regulator. 2. Start engine and run at idle. Check to determine if fuel pressure is within acceptable limits. Refer to SPECIFICATIONS. a. If pressure is low check for: ^ Plugged fuel filter ^ Restricted fuel line ^ Low voltage to pump (should be within 0.5 volts of battery voltage at connector). 3. Reconnect the vacuum line to the regulator. If fuel supply and return lines are OK, and electrical supply and ground is OK, and fuel pressure is still low, replace fuel pump. LEAKAGE TEST 1. Momentarily activate fuel pump by grounding test lead. Raise pressure to approximate operating pressure. 2. Remove ground from test lead and note pressure on gauge. Pressure should remain within 2 psi for 3 minutes after lead is ungrounded. a. If pressure is not maintained check for leaking fuel ^ Lines ^ Connectors ^ Injectors b. Disconnect fuel return line and plug engine side. Momentarily activate fuel pump by grounding test lead. Raise pressure to approximate operating pressure. If pressure holds replace regulator and retest. Reconnect the fuel return line. If pressure is not maintained replace fuel pump. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when fueling vehicle or when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. NOTE: Methanol and ethanol are not interchangeable. Methanol fuel can be used only in vehicles designed for methanol fuels. Ethanol fuel can be used only in vehicles designed for ethanol fuels. WARNING: The fuel tubes leading from the fuel tank to the engine are under pressure during vehicle operation. When fuel injected engines are turned off, the fuel in the fuel tubes remains pressurized for long periods of time to provide quick start-ups. Special procedures for servicing these pressurized fuel systems are outlined in this section. These procedures should be followed to prevent accidental spraying of fuel, causing personal injury or a fire hazard. WARNING: Do not swallow fuel of any kind. Fuels such as methanol or fuel ethanol and gasoline or mixtures of these fuels are highly toxic and if swallowed can cause death or permanent injury. Swallowing methanol can also cause blindness. Immediately seek medical attention from a physician or poison control center to treat anyone who has swallowed fuel. Be aware that if fuel is swallowed, the onset of potential ill health effects may be delayed 12-24 hours. AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR OF ANY KIND CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY. AVOID GETTING FUEL LIQUID IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. ALLOWING ANY FUEL TO GET IN YOUR EYES WILL CAUSE SEVERE IRRITATION. FAILURE TO SEEK PROPER MEDICAL ATTENTION FOR FUEL CONTACT WITH THE EYES COULD LEAD TO PERMANENT INJURY. IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. MAKE SURE YOU WASH YOUR HANDS BEFORE HANDLING FOOD. FUELS CONTAINING GASOLINE SUCH AS FUEL METHANOL AND FUEL ETHANOL MAY CONTAIN BENZENE, WHICH IS A CANCER-CAUSING AGENT. IF YOU ARE TAKING MEDICATION FOR THE TREATMENT OF ALCOHOLISM, SUCH AS ANTABUSE OR OTHER FORMS OF DISULFIRAM, SKIN CONTACT WITH FUEL METHANOL, FUEL ETHANOL OR BREATHING THEIR VAPORS CAN CAUSE THE SAME KIND OF ADVERSE REACTION AS DRINKING ALCOHOLIC BEVERAGES. IN SENSITIVE INDIVIDUALS, SERIOUS PERSONAL INJURY OR SICKNESS COULD RESULT. IF YOU ARE TAKING SUCH MEDICATION, YOU SHOULD TAKE EXTRA CARE TO AVOID SKIN CONTACT WITH FUEL AND TO AVOID BREATHING ITS VAPORS. IF YOU DO GET FUEL ON YOUR SKIN, WASH IT OFF IMMEDIATELY. CONSULT A PHYSICIAN PROMPTLY IF YOU EXPERIENCE AN ADVERSE REACTION. WARNING: Do not modify the fuel system configuration or components or replace components with parts not especially designed for use with fuel methanol. Ford motor company has specially-designed the materials, components and system configuration for methanol-fueled vehicles and each particular system is precisely calibrated for efficient operation. Ford ethanol vehicles require the same parts as the methanol-fueled vehicles, but are calibrated specifically for gasoline/ethanol-blended fuels. The use of different parts or materials could produce an untested configuration that could result in fire, personal injury or cause engine damage. WARNING: Do not operate engine or smoke while refueling. WARNING: Use of the incorrect fuel or blending of fuels can result in severe engine damage. Refer to fuel filler door for vehicle-specific fuel usage. WARNING: It is important that your flexible fuel vehicle be properly maintained by ford flexible fuel trained personnel. If a problem occurs, it is important that properly trained personnel diagnose the cause. If the problem relates to the fuel system, proper part replacement is imperative to keep your vehicle operating at normal performance. Flexible fuel components and standard fuel components are not interchangeable. If your vehicle is not serviced in accordance with flexible fuel vehicle procedures, damage may occur and your warranty may be invalidated. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System Information > Service Precautions > Page 3735 Fuel Pressure Release: Service and Repair WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube. Release pressure from fuel system at the fuel pressure relief valve using tool No. T80L-9974-B or equivalent. When relieving fuel pressure, crank engine with fuel pump electrical connector disconnected. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3744 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3745 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3746 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3747 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3748 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3749 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3750 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3751 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3752 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3753 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3754 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3755 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3756 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3757 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3758 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3759 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Customer Interest for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3760 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3766 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3767 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3768 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3769 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3770 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3771 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3772 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3773 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3774 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3775 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3776 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3777 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3778 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3779 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3780 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3781 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 3782 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3783 Idle Speed: By Symptom Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3784 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3785 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3786 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3787 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3788 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3789 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3790 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3791 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3792 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3793 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3794 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3795 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3796 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3797 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3798 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3799 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3800 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3801 ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3802 The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3803 If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3804 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3805 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3806 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3807 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3808 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3809 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3810 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3811 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3812 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3813 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3814 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3815 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3816 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed: > Page 3817 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Page 3818 Fuel injected Model, Idle Speed Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information > Technical Service Bulletins > Page 3819 Idle Speed: Adjustments IDLE SPEED 1. Place automatic transmission in PARK. 2. Engine OFF, back out throttle plate stop screw clear off the throttle lever pad. 3. With a .010 in. feeler gauge between the throttle plate stop screw and throttle lever pad turn the screw in until contact is made then turn it an additional 1.5 turns. 4. Start engine and stabilize for 2 minutes then goose the engine and let it return to idle, lightly depress and release the accelerator and let engine idle. If idle problem still exists check for other possible causes. 5. On Automatic Overdrive Transmission (AOD) applications or Automatic Transaxle (AXOD) application check Throttle Valve (TV) adjustment. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications Air Flow Meter/Sensor: Specifications Mass or Vane Airflow Sensor Engines with multi-port injection. 1.6L MFI, 1.9L MFI, 2.3L MFI: Vane Airflow Sensors, measured between second upper terminal (W/BK wire) and ground. 3.0L SHO, 3.8L Supercharged, 5.0L MFI H.O.: Mass Airflow Sensors, measured between terminal D (upper most) and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 3823 Air Flow Meter/Sensor: Locations Engine Compartment Component Locations RH Front Of Engine Compartment, In Air Duct Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 3824 Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > EEC IV Pinpoint Test Step KE15 - Revised Auxiliary Air Valve (Idle Speed): Technical Service Bulletins EEC IV Pinpoint Test Step KE15 Revised Article No. 89-25A-8 12/15/89 ENGINE/EMISSIONS DIAGNOSIS SHOP MANUAL, VOLUME H - PAGE 17-266 - PINPOINT TEST STEP KE15 REVISED FORD: 1989 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1989 AEROSTAR, BRONCO II, BRONCO, ECONOLINE, F SUPER DUTY, F-150, F-250, F-350, RANGER ISSUE: The Pinpoint Test Step KE15 on Page 17-266 of the 1989 Engine/Emission Shop Manual, Volume H, has incorrect direction if a NO answer is received. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > EEC IV Pinpoint Test Step KE15 - Revised > Page 3829 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Auxiliary Air Valve (Idle Speed) > Component Information > Technical Service Bulletins > EEC IV Pinpoint Test Step KE15 - Revised > Page 3830 ACTION: Refer to the pages in this TSB for the revised information showing KE6 changed to KE16. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid > Component Information > Description and Operation Bowl Vent Solenoid: Description and Operation Fig. 9 Carburetor fuel bowl solenoid vent valve This valve, Fig. 9, is a normally open valve located in the fuel bowl vent line. When the engine is running, the valve closes off the fuel bowl vent line. When the engine is shut off, the vent line returns to the normally open position. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Carburetor > Bowl Vent Solenoid > Component Information > Description and Operation > Page 3835 Bowl Vent Solenoid: Testing and Inspection 1. Apply 12 volts to valve and ensure valve closes to block air passage. 2. Replace valve if it does not close when energized. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Customer Interest: > 91813 > Apr > 91 > Engine - Rough Idle/Hesitation/Backfire/Stalling Fuel: Customer Interest Engine - Rough Idle/Hesitation/Backfire/Stalling Article No. 91-8-13 04/17/91 FUEL - USE OF UNLEADED GASOLINES - TIPS TO AVOID LEAN AIR - FUEL CONDITIONS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY, F47, F53 1991 EXPLORER ISSUE: Rough idle, hesitation, poor throttle response, induction backfire and stalls during cold start/warm up may be caused by the poor volatility of some high octane premium grade unleaded fuels (91 octane or higher (R+M)/2). When compared to regular grade unleaded fuel (87 octane (R+M)/2), high octane premium grade unleaded fuel may cause long crank time. ACTION: Use a regular grade unleaded fuel in all vehicles, except where a premium unleaded fuel is recommended in the Owner Guide. If lean air-fuel type symptoms are experienced, determine the grade and brand of fuel used and offer the following service tips. ^ Advise those using a higher octane grade fuel to switch to a regular grade unleaded fuel. For those using a regular grade fuel, advise them to try another brand. ^ Do not advise using a higher octane unleaded fuel than is recommended for that specific engine. Ford engines are designed to perform best using a high quality regular grade unleaded fuel. ^ Only advise using a higher octane unleaded fuel to avoid potentially damaging spark knock or ping, but do so only after mechanical fixes are ineffective. NOTE: ALL UNLEADED GASOLINES USED SHOULD CONTAIN DETERGENT ADDITIVES THAT ARE ADVERTISED AS HAVING "KEEP CLEAN" OR "CLEAN UP" PERFORMANCE FOR BOTH INTAKE VALVES AND FUEL INJECTORS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 98-26-2 > Jan > 99 > Fuel - Volatility Related Driveability Concerns Fuel: All Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 98-26-2 > Jan > 99 > Fuel - Volatility Related Driveability Concerns > Page 3849 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline Fuel: All Technical Service Bulletins Fuel - California Reformulated Gasoline Article No. 96-10-7 05/06/96 FUEL - CALIFORNIA REFORMULATED GASOLINE (CARFG) - SERVICE TIP FORD: 1983-86 LTD 1983-88 EXP 1983-96 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1985-94 TEMPO 1986-96 TAURUS 1989-96 PROBE 1995-96 CONTOUR LINCOLN-MERCURY: 1980-83 MARK VI 1983-88 LN7 1983-96 COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1985-94 TOPAZ 1986-96 SABLE 1991-96 TRACER 1993-96 CONTINENTAL, MARK VIII 1995-96 MYSTIQUE LIGHT TRUCK: 1983-96 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1984-90 BRONCO II 1986-96 AEROSTAR 1987-96 F SUPER DUTY 1991-96 EXPLORER 1993-96 VILLAGER 1995-96 WINDSTAR ISSUE: California introduced CaRFG around March 1, 1996 and statewide it must be available at all service stations by June 1, 1996 to help reduce emissions and improve gasoline quality. It will replace the traditional gasoline sold in Northern California and improve the reformulated gasoline that has been sold in Southern California since January 1995. California Air Resources Board (CARB) projects smog forming emissions from motor vehicles to be reduced by about 15 percent. ACTION: The following text is provided to give some answers to some commonly asked questions by our customers. POSITION Ford Motor Company recommends the use of CaRFG as a cost effective means of reducing emissions to provide cleaner air. We have participated in vehicle and laboratory testing of CaRFG to make sure it is acceptable for our customers' use. There are no unusual vehicle performance concerns expected based upon these studies. The use of CaRFG will not affect Ford's new vehicle and/or emissions warranty. WHAT DOES CaRFG CONSIST OF? CaRFG consists of the same basic components as other gasolines, but it reduces pollution because of its cleaner burning components. Features are: ^ reduced aromatic hydrocarbons to form less smog emissions ^ added oxygenates to reduce emissions ^ decreases the amount of fuel evaporating from the vehicle ^ lowered sulfur content to provide more efficient operation of the vehicle's catalytic converter Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3854 ^ reduced benzene by about one-half IS CaRFG MORE HAZARDOUS THAN CONVENTIONAL GASOLINES? CaRFG is a hazardous substance like conventional gasoline. Precautions should continue to be taken to avoid exposure to vapors or liquid when it is pumped or handled. It should never be siphoned or swallowed. HOW WILL CaRFG AFFECT VEHICLE PERFORMANCE? Properly blended CaRFG should have no adverse effect on vehicle performance or the durability of engine and fuel system components. Its basic properties are not significantly different than other cleaner burning gasolines that have been used in the U.S. for several years. If the vehicle is a certified California calibration 1996 or later model year, it was designed to operate on CaRFG gasoline. The vehicle will operate satisfactorily on gasolines in the other 49 states, but emission control system performance may be affected. Using gasolines other than CaRFG have substantially increased emissions from motor vehicles. WILL THE USE OF CaRFG AFFECT CALIFORNIA VEHICLE WARRANTY? No. The coverage of Ford's new vehicle warranty is not affected. In fact, Ford Owner Guides have consistently approved the use of properly blended reformulated gasolines containing oxygenates. Further information about properly fueling your vehicle is included in the Owner Guide. WILL FUEL ECONOMY BE AFFECTED? A very small reduction in fuel economy of less than one-half mile per gallon is possible if the customer was using gasoline without oxygenates. This is attributed to the lower energy content of oxygenates which have been in all Southern California gasolines since January of 1995 and in some gasolines since the 1970's. Many factors affect fuel economy like driving habits, vehicle maintenance, weather conditions, etc. Fuel economy can vary by more than a mile per gallon from one fill-up to the next with the same gasolines. For further details see TSB Article 95-12-2 for customer expectations regarding fuel economy. ARE SPECIAL ADDITIVES NECESSARY FOR CaRFG? No. It is not necessary to add anything to the vehicle fuel tank after the gasoline is purchased from the service station. California regulations require deposit control additives in CaRFG to minimize port fuel injector and intake valve deposits. WILL OLDER VEHICLES OPERATE SATISFACTORILY WITH THE NEW CaRFG? Older vehicles are expected to operate satisfactorily on CaRFG because vehicles have been operating on gasolines similar to CaRFG for a number of years. However, considerable testing indicates that older, high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasolines. Owners of these older vehicles are encouraged to follow their vehicle manufacturer's recommendations regarding vehicle maintenance. WILL THE SMELL BE DIFFERENT THAN CONVENTIONAL GASOLINE? CaRFG is not expected to smell different than the gasoline most vehicles are currently using. If an unusual odor is noticed, it would probably be from oxygenates. Most service stations use vapor recovery systems to minimize the release of gasoline vapors while refueling. The use of CaRFG should result in little or no "rotten egg" smell from the exhaust because CaRFG has much lower sulfur than conventional gasoline. WAS CaRFG TESTED BEFORE INTRODUCTION? It was tested for over five million miles in more than 800 vehicles under the guidance of CARB including experts representing automobile manufacturers, gasoline suppliers, fleet operations and government. There was no increase in problems identified with the use of CaRFG. DOES CaRFG COST MORE? The price at the pump cannot be accurately predicted, although a modest increase is likely. The price of CaRFG is subject to the competitive forces in the marketplace. Many factors including production costs, supply and demand, weather, crude oil prices, and taxes affect gasoline prices. WHERE CAN I GET MORE INFORMATION ON CaRFG? Additional information within the state of California on CaRFG is available from the California Air Resources Board toll-free at 1-800-922-7349 (within California only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3855 OTHER APPLICABLE ARTICLES: 95-12-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 623000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 91813 > Apr > 91 > Engine - Rough Idle/Hesitation/Backfire/Stalling Fuel: All Technical Service Bulletins Engine - Rough Idle/Hesitation/Backfire/Stalling Article No. 91-8-13 04/17/91 FUEL - USE OF UNLEADED GASOLINES - TIPS TO AVOID LEAN AIR - FUEL CONDITIONS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY, F47, F53 1991 EXPLORER ISSUE: Rough idle, hesitation, poor throttle response, induction backfire and stalls during cold start/warm up may be caused by the poor volatility of some high octane premium grade unleaded fuels (91 octane or higher (R+M)/2). When compared to regular grade unleaded fuel (87 octane (R+M)/2), high octane premium grade unleaded fuel may cause long crank time. ACTION: Use a regular grade unleaded fuel in all vehicles, except where a premium unleaded fuel is recommended in the Owner Guide. If lean air-fuel type symptoms are experienced, determine the grade and brand of fuel used and offer the following service tips. ^ Advise those using a higher octane grade fuel to switch to a regular grade unleaded fuel. For those using a regular grade fuel, advise them to try another brand. ^ Do not advise using a higher octane unleaded fuel than is recommended for that specific engine. Ford engines are designed to perform best using a high quality regular grade unleaded fuel. ^ Only advise using a higher octane unleaded fuel to avoid potentially damaging spark knock or ping, but do so only after mechanical fixes are ineffective. NOTE: ALL UNLEADED GASOLINES USED SHOULD CONTAIN DETERGENT ADDITIVES THAT ARE ADVERTISED AS HAVING "KEEP CLEAN" OR "CLEAN UP" PERFORMANCE FOR BOTH INTAKE VALVES AND FUEL INJECTORS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 98-26-2 > Jan > 99 > Fuel - Volatility Related Driveability Concerns Fuel: All Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 98-26-2 > Jan > 99 > Fuel - Volatility Related Driveability Concerns > Page 3865 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline Fuel: All Technical Service Bulletins Fuel - California Reformulated Gasoline Article No. 96-10-7 05/06/96 FUEL - CALIFORNIA REFORMULATED GASOLINE (CARFG) - SERVICE TIP FORD: 1983-86 LTD 1983-88 EXP 1983-96 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1985-94 TEMPO 1986-96 TAURUS 1989-96 PROBE 1995-96 CONTOUR LINCOLN-MERCURY: 1980-83 MARK VI 1983-88 LN7 1983-96 COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1985-94 TOPAZ 1986-96 SABLE 1991-96 TRACER 1993-96 CONTINENTAL, MARK VIII 1995-96 MYSTIQUE LIGHT TRUCK: 1983-96 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1984-90 BRONCO II 1986-96 AEROSTAR 1987-96 F SUPER DUTY 1991-96 EXPLORER 1993-96 VILLAGER 1995-96 WINDSTAR ISSUE: California introduced CaRFG around March 1, 1996 and statewide it must be available at all service stations by June 1, 1996 to help reduce emissions and improve gasoline quality. It will replace the traditional gasoline sold in Northern California and improve the reformulated gasoline that has been sold in Southern California since January 1995. California Air Resources Board (CARB) projects smog forming emissions from motor vehicles to be reduced by about 15 percent. ACTION: The following text is provided to give some answers to some commonly asked questions by our customers. POSITION Ford Motor Company recommends the use of CaRFG as a cost effective means of reducing emissions to provide cleaner air. We have participated in vehicle and laboratory testing of CaRFG to make sure it is acceptable for our customers' use. There are no unusual vehicle performance concerns expected based upon these studies. The use of CaRFG will not affect Ford's new vehicle and/or emissions warranty. WHAT DOES CaRFG CONSIST OF? CaRFG consists of the same basic components as other gasolines, but it reduces pollution because of its cleaner burning components. Features are: ^ reduced aromatic hydrocarbons to form less smog emissions ^ added oxygenates to reduce emissions ^ decreases the amount of fuel evaporating from the vehicle ^ lowered sulfur content to provide more efficient operation of the vehicle's catalytic converter Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3870 ^ reduced benzene by about one-half IS CaRFG MORE HAZARDOUS THAN CONVENTIONAL GASOLINES? CaRFG is a hazardous substance like conventional gasoline. Precautions should continue to be taken to avoid exposure to vapors or liquid when it is pumped or handled. It should never be siphoned or swallowed. HOW WILL CaRFG AFFECT VEHICLE PERFORMANCE? Properly blended CaRFG should have no adverse effect on vehicle performance or the durability of engine and fuel system components. Its basic properties are not significantly different than other cleaner burning gasolines that have been used in the U.S. for several years. If the vehicle is a certified California calibration 1996 or later model year, it was designed to operate on CaRFG gasoline. The vehicle will operate satisfactorily on gasolines in the other 49 states, but emission control system performance may be affected. Using gasolines other than CaRFG have substantially increased emissions from motor vehicles. WILL THE USE OF CaRFG AFFECT CALIFORNIA VEHICLE WARRANTY? No. The coverage of Ford's new vehicle warranty is not affected. In fact, Ford Owner Guides have consistently approved the use of properly blended reformulated gasolines containing oxygenates. Further information about properly fueling your vehicle is included in the Owner Guide. WILL FUEL ECONOMY BE AFFECTED? A very small reduction in fuel economy of less than one-half mile per gallon is possible if the customer was using gasoline without oxygenates. This is attributed to the lower energy content of oxygenates which have been in all Southern California gasolines since January of 1995 and in some gasolines since the 1970's. Many factors affect fuel economy like driving habits, vehicle maintenance, weather conditions, etc. Fuel economy can vary by more than a mile per gallon from one fill-up to the next with the same gasolines. For further details see TSB Article 95-12-2 for customer expectations regarding fuel economy. ARE SPECIAL ADDITIVES NECESSARY FOR CaRFG? No. It is not necessary to add anything to the vehicle fuel tank after the gasoline is purchased from the service station. California regulations require deposit control additives in CaRFG to minimize port fuel injector and intake valve deposits. WILL OLDER VEHICLES OPERATE SATISFACTORILY WITH THE NEW CaRFG? Older vehicles are expected to operate satisfactorily on CaRFG because vehicles have been operating on gasolines similar to CaRFG for a number of years. However, considerable testing indicates that older, high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasolines. Owners of these older vehicles are encouraged to follow their vehicle manufacturer's recommendations regarding vehicle maintenance. WILL THE SMELL BE DIFFERENT THAN CONVENTIONAL GASOLINE? CaRFG is not expected to smell different than the gasoline most vehicles are currently using. If an unusual odor is noticed, it would probably be from oxygenates. Most service stations use vapor recovery systems to minimize the release of gasoline vapors while refueling. The use of CaRFG should result in little or no "rotten egg" smell from the exhaust because CaRFG has much lower sulfur than conventional gasoline. WAS CaRFG TESTED BEFORE INTRODUCTION? It was tested for over five million miles in more than 800 vehicles under the guidance of CARB including experts representing automobile manufacturers, gasoline suppliers, fleet operations and government. There was no increase in problems identified with the use of CaRFG. DOES CaRFG COST MORE? The price at the pump cannot be accurately predicted, although a modest increase is likely. The price of CaRFG is subject to the competitive forces in the marketplace. Many factors including production costs, supply and demand, weather, crude oil prices, and taxes affect gasoline prices. WHERE CAN I GET MORE INFORMATION ON CaRFG? Additional information within the state of California on CaRFG is available from the California Air Resources Board toll-free at 1-800-922-7349 (within California only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 3871 OTHER APPLICABLE ARTICLES: 95-12-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 623000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information > Technical Service Bulletins > Page 3872 Fuel: Testing and Inspection PREPARATION Obtain a fuel sample from the bottom of the fuel tank so that any water present will be detected. The sample should be bright and clear. If the sample appears cloudy or contaminated with water (indicated by a layer at the bottom of the sample), this procedure should not be used and fuel system should be cleaned. TESTING 1. Fill a 100 ml cylinder with 1 ml graduation marks to the 90 ml mark. 2. Add 10 ml of water to bring the total fluid volume to 100 ml. Install a stopper. 3. Shake vigorously for 10 to 15 seconds. 4. Loosen stopper to release pressure. 5. Close stopper and repeat shaking for 10 to 15 seconds. 6. Place the cylinder on a level surface for approximately 5 minutes to allow adequate liquid separation. RESULTS EVALUATION If alcohol is present, the volume of the lower layer (now containing both alcohol and water) will be greater than 10 ml. For example, if lower layer volume is increased to 15 ml, it indicates at least 5 percent alcohol in the fuel. The actual amount of alcohol may be somewhat greater because this procedure does not extract all alcohol from fuel. Allowable Alcohol/Fuel Concentration Alcohol/Fuel Type % by Volume Methanol (Wood Alcohol) 5.0% Ethanol (Grain Alcohol) 10.0% MTBE (Methyl Tertiary Butyl Ether) 15.0% Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions Fuel Pressure Release: Service Precautions WARNING: Do not smoke, carry lighted tobacco or an open flame of any type when fueling vehicle or when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. NOTE: Methanol and ethanol are not interchangeable. Methanol fuel can be used only in vehicles designed for methanol fuels. Ethanol fuel can be used only in vehicles designed for ethanol fuels. WARNING: The fuel tubes leading from the fuel tank to the engine are under pressure during vehicle operation. When fuel injected engines are turned off, the fuel in the fuel tubes remains pressurized for long periods of time to provide quick start-ups. Special procedures for servicing these pressurized fuel systems are outlined in this section. These procedures should be followed to prevent accidental spraying of fuel, causing personal injury or a fire hazard. WARNING: Do not swallow fuel of any kind. Fuels such as methanol or fuel ethanol and gasoline or mixtures of these fuels are highly toxic and if swallowed can cause death or permanent injury. Swallowing methanol can also cause blindness. Immediately seek medical attention from a physician or poison control center to treat anyone who has swallowed fuel. Be aware that if fuel is swallowed, the onset of potential ill health effects may be delayed 12-24 hours. AVOID INHALING FUEL VAPORS. INHALING TOO MUCH FUEL VAPOR OF ANY KIND CAN LEAD TO EYE AND RESPIRATORY TRACT IRRITATION. IN SEVERE CASES, EXCESSIVE OR PROLONGED BREATHING OF FUEL VAPORS CAN CAUSE SERIOUS ILLNESS AND PERMANENT INJURY. AVOID GETTING FUEL LIQUID IN YOUR EYES. IF YOU GET ANY FUEL IN YOUR EYES, REMOVE CONTACT LENSES (IF WORN), FLUSH IMMEDIATELY WITH PLENTY OF WATER FOR AT LEAST 15 MINUTES AND SEEK MEDICAL ATTENTION. ALLOWING ANY FUEL TO GET IN YOUR EYES WILL CAUSE SEVERE IRRITATION. FAILURE TO SEEK PROPER MEDICAL ATTENTION FOR FUEL CONTACT WITH THE EYES COULD LEAD TO PERMANENT INJURY. IF YOU GET ANY FUEL ON YOUR SKIN, WASH WITH SOAP AND WATER. REPEATED OR PROLONGED SKIN CONTACT WITH FUEL LIQUID OR VAPOR CAUSES SKIN IRRITATION. MAKE SURE YOU WASH YOUR HANDS BEFORE HANDLING FOOD. FUELS CONTAINING GASOLINE SUCH AS FUEL METHANOL AND FUEL ETHANOL MAY CONTAIN BENZENE, WHICH IS A CANCER-CAUSING AGENT. IF YOU ARE TAKING MEDICATION FOR THE TREATMENT OF ALCOHOLISM, SUCH AS ANTABUSE OR OTHER FORMS OF DISULFIRAM, SKIN CONTACT WITH FUEL METHANOL, FUEL ETHANOL OR BREATHING THEIR VAPORS CAN CAUSE THE SAME KIND OF ADVERSE REACTION AS DRINKING ALCOHOLIC BEVERAGES. IN SENSITIVE INDIVIDUALS, SERIOUS PERSONAL INJURY OR SICKNESS COULD RESULT. IF YOU ARE TAKING SUCH MEDICATION, YOU SHOULD TAKE EXTRA CARE TO AVOID SKIN CONTACT WITH FUEL AND TO AVOID BREATHING ITS VAPORS. IF YOU DO GET FUEL ON YOUR SKIN, WASH IT OFF IMMEDIATELY. CONSULT A PHYSICIAN PROMPTLY IF YOU EXPERIENCE AN ADVERSE REACTION. WARNING: Do not modify the fuel system configuration or components or replace components with parts not especially designed for use with fuel methanol. Ford motor company has specially-designed the materials, components and system configuration for methanol-fueled vehicles and each particular system is precisely calibrated for efficient operation. Ford ethanol vehicles require the same parts as the methanol-fueled vehicles, but are calibrated specifically for gasoline/ethanol-blended fuels. The use of different parts or materials could produce an untested configuration that could result in fire, personal injury or cause engine damage. WARNING: Do not operate engine or smoke while refueling. WARNING: Use of the incorrect fuel or blending of fuels can result in severe engine damage. Refer to fuel filler door for vehicle-specific fuel usage. WARNING: It is important that your flexible fuel vehicle be properly maintained by ford flexible fuel trained personnel. If a problem occurs, it is important that properly trained personnel diagnose the cause. If the problem relates to the fuel system, proper part replacement is imperative to keep your vehicle operating at normal performance. Flexible fuel components and standard fuel components are not interchangeable. If your vehicle is not serviced in accordance with flexible fuel vehicle procedures, damage may occur and your warranty may be invalidated. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure Release > System Information > Service Precautions > Page 3877 Fuel Pressure Release: Service and Repair WARNING: Do not smoke, carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited, resulting in possible personal injury. CAUTION: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before servicing of the fuel system is begun. A valve is provided on the throttle body for this purpose. Remove the air cleaner and relieve system pressure by using Rotunda pressure gauge tool T80L-9974-A or equivalent and drain the system through the drain tube. Release pressure from fuel system at the fuel pressure relief valve using tool No. T80L-9974-B or equivalent. When relieving fuel pressure, crank engine with fuel pump electrical connector disconnected. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel Injector - Removal Procedure Revision Fuel Injector: Technical Service Bulletins Fuel Injector - Removal Procedure Revision SHOP MANUAL - 1989 - PAGE 24-11-11 - LOWER INTAKE MANIFOLD ILLUSTRATION IN STEP 6 REVISED Article No. 90-12B-10 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel Injector - Removal Procedure Revision > Page 3882 ISSUE: The illustration of the lower intake manifold in Step 6 of the Fuel lnjector Removal procedure on page 24-11-11 of the 1989 Thunderbird/Cougar Shop Manual is incorrect. ACTION: Refer to the pages following this TSB article for the revised illustration. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel Injector - Removal Procedure Revision > Page 3883 Fuel Injector: Technical Service Bulletins Fuel Injector Cleaner - Parts and Service Tips Article No.: 94-8-9 FUEL SYSTEM - MOTORCRAFT FUEL INJECTOR CLEANER - REPAIR PARTS AND SERVICE TIPS FORD: 1987-88 EXP 1987-90 TAURUS, TEMPO 1987-91 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1990 PROBE LINCOLN-MERCURY: 1987-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR 1988-89 TRACER 1991 TRACER LIGHT TRUCK: 1987-90 BRONCO 1987-91 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, F-47, F-53, RANGER 1991 EXPLORER ISSUE: The Motorcraft fuel injector cleaning system consists of: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel Injector - Removal Procedure Revision > Page 3884 ^ The original all-car fuel injector cleaning kit (CM1000), ^ The new Ford-application fuel injector kit (CM 1002) and ^ Motorcraft Pressurized fuel injector cleaner (CM1001). The Motorcraft Fuel injector cleaning method was introduced in TSB 91-19-3 as an alternate to the Rotunda Fuel Injector Tester / Cleaner, and is reimbursable as specified in the Service Labor Time Standards Manual. The Motorcraft injector cleaning system is available from the regular Parts Distribution System or from local Motorcraft Distributors. ACTION: No action is required. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel Injector - Removal Procedure Revision > Page 3885 NOTE: THIS TSB ARTICLE SUMMARIZES THE QUESTIONS ASKED MOST FREQUENTLY BY CALLERS TO THE MOTORCRAFT "800" LINE ABOUT THE MOTORCRAFT FUEL INJECTOR CLEANING METHOD. ALSO, A TOLL-FREE NUMBER IS AVAILABLE FOR ORDERING CLEANING KIT PARTS, OBTAINING INFORMATION AND MAKING SUGGESTIONS. Q. Why do we sometimes experience insufficient pressure to completely empty a cleaning can? A. If the can is pierced properly, you will seldom experience problems with inadequate pressure. However, to further reduce those instances of insufficient pressure to complete the cleaning process, Motorcraft recently made available a re-pressurizing device (S-79), which is included with all CM1000 and CM1002 kits, and is also available separately. The device allows service personnel to repressurize the can using compressed air whenever there is too little pressure to complete the cleaning procedure. Although there have been some cases of actual low can pressure, by far, the largest number of low pressure complaints have been due to improper can piercing. For best results, In addition to being hung upside-down, during the cleaning process, the can must also be upside-down pierced. Q. Why is it imperative that the can be pierced upside-down? A. Motorcraft fuel injector cleaner and the pressurizing gas are packaged together in an aerosol can. The piercing device contains a seal, which is intended to seal against the threaded cup of the can before it is pierced. When using a new piercing device with a new seal, the can needn't be upside-down. However, after a few cans have been pierced, the piercing device seal becomes compressed, and piercing can take place before the seal makes full contact with the can. The gas is always at the top of the can. Thus, if the can is pierced right-side up, the gas can rapidly escape before the seal makes full contact, resulting in insufficient pressure to do the cleaning job. If the can is upside-down when pierced, the liquid cleaner is in contact with the component being pierced, and the worst that can happen before the seal makes contact is the loss of a few drops of cleaner. Service personnel sometimes question the need to pierce the CM1001 cans upside-down, particularly if they have had experience with another injector cleaner packaged in what is referred to as a "barrier pack" can. In this case, the cleaner is in an inner aluminum tube which is surrounded by the pressurizing agent. In a barrier pack can, the pressurizing agent cannot escape unless a small rubber plug at the bottom of the can is removed. Q. Why isn't CM1001 packaged in a barrier pack can? A. There are several reasons. First, Motorcraft wants to provide an environmentally safe package, so it was decided to use compressed air or nitrogen to provide the pressure. It was not possible to use either of these gasses in the barrier pack cans since the cans cannot contain the required pressure for compressed air or nitrogen. Barrier cans generally use liquid propellant mixtures, and pressure is limited to 65-70 psig. Also, with the barrier pack, upon completion of the cleaning procedure, a small amount of product remains in the collapsed inner tube, and the outer shell still contains the liquid propellant, which requires proper disposal. When the CM1001 can is empty, neither product nor pressurizing gas remains in the can. Finally, the barrier pack can is considerably more expensive, and Motorcraft wanted to offer the most cost-effective cleaner possible. Q. How can dealers obtain replacement and supplemental parts? Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel Injector - Removal Procedure Revision > Page 3886 A. At the present time, all supplemental and replacement parts sales are handled directly by Shrader Canada Limited. Also, a toll-free number is available for ordering cleaning kit parts (1-800-662-6891). The Motorcraft fuel injector cleaner parts list/price sheet is shown in Figure 1. The most frequently ordered parts are the S-20 Ford 5/16-32 multipoint adapter, the S-35 can suspension bracket and S-70 can piercing device, followed (in approximate order) by the S-67 and S-62 seals, the S-72 diaphragm, disassembly tools S-17, S-18, S-41, and S-42, the S-44 plug, the S-45 and S-61 adapters, the S-48 female loop, the S-38 regulator and the S-69 supply assembly. Additional questions concerning the purchase of supplemental parts should be directed to Shrader Canada Limited, at 1-800-662-6891. LIMITED TIME OFFER A new installation video is available, and is included as part of CM-1002, Ford Application Kit. While supplies last, a free copy of the video will be Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel Injector - Removal Procedure Revision > Page 3887 provided to requesting dealerships who call 1-800-662-6891. OTHER APPLICABLE ARTICLES: 91-19-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel Injector - Removal Procedure Revision > Page 3888 Fuel Injector: Technical Service Bulletins Fuel Injectors - Rotunda Injector Tester/Cleaner INJECTOR TESTER/CLEANER-ROTUNDA MODEL 113-00001-MAINTENANCE REQUIREMENTS Article No. 89-15-3 FORD: 1984-89 ESCORT, EXP, TEMPO 1986-89 CROWN VICTORIA, MUSTANG, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1984-89 COUGAR 1984-87 LYNX 1984-89 TOPAZ 1986 CAPRI 1986-89 CONTINENTAL, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR 1988-89 TRACER MERKUR: 1987-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-89 F-150, F-250, F-350, RANGER 1986-89 AEROSTAR, ECONOLINE ISSUE: Proper maintenance and good working condition of the Rotunda Injector Tester/Cleaner, 113-00001, is essential for reliable diagnosis and cleaning of multi-port fuel injectors. If the equipment is not properly maintained, premature failure can result and flowmeter contamination can occur. This can cause erroneous float readings and result in improper diagnosis. ACTION: Use the following injector tester/cleaner maintenance techniques and procedures to ensure proper operation of the equipment. 1. Always use a good quality, clean and filtered gasoline in the tester tank. 2. Never leave a mixture of injector power flush and gasoline in the tester after use. 3. Always rinse the tester out by circulating clean gasoline through the unit before storage. 4. Flush the unit with denatured alcohol at least once a month. a. Allow the fluid to recirculate several minutes, while switching the flowmeter selection valve from # 1 to # 2 several times. b. Discard the mixture and repeat the procedure. 5. Change the fuel filter every other month. 6. Always calibrate the flowmeters before testing. OTHER APPLICABLE ARTICLES: 88-17-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000, 4500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel Injector - Removal Procedure Revision > Page 3889 Fuel Injector: Technical Service Bulletins Fuel Injector - New Cleaning Method Article No. 91-19-3 09/18/91 FUEL SYSTEM - NEW FUEL INJECTOR CLEANING METHOD - (3.OL PROBE ONLY) FORD: 1987-88 EXP 1987-90 TAURUS, TEMPO 1987-91 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1990 PROBE LINCOLN-MERCURY: 1987 LYNX 1987-90 SABLE, TOPAZ 1987-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR 1990-91 TRACER LIGHT TRUCK: 1987-90 BRONCO II 1987-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY, F-47, F-53 1991 EXPLORER ISSUE: A new warranty-reimbursable method is now available for cleaning standard design pintle fuel injectors. (Deposit Resistant Injectors "DRI's" do not require cleaning.) This new method is an alternate to the current procedure which utilizes the Rotunda Fuel lnjector Tester/Cleaner and is reimbursable as specified in the Labor Time Standards Manual. ACTION: If standard design pintle fuel injectors require cleaning, use the new cleaning method which utilizes Motorcraft Pressurized Fuel lnjector Cleaner (CM-1001) and the Motorcraft Fuel Injection Cleaning Kit (CM-1000). Both of these items are available from the regular Parts Distribution System or the local Motorcraft Distributor. The kit features: ^ Application for most Ford and Lincoln-Mercury EFI vehicles. ^ Application for most other domestic and import EFI vehicles. ^ Effective for both central and multi-port EFI systems. ^ Quick and easy hook up. ^ Uses pre-mixed Motorcraft Pressurized Fuel Injector Cleaner. ^ Environmentally-compatible can pressurizing. ^ Steel wire-reinforced hoses. ^ Easy-to-follow illustrated Instruction Manual provides step-by-step connection and cleaning procedures. ^ Includes replacement parts kit with seals, washers, regulator diaphragms and dust caps. ^ Full 1-year Manufacturer's Warranty on defects in materials and/or workmanship. ^ Completely reorderable components. PART NUMBER PART NAME CLASS CM-1001 Motorcraft Pressurized Fuel Z Injector Cleaner CM-1000 Motorcraft Fuel Injection Z Cleaning Kit OTHER APPLICABLE ARTICLES: NONE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Technical Service Bulletins > Fuel Injector - Removal Procedure Revision > Page 3890 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 490000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications Fuel Injector: Electrical Specifications FUEL INJECTOR RESISTANCE .......................................................................................................................................................... 13.0-16.0 OHMS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Electrical Specifications > Page 3893 Fuel Injector: Mechanical Specifications FUEL INJECTOR RESISTANCE .......................................................................................................................................................... 13.0-16.0 OHMS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Specifications > Page 3894 Fuel Injector: Locations FUEL INJECTORS: The fuel injectors are mounted in the lower intake manifold. FUEL PRESSURE REGULATOR: The fuel pressure regulator is attached to the fuel supply manifold. FUEL FILTER: The filter is located downstream of the electric electric fuel pump and is mounted on the underbody. FUEL PUMP: The fuel pump is mounted on the fuel sender assembly inside of the fuel tank. FUEL PUMP RELAY: LH side of trunk, behind wheelwell. INERTIA SWITCH: The inertia switch is located on the LH side of trunk, behind wheelwell. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions Fuel Injector: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 3897 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Diagram Information and Instructions > Page 3898 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3899 Fuel Injector: Description and Operation Fuel Injector PURPOSE The fuel injector atomizes and meters high pressure fuel delivered to the engines intake system. LOCATION Injectors are mounted in the lower intake manifold and positioned so their tips are directing fuel just ahead of the engine intake valves. CONSTRUCTION The low carbon steel electro-mechanical device consists of: A solenoid - Needle and valve assembly. The solenoid has an armature and a needle or ball valve with a spring holding the needle or ball closed against the valve seat. OPERATION The Electronic Control Assembly (ECA) activates the injector solenoid causing the pintle to move inward off the seat, allowing fuel flow through the orifice. The amount of fuel delivered by the injector depends on the amount of time that the injector nozzle is open. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3900 Fuel Injector: Testing and Inspection NOTE: Make sure injectors have been cleaned with an approved cleaner prior to testing. The injector balance test is done to verify a balance distribution of fuel to all cylinders. Start by hooking up a fuel pressure gauge at the schrader valve or in-line before the fuel pressure regulator (refer to gauge manufacturer instructions). Pressurize fuel rail by turning ignition ON engine OFF (fuel pump energized). The pressure should rise to maximum working pressure. Refer to SPECIFICATIONS. Remove injector harness connector and connect an injector pulse tester, pulse one injector at a time. Allow pressure to rise and stabilize in between each injector tested. NOTE: The time each injector is pulsed is very important. Each injector should be pulsed at the same time interval, (example . . 1 ms each). The rate of drop should be even across all the injectors. All pressure drops should be within 3% of each other, if not replace injector. If there is no pressure drop when injector is pulsed, verify there is a good connection between the injector and pulse tester. If connection is good, a check of the injector circuit is required. First, check the resistance of the injector, if resistance is OK verify there is power to injector by reconnecting the injector harness connector and start the engine, use a "Noid" light to check for pulses (light off and on). If it does not light this is an indication of a problem in the injector to ECM circuit. Refer to COMPUTERIZED ENGINE CONTROLS for further testing. If light pulses, recheck pressure drop to verify malfunction. NOTE: It may not be possible to connect a noid light to the harness while connected to injector. If this is the case, disconnect harness and connect noid light to harness and check pulses. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3901 Fuel Injector: Service and Repair REMOVAL Fuel Injector 1. Release fuel pressure from fuel system. 2. Carefully remove electrical harness connectors from individual injectors. 3. Disconnect throttle linkage at throttle ball. Disconnect AOD transmission linkage from throttle body. Remove two bolts securing throttle linkage bracket to intake. Position bracket with cables out of way. CAUTION: When disconnecting throttle cable from ball stud and pry slowly. Pulling by hand may damage the cable. 4. Disconnect upper intake manifold vacuum fitting connections by disconnecting all vacuum lines to vacuum tree, vacuum lines to EGR valve, and vacuum line to fuel pressure regulator. 5. Disconnect PCV system by disconnecting hose from fitting on rear of upper manifold. 6. Remove canister purge line(s) from fitting(s) on throttle body. 7. Disconnect water heater lines from the throttle body. 8. Disconnect EGR tube from EGR valve by removing flange nut. 9. Remove bolt from upper intake support bracket to upper manifold. 10. Remove six upper intake manifold retaining bolts. 11. Remove upper intake and throttle body as an assembly from lower intake manifold. Fuel Injector 12. Grasping injector body, pull up while gently rocking injector from side to side. Fuel Injector 13. Inspect injector rings (two per injector) for signs of deterioration. Replace as needed. CAUTION: Do not attempt to clean the injector pintle or metering orifice with tools or brushes. INSTALLATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component Information > Diagrams > Page 3902 1. Lubricate new O-rings with a light grade oil and install two on each injector. CAUTION: Never use silicone grease. It will clog the injectors. 2. Install injector(s) using light, twisting, pushing motion. 3. Secure the fuel supply manifold assembly using four retaining bolts. Tighten to 87 lb. in. (10 N-m). 4. Connect the fuel inlet and outlet lines at the fuel rail connections. Push in to connect. Connect fuel line retaining clips. 5. Position new gasket on lower intake mounting face. The use of alignment studs may be helpful. 6. Install electrical harness connectors to injectors. 7. Install upper intake manifold and throttle body assembly to lower manifold making sure gasket remains in place (if alignment studs aren't used). 8. Install six upper intake manifold retaining bolts and tighten to 24 lb. ft. (32 N-m). 9. Install upper intake support bracket to upper manifold attaching bolt. 10. Install EGR tube. 11. Install canister purge lines to fittings on throttle body. 12. Connect water heater lines to the throttle body. 13. Connect PCV hose to rear of upper manifold. 14. Connect vacuum lines to vacuum tree, EGR valve, and fuel pressure regulator. 15. Position throttle linkage bracket with cables to upper intake manifold. Install two attaching bolts and tighten TO 13 lb. ft. (17 N-m). Connect throttle cable and transmission cable to throttle body. 16. Connect electrical connectors at air bypass valve, TP sensor, and EGR position sensor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Fuel Pressure Regulator - Obsolete Part Return Fuel Pressure Regulator: Technical Service Bulletins Fuel Pressure Regulator - Obsolete Part Return Article No. 94-1-5 01/12/94 SERVICE PARTS RETURN OF OBSOLETE FUEL PRESSURE REGULATORS FORD: 1988-94 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1988-94 CONTINENTAL, COUGAR, SABLE 1991-94 TRACER ISSUE: New improved design fuel pressure regulators replace the obsolete parts. ACTION: Remove and return the obsolete parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. 1. Return obsolete parts (E6AZ-9C968-A, E8DZ-9C968-A and F1DZ-9C968-A) to your facing PDC using the least expensive transportation. 2. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". 3. In the Remarks Section write "Returned per TSB 94-1-5". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. NOTE: PARTS ARE OBSOLETE AND REPLACED BY (F4CZ-9C968-A and F4TZ-9C968-A) WHICH ARE AVAILABLE FOR ORDERING. PART NUMBER PART NAME CLASS F4CZ-9C968-A Fuel Pressure Regulator A F4TZ-9C968-A Fuel Pressure Regulator A OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 3907 Fuel Pressure Regulator: Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 3908 Fuel Pressure Regulator: Locations FUEL INJECTORS: The fuel injectors are mounted in the lower intake manifold. FUEL PRESSURE REGULATOR: The fuel pressure regulator is attached to the fuel supply manifold. FUEL FILTER: The filter is located downstream of the electric electric fuel pump and is mounted on the underbody. FUEL PUMP: The fuel pump is mounted on the fuel sender assembly inside of the fuel tank. FUEL PUMP RELAY: LH side of trunk, behind wheelwell. INERTIA SWITCH: The inertia switch is located on the LH side of trunk, behind wheelwell. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 3909 Fuel Pressure Regulator: Description and Operation Typical Fuel Pressure Regulator PURPOSE The fuel pressure regulator controls fuel pressure supplied to the injectors. The regulator also traps fuel during engine shutdown, thus eliminating the possibility of vapor formation in the fuel line, and provides instant restarts and initial idle speed. OPERATION Balancing one side of the diaphragm with manifold vacuum maintains a constant fuel pressure drop across the injectors. Fuel in excess of that used by the engine is bypassed through the regulator and returns to the fuel tank. CONSTRUCTION The regulator is a spring loaded diaphragm operated relief valve. One side of the diaphragm senses fuel pressure and the other side is connected to intake manifold vacuum. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator > Component Information > Technical Service Bulletins > Page 3910 Fuel Pressure Regulator: Service and Repair REMOVAL 1. Disconnect battery ground cable and secure it out of the way. 2. Remove fuel cap. 3. Release pressure from fuel system. 4. Remove vacuum line at pressure regulator. 5. Remove manifold inlet elbow. 6. Remove three retaining screws from regulator housing. 7. Remove pressure regulator assembly, gasket and O-ring. 8. If scraping is necessary, be careful not to damage fuel pressure regulator or fuel supply line gasket. INSTALLATION 1. Lubricate fuel pressure regulator O-ring with engine oil. NOTE: Never use silicone grease. It will clog the injectors. 2. Ensure gasket surfaces of fuel pressure regulator and fuel rail assemblies are clean. 3. Install O-ring and new gasket on regulator. 4. Install fuel pressure regulator on fuel rail assembly. Tighten the three retaining screws to 34 lb. in. (4 N-m). 5. Install manifold inlet elbow. 6. Install vacuum line to regulator. 7. Connect battery ground cable. 8. Add engine coolant. 9. Turn ignition switch from ON/OFF position several times without starting engine to check for fuel leaks. CAUTION: The fuel system is normally pressurized to 39 psi. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 8987 > Apr > 89 > Fuel Pump Noisy Fuel Pressure Pulsation Damper: All Technical Service Bulletins Fuel Pump - Noisy ^ FUEL PUMP - NOISY - 3.8L ENGINE ^ NOISE - FUEL PUMP - 3.8L ENGINE Article No. 89-8-7 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1988-89 CONTINENTAL 1989 COUGAR ISSUE: A noise heard in the passenger compartment may be caused by the electric fuel pump inside the fuel tank. This is caused by lack of a pulse damper in the fuel pump/sender assembly. The affected vehicles are as follows: ^ Continental units built before 11/05/89 ^ Thunderbird/Cougar units built before 1/20/89. ACTION: Install a new design fuel pump/sender assembly that has an integral pulse damper. Refer to the fuel pump/sender application chart below for the correct service part. Use the following procedure for fuel pump/sender removal and installation. FUEL VEHICLE ENGINE FUEL TANK PUMP/SENDER Continental 3.8L Base All E90Z-9H307-A Thunderbird/Cougar 3.8L Base 19 gallon E9SZ-9H307-C Thunderbird/Cougar 3.8L "SC" 19 gallon E9SZ-9H307-D 1. Make sure the noise is coming from the fuel pump/sender assembly. 2. Drain the fuel from the tank into a suitable container for reuse later. 3. Remove the fuel tank from the vehicle. Refer to the appropriate model Shop Manual, Section 24-50 for service details. 4. Remove the fuel pump/sender assembly from the fuel tank. Refer to the appropriate model Shop Manual, Section 24-35 for service details. 5. Remove and throw away the old fuel pump/sender assembly and rubber O-ring gasket. 6. Install a new rubber O-ring gasket in the fuel ring groove on the fuel tank. Use service part E6DZ-9417-A for Thunderbird/Cougar units and E1VZ-9417-B for Continental units. 7. Install a new fuel pump/sender assembly in the fuel tank. 8. Reinstall the fuel tank in the vehicle. 9. Refill the tank with fuel. Use the fuel that was drained out in Step 2. PART NUMBER PART NAME CLASS E6DZ-9417-A Gasket - pkg. of 4 R E1VZ-9417-B Gasket - pkg. of 3 AM E90Z-9H307-A Fuel Pump/Sender Assembly B E9SZ-9H307-C Fuel Pump/Sender Assembly B E9SZ-9H307-D Fuel Pump/Sender Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage OPERATION DESCRIPTION TIME 890807A Continental 1.0 Hr. 890807A Thunderbird/Cougar 1.2 Hrs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 8987 > Apr > 89 > Fuel Pump Noisy > Page 3919 DEALER CODING BASIC PART NO. CONDITION CODE 9H307 56 OASIS CODES: 4500, 7100, 7113 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Technical Service Bulletins > Customer Interest: > 8987 > Apr > 89 > Fuel Pump - Noisy Fuel Pressure Pulsation Damper: Customer Interest Fuel Pump - Noisy ^ FUEL PUMP - NOISY - 3.8L ENGINE ^ NOISE - FUEL PUMP - 3.8L ENGINE Article No. 89-8-7 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1988-89 CONTINENTAL 1989 COUGAR ISSUE: A noise heard in the passenger compartment may be caused by the electric fuel pump inside the fuel tank. This is caused by lack of a pulse damper in the fuel pump/sender assembly. The affected vehicles are as follows: ^ Continental units built before 11/05/89 ^ Thunderbird/Cougar units built before 1/20/89. ACTION: Install a new design fuel pump/sender assembly that has an integral pulse damper. Refer to the fuel pump/sender application chart below for the correct service part. Use the following procedure for fuel pump/sender removal and installation. FUEL VEHICLE ENGINE FUEL TANK PUMP/SENDER Continental 3.8L Base All E90Z-9H307-A Thunderbird/Cougar 3.8L Base 19 gallon E9SZ-9H307-C Thunderbird/Cougar 3.8L "SC" 19 gallon E9SZ-9H307-D 1. Make sure the noise is coming from the fuel pump/sender assembly. 2. Drain the fuel from the tank into a suitable container for reuse later. 3. Remove the fuel tank from the vehicle. Refer to the appropriate model Shop Manual, Section 24-50 for service details. 4. Remove the fuel pump/sender assembly from the fuel tank. Refer to the appropriate model Shop Manual, Section 24-35 for service details. 5. Remove and throw away the old fuel pump/sender assembly and rubber O-ring gasket. 6. Install a new rubber O-ring gasket in the fuel ring groove on the fuel tank. Use service part E6DZ-9417-A for Thunderbird/Cougar units and E1VZ-9417-B for Continental units. 7. Install a new fuel pump/sender assembly in the fuel tank. 8. Reinstall the fuel tank in the vehicle. 9. Refill the tank with fuel. Use the fuel that was drained out in Step 2. PART NUMBER PART NAME CLASS E6DZ-9417-A Gasket - pkg. of 4 R E1VZ-9417-B Gasket - pkg. of 3 AM E90Z-9H307-A Fuel Pump/Sender Assembly B E9SZ-9H307-C Fuel Pump/Sender Assembly B E9SZ-9H307-D Fuel Pump/Sender Assembly OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage OPERATION DESCRIPTION TIME 890807A Continental 1.0 Hr. 890807A Thunderbird/Cougar 1.2 Hrs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Technical Service Bulletins > Customer Interest: > 8987 > Apr > 89 > Fuel Pump - Noisy > Page 3925 DEALER CODING BASIC PART NO. CONDITION CODE 9H307 56 OASIS CODES: 4500, 7100, 7113 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Pressure Pulsation Damper: > 9128 > Jan > 91 > Analog Speedometer - Inaccurate At High Speeds Speedometer Head: All Technical Service Bulletins Analog Speedometer - Inaccurate At High Speeds Article No. 91-2-8 January 23, 1991 SPEEDOMETER - ANALOG (CONVENTIONAL) - INACCURATE AT HIGH SPEEDS-VEHICLES BUILT BEFORE 4/01/90 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The base or performance analog speedometer may give inaccurate speed indications above 70 mph (112 km/h). This is caused by calibration tolerances within the speedometer head. ACTION: Install a new more accurate speedometer. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-10, for service details. SPEEDOMETER IDENTIFICATION Late model or improved speedometers can be identified by the white calibration dots located on the face of the speedometer at the 60 mph (100 km/h) graduation. Early production speedometers were not marked with calibration dots. NOTE: SPEEDOMETER PART NUMBERS WERE NOT CHANGED WHEN THE PRODUCTION CHANGES WERE IMPLEMENTED. PART NUMBERS FOR THE BASE AND PERFORMANCE SPEEDOMETERS ARE SHOWN IN THE PARTS BLOCK. PART NUMBER PART NAME CLASS FOSZ-17255-A Speedometer (English - Base B Analog) FOSZ-17255-B Speedometer (Metric - Base ZC Analog) FOSZ-17255-C Speedometer (English - B Performance Analog) FOSZ-17256-D Speedometer (Metric - ZC Performance Analog) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910208A Install Speedometer 1.2 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 17255 53 OASIS CODES: 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Pressure Pulsation Damper: > 9128 > Jan > 91 > Analog Speedometer - Inaccurate At High Speeds > Page 3931 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Pressure Pulsation Damper: > 8927 > Jan > 89 > Speedometer/Odometer - Inaccurate Readings Speedometer Head: All Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND ODOMETER READINGS Article No. 89-2-7 FORD: 1989 AND PRIOR ALL CAR LINES LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle components or systems. The information in this TSB article is intended to assist technicians in speedometer/odometer concern diagnosis. ACTION: Use the following supplemental information below to assist in speedometer/odometer diagnostics. OPERATION A mechanical analog speedometer displays vehicle speed and the odometer displays total distance traveled. The speedometer/odometer assembly is cable driven by either a transmission or a transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed so that all are identical and have no error in the speedometer head. Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the speedometer/odometer. An electronic signal is sent from a speed sensor to the digital speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle, similar to a cable. Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio and speedometer/odometer drive and driven gears. TIRES Improper tire rolling radius and inflation pressure, temperature and size may contribute to inaccurate system readings. System accuracy testing should be performed after the tires are set at the correct pressure as shown on the safety compliance certification label. The tires should be warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a constant speed within the posted speed limit. AXLE/TRANSAXLE RATIO The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios are available, but usually are not a concern when dealing with speedometer/odometer concerns unless the gear ratio has been changed. WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel drive vehicles have several driven gears with various numbers of teeth available to correct input to the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears for correction. GENERAL DESCRIPTION The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance traveled. Ford Motor vehicles are well within those limits. The speed indication is biased high, except on police vehicles with certified calibration speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the actual speed. This is intended to protect the consumer against violating speed laws. Most customer concerns are related to speedometers reading too high at true speeds between 50 MPH and 65 MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10% greater than true speed. The speedometer head is an instrument which processes information sent to it by the rotating speedometer cable. If the system components send the Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Pressure Pulsation Damper: > 8927 > Jan > 89 > Speedometer/Odometer - Inaccurate Readings > Page 3936 wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the speedometer head odometer, start by checking the accuracy of the odometer even if the customer concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads established at mile increments or a known local course. If roads with mile markers are used, a five mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The odometer should be checked again to verify any corrective action. If the indicated speed error exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of drive gears, parts not splined or loose yoke nuts. If the vehicle has speed control, the speed accuracy can be checked using the verified odometer vs. time. The formula is as follows: 3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES: 60 MPH (96 Km/h) requires 60 seconds to cover one mile 55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile 50 MPH (80 Km/h) requires 72 seconds to cover one mile ARTICLE SUPERSEDED: 84-14-6, date 7/3/84 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2300, 2310, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Pressure Pulsation Damper: > 9128 > Jan > 91 > Analog Speedometer - Inaccurate At High Speeds > Page 3942 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Pulsation Damper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Pressure Pulsation Damper: > 8927 > Jan > 89 > Speedometer/Odometer - Inaccurate Readings > Page 3947 wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the speedometer head odometer, start by checking the accuracy of the odometer even if the customer concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads established at mile increments or a known local course. If roads with mile markers are used, a five mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The odometer should be checked again to verify any corrective action. If the indicated speed error exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of drive gears, parts not splined or loose yoke nuts. If the vehicle has speed control, the speed accuracy can be checked using the verified odometer vs. time. The formula is as follows: 3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES: 60 MPH (96 Km/h) requires 60 seconds to cover one mile 55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile 50 MPH (80 Km/h) requires 72 seconds to cover one mile ARTICLE SUPERSEDED: 84-14-6, date 7/3/84 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2300, 2310, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections Fuel Pressure: Technical Service Bulletins Fuel Pressure Specification - Corrections ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-SECTION 11-SPECIFICATION CORRECTIONS ENGINE EMISSIONS DIAGNOSIS SHOP MANUAL- 1989-SECTION 17-SPECIFICATION CORRECTIONS Article No. 89-12A-25 FORD: 1989 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR LIGHT TRUCK: 1989 AEROSTAR, BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER ISSUE: The pressure values shown for the 2.5L CFI engine in both "Key on engine off" and "running" conditions are incorrectly shown in the Electric Fuel Delivery System (EFD) on page 11-14 and the Fuel Control Pinpoint Test H on page 17-185. The 1988 date in the chart titles for both Passenger Car Engines and Light Truck Engines is incorrect on page 17-185. The 3.0L SHO SEFI "Key on engine off" value in the chart on page 11-14 is incorrect. ACTION: Refer to the pages following this TSB article for the corrected charts. This information should be inserted in your 1989 Engine Emissions Diagnosis Manual, pages 11-14 and 17-185. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 680000 Fuel Delivery Systems 1989 11-13 Electric Fuel Delivery System EFD Electrical Schematic VEHICLE APPLICATION E Series 1988 and later model years, EFI F Series 1986 and later model years, EFI 11-14 1989 Fuel Delivery Systems Electric Fuel Delivery System EFD Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 3953 FUEL PRESSURE SPECIFICATION TABLE EEC-IV - Pinpoint Tests - All Vehicles 1989 17-185 Fuel Control Pinpoint Test GH Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 3954 FUEL PRESSURE SPECIFICATION TABLE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Fuel Pressure Specification - Corrections > Page 3955 17-186 1989 EEC-IV-Pinpoint Tests-All Vehicles Fuel Control Pinpoint Test H Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Page 3956 Fuel Pressure: Specifications Key On Engine Off 35 - 40 psi Key On Engine Running 30 - 40 psi Engine Running Vacuum Hose Disconnected From Fuel Pressure Regulator 35 - 40 psi Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure > System Information > Technical Service Bulletins > Page 3957 Fuel Pressure: Testing and Inspection STO Connector STATIC PRESSURE TEST 1. Check for adequate fuel supply. 2. Turn key OFF 3. Install fuel pressure gauge to test port on fuel rail. 4. Install test lead to fuel pump lead of STO test connector. 5. Turn Key ON Engine OFF (KOEO). 6. Ground test lead to run fuel pump. 7. Check to determine if fuel pressure is within acceptable limits. a. If pressure is low but greater than 3 psi (indicates fuel pump is running but not enough pressure) check for: ^ Plugged fuel filter ^ Kinked fuel line ^ Low voltage to pump (should be within 0.5 volts of battery voltage at connector). ^ Disconnect the fuel return line and note if fuel is being returned during this low pressure condition. If fuel is being returned, replace the fuel pressure regulator. Reconnect the fuel return line. b. If pressure is less than 3 psi (pump not running) check for: ^ Defective fuse link ^ Inertia switch open ^ Wiring at fuel pump/tank connector loose or open ^ Fuel pump ground connection at chassis loose or defective ^ Improper fuel pump relay operation If fuel supply and return lines are OK, and electrical supply and ground are OK, and fuel pressure is still low, replace fuel pump. DYNAMIC PRESSURE TEST 1. Disconnect and plug the vacuum line to the pressure regulator. 2. Start engine and run at idle. Check to determine if fuel pressure is within acceptable limits. Refer to SPECIFICATIONS. a. If pressure is low check for: ^ Plugged fuel filter ^ Restricted fuel line ^ Low voltage to pump (should be within 0.5 volts of battery voltage at connector). 3. Reconnect the vacuum line to the regulator. If fuel supply and return lines are OK, and electrical supply and ground is OK, and fuel pressure is still low, replace fuel pump. LEAKAGE TEST 1. Momentarily activate fuel pump by grounding test lead. Raise pressure to approximate operating pressure. 2. Remove ground from test lead and note pressure on gauge. Pressure should remain within 2 psi for 3 minutes after lead is ungrounded. a. If pressure is not maintained check for leaking fuel ^ Lines ^ Connectors ^ Injectors b. Disconnect fuel return line and plug engine side. Momentarily activate fuel pump by grounding test lead. Raise pressure to approximate operating pressure. If pressure holds replace regulator and retest. Reconnect the fuel return line. If pressure is not maintained replace fuel pump. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Technical Service Bulletins > Page 3971 Fuel Pump Relay: Locations FUEL INJECTORS: The fuel injectors are mounted in the lower intake manifold. FUEL PRESSURE REGULATOR: The fuel pressure regulator is attached to the fuel supply manifold. FUEL FILTER: The filter is located downstream of the electric electric fuel pump and is mounted on the underbody. FUEL PUMP: The fuel pump is mounted on the fuel sender assembly inside of the fuel tank. FUEL PUMP RELAY: LH side of trunk, behind wheelwell. INERTIA SWITCH: The inertia switch is located on the LH side of trunk, behind wheelwell. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3974 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 3975 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description Fuel Pump Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3978 X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3979 Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3980 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3981 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3982 Fuel Pump Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3983 X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 - CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3984 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3985 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3986 Fig. 23 Integrated Controller Pinpoint Tests X13 & X14 (Part 4 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3987 Fig. 23 Integrated Controller Pinpoint Tests X15 (Part 5 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3988 Fig. 23 Integrated Controller Pinpoint Test X16 & X17 (Part 6 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3989 Fig. 23 Integrated Controller Pinpoint Tests X18, X19, X20 & X21 (Part 7 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3990 Fig. 23 Integrated Controller Pinpoint Test X22 (Part 8 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3991 Fig. 23 Integrated Controller Pinpoint Tests X23 & X25 (Part 9 Of 26) Fig. 23 Integrated Controller Pinpoint Tests X26, X27 & X30 (Part 10 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3992 Fig. 23 Integrated Controller Pinpoint Tests X31 & X32 (Part 11 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3993 Fig. 23 Integrated Controller Pinpoint Tests X33 & X35 (Part 12 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3994 Fig. 23 Integrated Controller Pinpoint Tests X36 & X37 (Part 13 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3995 Fig. 23 Integrated Controller Pinpoint Tests X40, X41, X42 & X43 (Part 14 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3996 Fig. 23 Integrated Controller Pinpoint Tests X44, X45 & X46 (Part 15 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3997 Fig. 23 Integrated Controller Pinpoint Tests X50, X51 & X52 (Part 16 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3998 Fig. 23 Integrated Controller Pinpoint Tests X53, X54 & X55 (Part 17 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 3999 Fig. 23 Integrated Controller Pinpoint Tests X56, X57 & X58 (Part 18 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4000 Fig. 23 Integrated Controller Pinpoint Tests X59, X60 & X80 (Part 19 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4001 Fig. 23 Integrated Controller Pinpoint Tests X81, X82 & X83 (Part 20 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4002 Fig. 23 Integrated Controller Pinpoint Tests X84, X90 & X91 (Part 21 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4003 Fig. 23 Integrated Controller Pinpoint Tests X92, X93 & X94 (Part 22 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4004 Fig. 23 Integrated Controller Pinpoint Tests X95 & X96 (Part 23 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4005 Fig. 23 Integrated Controller Pinpoint Tests X100 & X101 (Part 24 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4006 Fig. 23 Integrated Controller Pinpoint Tests X102 & X103 (Part 25 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4007 Fig. 23 Integrated Controller Pinpoint Test X104 (Part 26 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injection Supply Manifold Assembly <--> [Fuel Rail] > Component Information > Specifications Fig. 20 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injection Supply Manifold Assembly <--> [Fuel Rail] > Component Information > Service and Repair > Supercharged Fuel Injection Supply Manifold Assembly: Service and Repair Supercharged REMOVAL Fuel Supply Manifold - Supercharged 1. Disconnect battery ground cable and secure it out of the way. 2. Release pressure from fuel system. 3. Remove supercharger and throttle body. 4. Using a spring lock coupling remover, disconnect the crossover fuel hose from the fuel rail assembly. 5. Remove four fuel rail assembly retaining bolts (two on each side). 6. Carefully disengage fuel rail from fuel injectors and remove fuel rail. NOTE: It may be easier to remove injectors with the fuel rail as an assembly. 7. Using a rocking, side to side motion while liting to remove injectors from fuel rail. INSTALLATION 1. Ensure injector caps are clean and free of contamination. 2. Place the fuel injector fuel rail assembly over each of the injectors into the fuel rail. Ensure injectors are well seated in the fuel rail assembly. NOTE: It may be easier to seat the injectors in the fuel rail and then seat the entire assembly in the lower intake manifold. 3. Secure the fuel rail assembly using four retaining bolts. Tighten to 70-97 lb. in. (8-11 N-m). 4. Install supercharger and throttle body. 5. Connect fuel inlet and outlet lines to fuel fuel rail assembly. 6. Firmly push and pull the fuel inlet and outlet lines to ensure that they are positively locked to the fuel rail connectors. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injection Supply Manifold Assembly <--> [Fuel Rail] > Component Information > Service and Repair > Supercharged > Page 4013 Fuel Injection Supply Manifold Assembly: Service and Repair Non-Supercharged REMOVAL Intake Manifold - Exploded View 1. Verify fuel rail assembly is depressurized by removing fuel tank cap and releasing pressure from fuel system at pressure relief valve on fuel rail assembly using a fuel pressure gauge. 2. Disconnect battery ground cable and secure it out of the way. 3. Remove upper manifold assembly, as outlined in this section. 4. Remove spring lock coupling retainer clips from fuel inlet and return fittings. 5. Disconnect the crossover fuel hose from the fuel rail assembly. 6. Disengage fuel rail from fuel injectors and remove fuel rail. 7. Use a rocking, side to side motion while lifting to remove injectors from fuel rail. INSTALLATION 1. Push fuel rail down to ensure all injector O-rings are fully seated in the fuel rail cups and intake manifold. 2. Install retaining bolts while holding fuel rail down. Tighten bolts to 87 lb. in. (10 N-m). 3. Install spring lock coupling. 4. With injector wiring disconnected, turn ignition to the RUN position to allow the fuel pump to pressurize the system. 5. Check for fuel leaks, using a clean towel. 6. Connect fuel injector wiring harness. Run vehicle at idle for two minutes. 7. Turn engine off and inspect for leaks. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation Fuel Return Line: Description and Operation FUEL LINES AND CONNECTORS Hair Pin Clip Duck Bill Clip NYLON PUSH CONNECT FITTINGS Nylon push connect fittings are designed with two different retaining clips. The "hairpin" clip is used on 5/16 inch (7.9mm) diameter tubing. The "duckbill" clip is used on 1/4 & 1/2 inch (6.35 & 12.7mm) diameter tubing. Push Connect Fittings SPRING LOCK COUPLING The spring lock coupling is a fuel line coupling held together by a garter spring inside a circular cage. When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. As a redundant locking feature, a horseshoe shaped retaining clip is incorporated to improve the retaining reliability of the spring lock. FUEL FILLER NECK (FILL PIPE RESTRICTOR) Fuel Filler To prevent accidental filling with other than unleaded fuel, vehicles that require unleaded fuel have a special filler tube. This filler tube has a restriction in it so that the only nozzles that can be inserted are the smaller diameter nozzles of pumps dispensing unleaded fuel. It is recommended that the amount of fuel put in the tank when filling be limited to the automatic pump shutoff. Due to the expansion of fuel during Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Page 4017 temperature increases, overfilling ("topping off") can cause fuel overflow at the filler cap when the vehicle is standing or the cap is removed. FUEL SUPPLY MANIFOLD Fuel Supply Manifold Fuel Supply Manifold - Supercharged The fuel supply manifold delivers high pressure fuel from the vehicle fuel supply line to the fuel injectors. The assembly consists of a tubular fuel rail, six injector connectors, mounting flange for the fuel pressure regulator and mounting attachments which locate the fuel supply manifold assembly and provide fuel injector retention. The fuel inlet and outlet connections have push connect fittings. SEALED FILL CAP The sealed cap incorporates a build-in pressure-vacuum relief valve. Fuel system vacuum relief is provided after approximately 0.50 inches vacuum is reached inside the tank. Pressure relief is provided when pressure inside the tank builds up approximately 2.2 psi. Under normal operating conditions, the fill cap operates as a check valve preventing vapors from escaping the tank through the cap. VAPOR VENT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Page 4018 Vapor Vent In-tank venting provides a vapor space above the gasoline surface in the fuel tank. This area is sufficient to permit adequate breathing space for the tank vapor valve assembly under all static and most dynamic condition. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Page 4019 Fuel Return Line: Service and Repair SPRING LOCK COUPLING Fuel Line Couplings REMOVAL 1. Relieve fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF. 2. Disconnect the negative battery cable. 3. Remove retaining clip from the spring-lock coupling by hand only. DO NOT use any sharp tool or screwdriver as it may damage the spring lock coupling. 4. Twist fitting to free it from any adhesion at the O-ring seals. 5. Fit Spring-Lock Coupling Tool D87L-9280-A (3/8 inch) or D87L-9280B (1/2 inch) or equivalent to coupling. 6. Close tool and push into open side of cage to expand garter spring and release female fitting. 7. After garter spring is expanded, pull fittings apart. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Page 4020 8. Remove tool from disconnected coupling. INSTALLATION 1. Ensure garter spring is in cage of male fitting. If garter spring is missing, install a new spring by pushing it into cage opening. If carter spring is damaged, remove it from cage with a small wire hook (do not use a screwdriver) and install a new spring. 2. Clean all dirt or foreign material from both pieces of coupling. 3. Replace missing or damaged O-rings. CAUTION: Use only the specified O-rings as they are made of a special material. The use of any O-ring other than specified may allow the connection to leak intermittently during vehicle operation. Lubricate male fitting and O-rings and inside of female fitting with clean engine oil. 4. Fit female fitting to male fitting and push until garter spring snaps over flared end of female fitting. 5. Ensure coupling engagement by pulling on fitting and visually checking to ensure garter spring is over flared end of female fitting. 6. Position retaining clip over metal portion of spring lock coupling. Firmly push retaining clip onto spring-lock coupling. Ensure horseshoe portion of clip is over the coupling. DO NOT install retaining clip over rubber fuel line. NOTE: Install the large "black" clip to the supply side fuel line and the smaller "gray" clip to the return side fuel line. DUCKBILL CLIP CONNECTOR Duckbill Clip Connector REMOVAL To remove duckbill, use special tool shown, or pliers with thin jaws, to release the clip. Pull the connector apart gently. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component Information > Description and Operation > Page 4021 Duck Bill Clip INSTALLATION 1. Install fitting onto tube and push fitting onto tube end until a "click" is heard.. 2. Pull on fitting to ensure it is fully engaged. HAIRPIN CLIP CONNECTOR Hair Pin Clip REMOVAL 1. Inspect the push connect fittings for accumulation of dirt. If more than a light coating of dust is present, clean the fitting before disassembly. 2. Some adhesion between the seals in the fitting and the tubing will occur with time. To separate, twist the fitting on the tube, then push and pull the fitting until it moves freely on the tube. 3. Remove "hairpin" type clip from fitting by: a. Bend the shipping tab downward so that it will clear the body. b. Spread the two clip legs approximately 3.2 mm (1/8 inch) each to disengage the body and push the legs into the fitting. c. Lightly pull from the triangular end of the clip and work it clear of the tube and fitting. CAUTION: Do not use any tools. 4. Grasp the fitting and hose assembly and pull in an axial direction to remove the fitting from the steel tube. 5. Once the fitting is removed from the tube end, inspect the fitting and tube for any internal parts that may have been dislodged from the fitting. INSTALLATION 1. It is recommended that the original clip not be reused. To install the new clip, insert clip into any two adjacent openings with the triangular portion pointing away from the fitting opening. Install clip to fully engage the body (legs) of "hairpin" clip locked on outside of body. 2. Before installing fitting on the tube, wipe tube end clean with a cloth. Inspect the fitting to ensure it is free of dirt and/or obstructions. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation Fuel Supply Line: Description and Operation FUEL LINES AND CONNECTORS Hair Pin Clip Duck Bill Clip NYLON PUSH CONNECT FITTINGS Nylon push connect fittings are designed with two different retaining clips. The "hairpin" clip is used on 5/16 inch (7.9mm) diameter tubing. The "duckbill" clip is used on 1/4 & 1/2 inch (6.35 & 12.7mm) diameter tubing. Push Connect Fittings SPRING LOCK COUPLING The spring lock coupling is a fuel line coupling held together by a garter spring inside a circular cage. When the coupling is connected together, the flared end of the female fitting slips behind the garter spring inside the cage of the male fitting. The garter spring and cage then prevent the flared end of the female fitting from pulling out of the cage. As a redundant locking feature, a horseshoe shaped retaining clip is incorporated to improve the retaining reliability of the spring lock. FUEL FILLER NECK (FILL PIPE RESTRICTOR) Fuel Filler To prevent accidental filling with other than unleaded fuel, vehicles that require unleaded fuel have a special filler tube. This filler tube has a restriction in it so that the only nozzles that can be inserted are the smaller diameter nozzles of pumps dispensing unleaded fuel. It is recommended that the amount of fuel put in the tank when filling be limited to the automatic pump shutoff. Due to the expansion of fuel during Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Page 4025 temperature increases, overfilling ("topping off") can cause fuel overflow at the filler cap when the vehicle is standing or the cap is removed. FUEL SUPPLY MANIFOLD Fuel Supply Manifold Fuel Supply Manifold - Supercharged The fuel supply manifold delivers high pressure fuel from the vehicle fuel supply line to the fuel injectors. The assembly consists of a tubular fuel rail, six injector connectors, mounting flange for the fuel pressure regulator and mounting attachments which locate the fuel supply manifold assembly and provide fuel injector retention. The fuel inlet and outlet connections have push connect fittings. SEALED FILL CAP The sealed cap incorporates a build-in pressure-vacuum relief valve. Fuel system vacuum relief is provided after approximately 0.50 inches vacuum is reached inside the tank. Pressure relief is provided when pressure inside the tank builds up approximately 2.2 psi. Under normal operating conditions, the fill cap operates as a check valve preventing vapors from escaping the tank through the cap. VAPOR VENT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Page 4026 Vapor Vent In-tank venting provides a vapor space above the gasoline surface in the fuel tank. This area is sufficient to permit adequate breathing space for the tank vapor valve assembly under all static and most dynamic condition. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Page 4027 Fuel Supply Line: Service and Repair SPRING LOCK COUPLING Fuel Line Couplings REMOVAL 1. Relieve fuel system pressure, refer to MAINTENANCE PROCEDURES/FUEL SYSTEM PRESSURE RELIEF. 2. Disconnect the negative battery cable. 3. Remove retaining clip from the spring-lock coupling by hand only. DO NOT use any sharp tool or screwdriver as it may damage the spring lock coupling. 4. Twist fitting to free it from any adhesion at the O-ring seals. 5. Fit Spring-Lock Coupling Tool D87L-9280-A (3/8 inch) or D87L-9280B (1/2 inch) or equivalent to coupling. 6. Close tool and push into open side of cage to expand garter spring and release female fitting. 7. After garter spring is expanded, pull fittings apart. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Page 4028 8. Remove tool from disconnected coupling. INSTALLATION 1. Ensure garter spring is in cage of male fitting. If garter spring is missing, install a new spring by pushing it into cage opening. If carter spring is damaged, remove it from cage with a small wire hook (do not use a screwdriver) and install a new spring. 2. Clean all dirt or foreign material from both pieces of coupling. 3. Replace missing or damaged O-rings. CAUTION: Use only the specified O-rings as they are made of a special material. The use of any O-ring other than specified may allow the connection to leak intermittently during vehicle operation. Lubricate male fitting and O-rings and inside of female fitting with clean engine oil. 4. Fit female fitting to male fitting and push until garter spring snaps over flared end of female fitting. 5. Ensure coupling engagement by pulling on fitting and visually checking to ensure garter spring is over flared end of female fitting. 6. Position retaining clip over metal portion of spring lock coupling. Firmly push retaining clip onto spring-lock coupling. Ensure horseshoe portion of clip is over the coupling. DO NOT install retaining clip over rubber fuel line. NOTE: Install the large "black" clip to the supply side fuel line and the smaller "gray" clip to the return side fuel line. DUCKBILL CLIP CONNECTOR Duckbill Clip Connector REMOVAL To remove duckbill, use special tool shown, or pliers with thin jaws, to release the clip. Pull the connector apart gently. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component Information > Description and Operation > Page 4029 Duck Bill Clip INSTALLATION 1. Install fitting onto tube and push fitting onto tube end until a "click" is heard.. 2. Pull on fitting to ensure it is fully engaged. HAIRPIN CLIP CONNECTOR Hair Pin Clip REMOVAL 1. Inspect the push connect fittings for accumulation of dirt. If more than a light coating of dust is present, clean the fitting before disassembly. 2. Some adhesion between the seals in the fitting and the tubing will occur with time. To separate, twist the fitting on the tube, then push and pull the fitting until it moves freely on the tube. 3. Remove "hairpin" type clip from fitting by: a. Bend the shipping tab downward so that it will clear the body. b. Spread the two clip legs approximately 3.2 mm (1/8 inch) each to disengage the body and push the legs into the fitting. c. Lightly pull from the triangular end of the clip and work it clear of the tube and fitting. CAUTION: Do not use any tools. 4. Grasp the fitting and hose assembly and pull in an axial direction to remove the fitting from the steel tube. 5. Once the fitting is removed from the tube end, inspect the fitting and tube for any internal parts that may have been dislodged from the fitting. INSTALLATION 1. It is recommended that the original clip not be reused. To install the new clip, insert clip into any two adjacent openings with the triangular portion pointing away from the fitting opening. Install clip to fully engage the body (legs) of "hairpin" clip locked on outside of body. 2. Before installing fitting on the tube, wipe tube end clean with a cloth. Inspect the fitting to ensure it is free of dirt and/or obstructions. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level Fuel Gauge Sender: Customer Interest Fuel Gauge - Intermittently Shows Increase In Fuel Level Article No. 91-13-4 06/26/91 GAUGE - FUEL - ELECTRONIC - SHOWS FUEL INCREASES OR DISPLAYS "CO" INTERMITTENTLY - VEHICLES BUILT FROM 6/1/89 TO 1/15/90 FORD: 1989-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989-90 AEROSTAR This TSB article is being republished in its entirety to correct the fuel pump/sender part number listed for the 1989 Taurus/Sable. ISSUE: The electronic instrument cluster (EIC) fuel gauge may intermittently show an increase in the fuel level or display circuit open "CO". This happens when the fuel tank level is above 1/2 full. The condition is caused by either an intermittent high resistance contact or an open circuit internal to the fuel sender unit. ACTION: Perform the diagnostic procedures outlined in the appropriate Shop Manual, Sections 33-05 for Cars and 13-01A for the Aerostar to determine if a new fuel pump/sender is required. 1. Replace the fuel sender assembly. Refer to the appropriate Shop Manual, Sections 24-35 for cars and 13-03 for the Aerostar for service details. FUEL PUMP/SENDER APPLICATION CHART MODEL YEAR APPLICATION DESCRIPTION PART NUMBER 1989 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-C 1990 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-A 1989-90 Continental Fuel Pump/Sender E90Z-9H307-A 1989-90 Mark VII Fuel Pump/Sender E5LY-9275-A 1989 Town Car Fuel Pump/Sender E5VY-9275-A 1990 Town Car Fuel Pump/Sender F0VY-9H307-C 1989-90 Thunderbird/Cougar Fuel Pump/Sender F1SZ-9H307-B 1989-90 Aerostar Fuel Pump/Sender E99Z-9H307-A PART NUMBER PART NAME CLASS F0DZ-9H307-C Fuel Pump/Sender C E90Z-9H307-A Fuel Pump/Sender B F0DZ-9H307-A Fuel Pump/Sender B E5LY-9275-A Fuel Pump/Sender R E5VY-9275-A Fuel Pump/Sender BM F0VY-9H307-C Fuel Pump/Sender B F1SZ-9H307-B Fuel Pump/Sender B E99Z-9H307-A Fuel Pump/Sender B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-7-11 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level > Page 4039 OPERATION DESCRIPTION TIME 911304A Replace Fuel Pump/Sender 1.5 Hrs. - 1990 Town Car, Thunderbird, Cougar 911304A Replace Fuel Pump/Sender 1.2 Hrs. - Aerostar 911304A Replace Fuel Pump/Sender 1.0 Hr. - Continental, 1989 Town Car 911304A Replace Fuel Pump/Sender 0.9 Hr. - Taurus, Sable, Mark VII DEALER CODING BASIC PART NO. CONDITION CODE 9H307 28 OASIS CODES: 204000, 204100, 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 891411 > Jul > 89 > Fuel Gauge Occasionally Sticks In FULL Position Fuel Gauge Sender: Customer Interest Fuel Gauge - Occasionally Sticks In FULL Position GAUGE-FUEL-OCCASIONALLY STICKS IN "FULL" POSITION Article No. 89-14-11 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A fuel gauge that ocassionally sticks in the "FULL" position may be caused by a binding fuel pump float assembly. The fuel pump float binds on the inner surface of the fuel tank and holds the float in the "FULL" position. This is most likely to occur when driving on unpaved or rough roads. ACTION: Modify the fuel pump float to prevent the binding condition. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 24-12 for removal and installation instructions. 1. Remove the fuel pump assembly. 2. Unscrew the nut from the end of the float rod assembly. 3. Remove the float from the rod. 4. Using a sharp knife, cut 3/8" to 1/2" (9.525 mm to 12.7 mm) off the end of the float. 5. Reinstall the shortened float on the float rod. 6. Install float retaining nut. NOTE: ALLOW CLEARANCE BETWEEN THE RETAINING NUT AND FLOAT SO THAT THE FLOAT SPINS FREELY. 7. Using diagonal cutters, trim the float rod so that it is flush with the retaining nut. 8. Reinstall the fuel sender. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891411A Modify Float 1.3 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 41 OASIS CODES: 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Intermittently Shows Increase In Fuel Level Article No. 91-13-4 06/26/91 GAUGE - FUEL - ELECTRONIC - SHOWS FUEL INCREASES OR DISPLAYS "CO" INTERMITTENTLY - VEHICLES BUILT FROM 6/1/89 TO 1/15/90 FORD: 1989-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989-90 AEROSTAR This TSB article is being republished in its entirety to correct the fuel pump/sender part number listed for the 1989 Taurus/Sable. ISSUE: The electronic instrument cluster (EIC) fuel gauge may intermittently show an increase in the fuel level or display circuit open "CO". This happens when the fuel tank level is above 1/2 full. The condition is caused by either an intermittent high resistance contact or an open circuit internal to the fuel sender unit. ACTION: Perform the diagnostic procedures outlined in the appropriate Shop Manual, Sections 33-05 for Cars and 13-01A for the Aerostar to determine if a new fuel pump/sender is required. 1. Replace the fuel sender assembly. Refer to the appropriate Shop Manual, Sections 24-35 for cars and 13-03 for the Aerostar for service details. FUEL PUMP/SENDER APPLICATION CHART MODEL YEAR APPLICATION DESCRIPTION PART NUMBER 1989 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-C 1990 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-A 1989-90 Continental Fuel Pump/Sender E90Z-9H307-A 1989-90 Mark VII Fuel Pump/Sender E5LY-9275-A 1989 Town Car Fuel Pump/Sender E5VY-9275-A 1990 Town Car Fuel Pump/Sender F0VY-9H307-C 1989-90 Thunderbird/Cougar Fuel Pump/Sender F1SZ-9H307-B 1989-90 Aerostar Fuel Pump/Sender E99Z-9H307-A PART NUMBER PART NAME CLASS F0DZ-9H307-C Fuel Pump/Sender C E90Z-9H307-A Fuel Pump/Sender B F0DZ-9H307-A Fuel Pump/Sender B E5LY-9275-A Fuel Pump/Sender R E5VY-9275-A Fuel Pump/Sender BM F0VY-9H307-C Fuel Pump/Sender B F1SZ-9H307-B Fuel Pump/Sender B E99Z-9H307-A Fuel Pump/Sender B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-7-11 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level > Page 4049 OPERATION DESCRIPTION TIME 911304A Replace Fuel Pump/Sender 1.5 Hrs. - 1990 Town Car, Thunderbird, Cougar 911304A Replace Fuel Pump/Sender 1.2 Hrs. - Aerostar 911304A Replace Fuel Pump/Sender 1.0 Hr. - Continental, 1989 Town Car 911304A Replace Fuel Pump/Sender 0.9 Hr. - Taurus, Sable, Mark VII DEALER CODING BASIC PART NO. CONDITION CODE 9H307 28 OASIS CODES: 204000, 204100, 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return Technical Service Bulletin # RSB89170 Date: 891122 Remanufacturer Letter # 1 November 22, 1989 RSB # 89-170 To: All Ford Authorized Remanufacturers Subject: Sort and Return of Fuel & Send Assy. - E9DZ-9H307-C E5ZZ-9A407-A Gentlemen: Because certain fuel pump and sender assemblies may not meet Ford's high quality requirements, you are authorized to return unused parts for credit. Part Number Explanation E9DZ-9H307-C Action Required E5ZZ-9A407-A ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 - 1989; 0901 September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section, write "Returned per FPSD Purge 1079". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Returns restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Remanufacturer Letter # 2 November 22, 1989 RSB # 89-171 To: Ford Authorized Remanufacturers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1080". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 4054 ^ Return parts to your Facing PDC using least expensive trarisportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 1 December 7, 1989 To: Ford and Lincoln Mercury, Dealers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date ccde of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section Write "Returned per FPSD Purge # 1080". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 3 December 7, 1989 To: Ford and Lincoln Mercury Dealers Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 4055 Subject: Return of Fuel Pump & Sender Assy. - E9DZ-9H307-C and Fuel Pump & Bracket Assy. E5ZZ-9A407-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1079". ^ Return parts to your Facing PDC using-least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject part. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacemeut stock of the same part numbers is available for ordering immediately. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 4060 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 891411 > Jul > 89 > Fuel Gauge - Occasionally Sticks In FULL Position Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Occasionally Sticks In FULL Position GAUGE-FUEL-OCCASIONALLY STICKS IN "FULL" POSITION Article No. 89-14-11 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A fuel gauge that ocassionally sticks in the "FULL" position may be caused by a binding fuel pump float assembly. The fuel pump float binds on the inner surface of the fuel tank and holds the float in the "FULL" position. This is most likely to occur when driving on unpaved or rough roads. ACTION: Modify the fuel pump float to prevent the binding condition. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 24-12 for removal and installation instructions. 1. Remove the fuel pump assembly. 2. Unscrew the nut from the end of the float rod assembly. 3. Remove the float from the rod. 4. Using a sharp knife, cut 3/8" to 1/2" (9.525 mm to 12.7 mm) off the end of the float. 5. Reinstall the shortened float on the float rod. 6. Install float retaining nut. NOTE: ALLOW CLEARANCE BETWEEN THE RETAINING NUT AND FLOAT SO THAT THE FLOAT SPINS FREELY. 7. Using diagonal cutters, trim the float rod so that it is flush with the retaining nut. 8. Reinstall the fuel sender. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891411A Modify Float 1.3 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 41 OASIS CODES: 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return Technical Service Bulletin # RSB89170 Date: 891122 Remanufacturer Letter # 1 November 22, 1989 RSB # 89-170 To: All Ford Authorized Remanufacturers Subject: Sort and Return of Fuel & Send Assy. - E9DZ-9H307-C E5ZZ-9A407-A Gentlemen: Because certain fuel pump and sender assemblies may not meet Ford's high quality requirements, you are authorized to return unused parts for credit. Part Number Explanation E9DZ-9H307-C Action Required E5ZZ-9A407-A ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 - 1989; 0901 September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section, write "Returned per FPSD Purge 1079". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Returns restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Remanufacturer Letter # 2 November 22, 1989 RSB # 89-171 To: Ford Authorized Remanufacturers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1080". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 4070 ^ Return parts to your Facing PDC using least expensive trarisportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 1 December 7, 1989 To: Ford and Lincoln Mercury, Dealers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date ccde of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section Write "Returned per FPSD Purge # 1080". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 3 December 7, 1989 To: Ford and Lincoln Mercury Dealers Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 4071 Subject: Return of Fuel Pump & Sender Assy. - E9DZ-9H307-C and Fuel Pump & Bracket Assy. E5ZZ-9A407-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1079". ^ Return parts to your Facing PDC using-least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject part. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacemeut stock of the same part numbers is available for ordering immediately. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 4076 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 4077 Fuel Gauge Sender: Locations On RH Frame Rail Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests Fuel Gauge Sender: Pinpoint Tests Fig. 1 Fuel Indicating System Diagnosis (Part 1 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 4080 Fig. 1 Fuel Indicating System Diagnosis (Part 2 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 4081 Fig. 1 Fuel Indicating System Diagnosis (Part 3 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 4082 Fig. 1 Fuel Indicating System Diagnosis (Part 4 Of 5). Models w/Magnetic Gauge Fig. 1 Fuel Indicating System Diagnosis (Part 5 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 4083 Fig. 2 Fuel Indicating System Diagnosis (Part 1 Of 2) Fig. 2 Fuel Indicating System Diagnosis (Part 2 Of 2) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 4084 Fuel Gauge Sender: Component Tests and General Diagnostics Magnetic Type The required test equipment consists of a Rotunda Gauge Tester part No. 021-00055 or equivalent, a pair of 10 ohm and 75 ohm resistor or another fuel sender of known quality. 1. Perform test with resistors as follows: a. Disconnect wiring connector at sender unit, then connect resistor between gauge lead and a suitable ground. b. Turn ignition switch to On position. c. With 10 ohm resitor, the gauge pointer should contact the Full mark. d. With 75 ohm resistor, the gauge pointer should contact the Empty mark. 2. Perform test with fuel sender of known quality as follows: a. Turn ignition switch to Off position. b. Disconnect wiring connector from sender and connect it to test sender. c. Move float rod away from fuel filter against Full stop position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or above the Full mark. d. Move float rod toward fuel filter against Empty stop position. Turn ignition switch to Off position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or below the Empty mark. e. If gauge performs as indicated, perform fuel sender unit tests. Refer to DIAGNOSTIC CHARTS for fuel sender unit tests. f. If gauge is out of calibration at the Empty mark, or both the Empty and Full mark, replace gauge. Bimetal Type The required test equipment consists of a Rotunda Gauge Tester part No. 021-00055 or equivalent, a pair of 22 ohm and 145 ohm resistor or another fuel sender of known quality. 1. Perform test with resistors as follows: a. Disconnect wiring connector at sender unit, then connect resistor between gauge lead and a suitable ground. b. Turn ignition switch to On position. c. With 145 ohm resitor, the gauge pointer should contact the Full mark. d. With 22 ohm resistor, the gauge pointer should contact the Empty mark. 2. Perform test with fuel sender of known quality as follows: a. Turn ignition switch to Off position. b. Disconnect wiring connector from sender and connect it to test sender. c. Move float rod away from fuel filter against Full stop position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or above the Full mark. d. Move float rod toward fuel filter against Empty stop position. Turn ignition switch to Off position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or below the Empty mark. e. If gauge performs as indicated, perform fuel sender unit tests. Refer to DIAGNOSTIC CHARTS for fuel sender unit tests. f. If gauge is out of calibration at the Empty mark, or both the Empty and Full mark, replace gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4093 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4094 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4095 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4096 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4097 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4098 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4099 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4100 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4101 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4102 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4103 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4104 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4105 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4106 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4107 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4108 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4109 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4115 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4116 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4117 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4118 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4119 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4120 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4121 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4122 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4123 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4124 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4125 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4126 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4127 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4128 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4129 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4130 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4131 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 89138 > Jun > 89 > Air By Pass Valve Cleaning/Replacement Service Tips Idle Speed Control Bypass Air (ISC-BPA) Valve: All Technical Service Bulletins Air By Pass Valve Cleaning/Replacement Service Tips FUEL SYSTEM-3.8L EFI-AIR BY-PASS VALVECLEANING AND REPLACEMENT SERVICE TIPS Article No. 89-13-8 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, SABLE ISSUE: Two different types of air by-pass valves have been released for use on 3.8L EFI engines. One type of valve has a silver metal housing and the other type has a black plastic housing. Both of the valves function in the same manner. Air by-pass valves that have a black plastic housing cannot be cleaned, they must be replaced. Valves that have silver metal housings can be cleaned. ACTION: If cleaning or replacement of an air by-pass valve is required, refer to the following supplemental service information. Also refer to the appropriate Car Shop Manual, Section 24-11 for service details. Figure 1 Figure 2 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 89138 > Jun > 89 > Air By Pass Valve Cleaning/Replacement Service Tips > Page 4136 Figure 3 1. Do not clean the black plastic air by-pass valve, Figure 1. This valve cannot be cleaned with carburetor cleaner because it can damage the valve's internal components. CAUTION: IF THE BLACK PLASTIC AIR BY-PASS VALVE REQUIRES SERVICE, IT MUST BE REPLACED. 2. The silver metal air by-pass valve can be cleaned. Use carburetor cleaner (D9AZ-19579-BA) to clean it. 3. Mount the black plastic air by-pass valve with the electrical connector on the in-board side of the throttle body, Figure 3. Do NOT mount it on the rocker cover side of the throttle body. 4. Reinstall the silver metal air by-pass valve in the same position as it was originally installed. PART NUMBER PART NAME CLASS D9AZ-19579-BA Carburetor Cleaner - Pkg. of 12 B E9SZ-9F715-E Air By-Pass Valve - Black B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4600 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 89138 > Jun > 89 > Air By Pass Valve Cleaning/Replacement Service Tips Idle Speed Control Bypass Air (ISC-BPA) Valve: All Technical Service Bulletins Air By Pass Valve Cleaning/Replacement Service Tips FUEL SYSTEM-3.8L EFI-AIR BY-PASS VALVECLEANING AND REPLACEMENT SERVICE TIPS Article No. 89-13-8 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, SABLE ISSUE: Two different types of air by-pass valves have been released for use on 3.8L EFI engines. One type of valve has a silver metal housing and the other type has a black plastic housing. Both of the valves function in the same manner. Air by-pass valves that have a black plastic housing cannot be cleaned, they must be replaced. Valves that have silver metal housings can be cleaned. ACTION: If cleaning or replacement of an air by-pass valve is required, refer to the following supplemental service information. Also refer to the appropriate Car Shop Manual, Section 24-11 for service details. Figure 1 Figure 2 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Technical Service Bulletins > All Other Service Bulletins for Idle Speed Control Bypass Air (ISC-BPA) Valve: > 89138 > Jun > 89 > Air By Pass Valve Cleaning/Replacement Service Tips > Page 4142 Figure 3 1. Do not clean the black plastic air by-pass valve, Figure 1. This valve cannot be cleaned with carburetor cleaner because it can damage the valve's internal components. CAUTION: IF THE BLACK PLASTIC AIR BY-PASS VALVE REQUIRES SERVICE, IT MUST BE REPLACED. 2. The silver metal air by-pass valve can be cleaned. Use carburetor cleaner (D9AZ-19579-BA) to clean it. 3. Mount the black plastic air by-pass valve with the electrical connector on the in-board side of the throttle body, Figure 3. Do NOT mount it on the rocker cover side of the throttle body. 4. Reinstall the silver metal air by-pass valve in the same position as it was originally installed. PART NUMBER PART NAME CLASS D9AZ-19579-BA Carburetor Cleaner - Pkg. of 12 B E9SZ-9F715-E Air By-Pass Valve - Black B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4600 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Electrical Specifications IDLE SPEED CONTROL - FI ENGINES W/ISC. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Electrical Specifications > Page 4145 Idle Speed Control Bypass Air (ISC-BPA) Valve: Mechanical Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4146 Idle Speed Control Bypass Air (ISC-BPA) Valve: Locations Engine Compartment. Top Center Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Specifications > Page 4147 Idle Speed Control Bypass Air (ISC-BPA) Valve: Description and Operation The idle speed control/bypass air valve controls idle speed by regulating air that bypasses the throttle plate. There are two parts to the (ISC-BPA). The bypass air valve (BPA) and the idle speed control solenoid (ISC). The BPA valve is thermally controlled and functions only during cold engine conditions (below 140 degrees F). The ISC valve is controlled by the electronic control assembly and operates under all engine speed and temperature conditions. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Service and Repair > Procedures Idle Speed Control Bypass Air (ISC-BPA) Valve: Procedures WITH SPECIAL TOOLS CAUTION: DO NOT use the following procedure on a Nippondenso ISC-BPA valve (black plastic), as damage may result. Nippondenso valves are serviced by replacement only. Use only spray carburetor cleaner (Ford D9AZ-19579-BA, or equivalent). DO NOT spray directly on on throttle plates or use any type of scrubbing method. If the vehicle is equipped with a Mass Air Flow (MAF) sensor, do not run the engine while cleaning the Idle Speed Control By-Pass Air ISC-BPA valve. 1. Remove the throttle inlet air duct. 2. Disconnect the ISC-BPA valve connector. 3. Connect the ISC-BPA actuator (Rotunda 113-00009, or equivalent) and the injector tester/cleaner (Rotunda 113-00001, or equivalent) to the vehicle. 4. START the actuator and then START the engine (non MAF engines only). 5. Spray carburetor cleaner (Ford D9AZ-19579-BA, or equivalent) into the ISC-BPA valve for five seconds while actuator is operating. 6. Turn OFF the actuator and STOP the engine (if running). Allow the solvent to soak for 15 minutes. 7. Turn ON the actuator and START the engine (non MAF engines only). 8. Spray carburetor cleaner into the idle ISC-BPA for up to 6 seconds (MAF equipped) or 1 minute (non MAF equipped). 9. Turn OFF the actuator and shut OFF the engine (if running). 10. Install the throttle inlet air duct and START the engine, allowing to run for 1 minute. 11. Disconnect the actuator from the ISC-BPA valve. Connect the ISC-BPA connector. 12. START the engine and check for proper operation. WITH OUT SPECIAL TOOLS Fig. 1 Air bypass valve solenoid CAUTION: DO NOT use the following procedure on a Nippondenso ISC-BPA valve (black plastic), as damage may result. Nippondenso valves are serviced by replacement only. 1. Remove the Idle Speed Control By-Pass Air ISC-BPA valve from the throttle body. 2. Remove the electrical solenoid assembly from the mechanical portion of the ISC-BPA valve by removing the two screws, then sliding the mechanical portion away from the solenoid. 3. Soak the mechanical portion of the ISC-BPA in carburetor cleaner (Ford D9AZ-19579-BA, or equivalent) for up to 3 minutes. CAUTION: DO NOT exceed 3 minutes soaking time and DO NOT use choke cleaner, as internal damage may occur. 4. With the mechanical portion completely submerged, shake in all directions (up, down, right, and left). Push in the on the rod that mates with the solenoid assembly and again shake in all directions with the rod pushed in as far as possible. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Service and Repair > Procedures > Page 4150 5. Remove the valve from the cleaning fluid and dry it out with compressed air. 6. Reassemble the ISC-BPA valve and install on the vehicle, torquing the bolts to 71-102 lb. in. (8-11 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed Control Bypass Air (ISC-BPA) Valve <--> [Idle Speed/Throttle Actuator - Electronic] > Component Information > Service and Repair > Procedures > Page 4151 Idle Speed Control Bypass Air (ISC-BPA) Valve: Removal and Replacement Intake Manifold - Exploded View REMOVAL 1. Disconnect wiring harness connector from idle air by-pass valve assembly. 2. Remove the two retaining screws. 3. Remove valve and gasket. 4. Clean gasket mating surfaces. NOTE: If scraping is necessary, use care not to damage valve or throttle body gasket surfaces, or drop material into the throttle body. INSTALLATION 1. Install gasket and valve on throttle body. 2. Install the retaining screws. Torque to 87 in lbs (10 Nm). 3. Connect electrical wiring harness connector. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Description and Operation > Altitude Compensator Idle/Altitude Compensator (Non Comp. Controlled): Description and Operation Altitude Compensator Fig. 7 Electrical type altitude compensator Electrical The electrical type altitude compensator, Fig. 7, is mounted on the ignition module. The compensator improves emissions and aids engine performance at altitudes above 4000 ft. by advancing the timing and leaning the air/fuel mixture. Fig. 8 Mechanical type altitude compensator Mechanical The mechanical type altitude compensator, Fig. 8, is mounted on the bulkhead. The compensator leans the air/fuel mixture at altitudes above 3000 ft. by supplying additional filtered air to the carburetor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Description and Operation > Altitude Compensator > Page 4156 Idle/Altitude Compensator (Non Comp. Controlled): Description and Operation Hot Idle Compensator Fig. 14 Hot Idle Compensator The hot idle compensator, Fig. 14, cools the engine during hot idle operation. The compensator may be integral with the carburetor or mounted separately. When open, the compensator bleeds air into the manifold, leaning out the air/fuel mixture at idle. This increased air intake causes an increase in engine idle speed, resulting in cooling of the engine. Temperature rise on the bi-metal sensor lifts the normally closed valve and opens the air passage. A valve that does not fully close will cause high idle speed and excessive exhaust emission. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle/Altitude Compensator (Non Comp. Controlled) > Component Information > Description and Operation > Page 4157 Idle/Altitude Compensator (Non Comp. Controlled): Testing and Inspection Electrical 1. Check and record engine timing. 2. Disconnect compensator from ignition module and connect suitable jumper wire across module connectors. Recheck engine timing. 3. At altitudes of 3000 ft. or lower, timing should change as follows: Ford & Mercury full size models, with V8-302, advance 6°; all other models, advance 8°. 4. At altitudes of 4000 ft. or higher, there should be no change in timing. Fig. 8 Mechanical type altitude compensator Mechanical 1. Connect a suitable vacuum gauge to air inlet nipple, Fig. 8, and check for vacuum with engine running. 2. On 4-140 engine, there should be no vacuum at altitudes of 2500 ft. or lower and vacuum should be present at altitudes of 3000 ft. or higher. 3. On 4-97 and V6-232 engines, there should be not vacuum at altitudes of 3500 ft. or lower and vacuum should be present at altitudes of 4000 ft. or higher. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations FUEL INJECTORS: The fuel injectors are mounted in the lower intake manifold. FUEL PRESSURE REGULATOR: The fuel pressure regulator is attached to the fuel supply manifold. FUEL FILTER: The filter is located downstream of the electric electric fuel pump and is mounted on the underbody. FUEL PUMP: The fuel pump is mounted on the fuel sender assembly inside of the fuel tank. FUEL PUMP RELAY: LH side of trunk, behind wheelwell. INERTIA SWITCH: The inertia switch is located on the LH side of trunk, behind wheelwell. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4163 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4164 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 4165 Fuel Pump Inertia Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch PURPOSE The inertia switch is used to shut the fuel pump "Off" in the event of a collision. CONSTRUCTION The inertia switch consists of a steel ball held in place by a magnet. OPERATION When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate. This opens the electrical contacts of the switch and disrupts power to the electric fuel pump. The engine will quit running within a few seconds after the fuel pump loses power. The inertia switch must then be manually reset before the engine can be restarted. WARNING: DO NOT reset the inertia switch button if you see or smell fuel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Inlet Tube Intake Air Duct: Service and Repair Inlet Tube Supercharger System REMOVAL 1. Disconnect the inlet tube from the supercharger outlet adapter. 2. Remove four nuts retaining inlet and outlet tubes to intercooler. CAUTION: The inlet tube must be disconnected from the intercooler so the sealing surfaces and retaining studs are not damaged from bending while removing the inlet tube. 3. Remove nut and push-on nut retaining inlet tube to alternator-power steering pump bracket. NOTE: To remove the inlet tube in the vehicle, the stud must also be removed from the alternator/power steering pump bracket. 4. Remove inlet tube. CAUTION: Use extreme care during removal and installation of the intercooler tubes so as not to scratch, nick or contaminate the sealing surfaces. NOTE: Whenever the outlet tube is disconnected from the intercooler sealing surfaces must be resealed. This is necessary because the existing seal may be disturbed or broken from the unintentional bending while removing the inlet tube. INSTALLATION 1. Clean and inspect the sealing surfaces of the supercharger outlet adapter intake elbow, intercooler and tubes. NOTE: Make sure there are no foreign particles on the sealing surfaces of the tubes. It is important that the intercooler tubes seal completely. The engine uses "MASS AIRFLOW" system to calculate fuel flow. Any air leak will cause poor operation and performance. 2. Install gasket sealant tape circumferentially to the spherical seat surfaces of the intercooler tubes. Overlap the tape ends approximately 6mm (1/4 inch). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Inlet Tube > Page 4170 CAUTION: Do not stretch the tape during installation or the seal may leak. NOTE: During proper installation, a slight wrinkling will occur on the tape edge at the inner diameter. CAUTION: The system must be torqued in sequence and to specification for that step. This is required for proper alignment of the system to insure proper sealing of the intercooler tubes. 3. Apply anti-seize/lubricating compound to the inner backside spherical seat surface and threads of the supercharger outlet adapter collar. 4. Position inlet tube, then install upper stud into alternator-power steering pump bracket. 5. Install push-on nut onto stud tight enough to retain tube against alternator-power steering pump bracket surface but free enough to allow tube movement to ensure seating of spherical seat in inlet tube to supercharger outlet adapter. 6. Fully hand tighten the supercharger outlet adaptor collar onto threaded tube end of inlet tube assembly. 7. Install intercooler assembly to inlet and outlet tubes. Install nuts to studs tight enough to retain intercooler and tubes together but free enough to allow movement on spherical seats. DO NOT TIGHTEN AT THIS TIME. 8. Tighten supercharger outlet adapter collar to inlet tube to 200 Nm (148 lb-ft). NOTE: It is important to tighten the collar to 200 Nm (148 lb-ft) so the gasket sealant tape seats and forms properly to the shape of the sealing surface. 9. Wait 10 minutes minimum and retighten supercharger outlet collar to 200 Nm (148 lb-ft). NOTE: When first compressed, the sealant tape flows and forms to the sealing surface. If the collar is not retightened, the torque if the collar will drop causing a leak at this joint. 10. Tighten inlet and outlet tube to intercooler nuts to 20-30 Nm (15-22 lb-ft). 11. Install nut retaining inlet tube to alternator-power steering pump support bracket and tighten to 40-55 Nm (30-40 lb-ft). 12. START engine and check for leaks using propane. For procedure See: Supercharger/Testing and Inspection/Component Tests and General Diagnostics Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Inlet Tube > Page 4171 Intake Air Duct: Service and Repair Intake Elbow Assembly Air Bypass Valve Actuator REMOVAL 1. Remove cowl vent screens. 2. Disconnect electrical connection at intake air temperature sensor. 3. Disconnect vacuum lines at intake elbow. 4. Remove two nuts attaching intercooler outlet tube to elbow. 5. Loosen intercooler outlet tube at alternator/ power steering pump bracket. 6. Slightly loosen support bracket at front of cylinder block. Allow bracket to pivot during outlet tube installation. 7. Loosen clamp at air bypass valve inlet hose. 8. Remove three elbow to manifold retaining bolts and slide elbow from hose to remove. INSTALLATION 1 Clean and inspect gasket surfaces and install gasket on intake manifold. 2. Slide elbow into bypass hose. Align paint stripe on hose with rib on elbow assembly. Tighten clamps to 2.3-3.4 Nm (20-30 lb-in). 3. Position intake elbow and gasket. Install three retaining bolts, tighten to 26-38 Nm (20-28 lb-ft). 4. Install intercooler inlet and outlet tubes as outlined. 5. Connect vacuum lines. 6. Connect electrical connection at intake air temperature sensor. 7. Install cowl vent screens. 8. START engine and check for proper operation and leaks using propane. For procedure See: Supercharger/Testing and Inspection/Component Tests and General Diagnostics Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Duct > Component Information > Service and Repair > Inlet Tube > Page 4172 Intake Air Duct: Service and Repair Mini-Sealing Procedure Intercooler Tube Connections For leaks at joint between intercooler and inlet or outlet tube: 1. Slightly loosen nut retaining inlet tube to alternator-power steering pump bracket. 2. Tighten nuts at intercooler flanges to 15-22 lb. ft. (20-30 N-m). 3. Tighten nut at alternator-power steering pump bracket to 30-40 lb. ft. (40-55 N-m). 4. Recheck all joints with propane. Supercharger Outlet Adapter/Tube Connection For leak(s) at supercharger outlet adapter collar and the inlet tube joint: 1. Slightly loosen nut retaining inlet tube to alternator-power steering pump bracket. 2. Tighten collar to 148 lb. ft. (200 N-m). 3. Wait 10 minutes minimum and retighten collar to 148 lb. ft. (200 N-m). NOTE: When compressed, the sealant tape flows and forms to the sealing surface. If the "collar" is not retorqued, the torque of the "collar" will drop causing a leak at this joint. 4. Tighten nut at alternator-power steering pump bracket to 30-40 lb.ft. (40-55 N-m). 5. Recheck all joints with propane. Intake Elbow Adapter/Outlet Tube Connection For leak(s) at intake elbow adapter to outlet tube joint: 1. Slightly loosen nut retaining outlet tube to alternator-power steering pump bracket. 2. Loosen bolt retaining outlet tube to cylinder block support bracket bottom. 3. Tighten nuts at intake elbow adapter to 15-22 lb. ft. (20-30 N-m). 4. Tighten nut at alternator-power steering pump bracket to 30-40 lb. ft. (40-55 N-m). 5. Tighten bolt retaining outlet tube to cylinder block support bracket to 30-40 lb. ft. (40-55 N-m). 6. Recheck all joints with propane. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Upper Intake Manifold <--> [Intake Air Plenum] > Component Information > Service and Repair Upper Intake Manifold: Service and Repair Supercharger REMOVAL 1. Partially drain coolant. 2. Remove cowl vent screens. 3. Remove elbow assembly as outlined. 4. Remove throttle valve intake air tube. 5. Disconnect throttle cable. 6. Disconnect coolant hoses at throttle housing. 7. Remove throttle cable bracket retaining bolts and position bracket out of the way. 8. Disconnect PCV tube. 9. Disconnect vacuum lines, plenum assembly and EGR transducer. 10. Disconnect electrical connections at throttle position sensor, idle air bypass valve and EGR transducer. 11. Remove two EGR retaining bolts and pull EGR away from plenum (if equipped). 12. Remove EGR transducer bracket mounting screw and remove transducer. 13. Remove four plenum assembly retaining bolts 14. Loosen bypass hose clamp. 15. Remove plenum and throttle body assembly as a unit. Remove four throttle body attaching nuts and separate plenum from throttle body. INSTALLATION 1. Clean and inspect gasket surfaces. 2. Install throttle valve assembly to plenum, using new gasket. Tighten nuts to 20-30 Nm (1 5-22 lb-ft). 3. Apply Loctite 510 or equivalent to plenum mating surface. Slide plenum into bypass hose and install plenum assembly and four retaining bolts. Tighten to 21-32 Nm (16-24 lb-ft). Tighten clamps to 2.3-3.4 Nm (20-30 lb-in). 4. Install EGR transducer and bracket. Tighten bolt to 8-11.5 Nm (72-96 lb-in). 5. Install EGR valve. Tighten bolts to 20-30 Nm (15-22 lb-ft). Ensure new gasket is in place. 6. Connect electrical connectors at EGR transducer, idle air bypass valve and throttle position sensor. 7. Connect coolant hoses to throttle housing. 8. Connect vacuum lines at plenum and EGR transducer. Install PCV tube. 9. Install throttle cable bracket. Tighten bolts to 20-30 Nm (15-22 lb-ft). 10. Connect throttle cable. 11. Install air intake tube. 12. Install elbow assembly as outlined. 13. Install cowl vent screens. 14. Top off coolant. 15. START engine and check for proper operation and leaks using propane. For procedure See: Supercharger/Testing and Inspection/Component Tests and General Diagnostics Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions Integrated Control Relay Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4180 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4181 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4182 Integrated Control Relay Module: Electrical Diagrams Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4183 Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Inside Power Distribution Box Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Customer Interest for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: Customer Interest Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Pump Relay: > 90183 > Aug > 90 > Fuel Pump - Buzzing/Humming After Engine Shut Down Fuel Pump Relay: All Technical Service Bulletins Fuel Pump - Buzzing/Humming After Engine Shut Down ^ NO START - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L - LOW STATE OF BATTERY CHARGE ^ BATTERY - DISCHARGED - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ FUEL PUMP - NOISY - 1.9L, 2.3L, 3.0L, 3.8L, 4.9L, 5.0L, 5.8L, 7.5L ^ NOISE - "BUZZING" OR "HUMMING" FROM FUEL PUMP AFTER ENGINE IS TURNED OFF Article No. 90-18-3 FORD: 1983-90 CROWN VICTORIA, ESCORT, EXP, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-90 TAURUS LINCOLN-MERCURY: 1983-87 LYNX 1983-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1985-86 CAPRI, MARQUIS 1986-90 SABLE LIGHT TRUCK: 1983-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A "buzzing" or "humming" noise from the fuel pump may occur after the engine has been shut off. There may also be a no start condition or a discharged battery. These conditions are caused by a sticking fuel pump relay. ACTION: Install a new fuel pump relay. Refer to the following procedure for service details. 1. Check the fuel pump relay circuit for proper operation. Refer to the appropriate EVTM for troubleshooting details. 2. Install a new fuel pump relay, if the old one is defective. 3. Check the vehicle for proper operation. PART NUMBER PART NAME F19Z-9345-A Fuel Pump Relay Assy. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901803A 1985-86 LTD/Marquis 0.6 Hr. (includes pinpoint test) 901803A 1990 Town Car (includes 0.4 Hr. pinpoint test) 901803A All Other Cars (includes 0.5 Hr. pinpoint test) 901803A All Trucks (includes pinpoint 0.5 Hr. test) DEALER CODING BASIC PART NO. CONDITION CODE 9345 09 OASIS CODES: 404000, 603300, 203000, 203100, 702000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Technical Service Bulletins > Page 4201 Fuel Pump Relay: Locations FUEL INJECTORS: The fuel injectors are mounted in the lower intake manifold. FUEL PRESSURE REGULATOR: The fuel pressure regulator is attached to the fuel supply manifold. FUEL FILTER: The filter is located downstream of the electric electric fuel pump and is mounted on the underbody. FUEL PUMP: The fuel pump is mounted on the fuel sender assembly inside of the fuel tank. FUEL PUMP RELAY: LH side of trunk, behind wheelwell. INERTIA SWITCH: The inertia switch is located on the LH side of trunk, behind wheelwell. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4204 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 4205 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description Fuel Pump Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4208 X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 - CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4209 Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4210 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4211 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4212 Fuel Pump Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4213 X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 - CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4214 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4215 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4216 Fig. 23 Integrated Controller Pinpoint Tests X13 & X14 (Part 4 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4217 Fig. 23 Integrated Controller Pinpoint Tests X15 (Part 5 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4218 Fig. 23 Integrated Controller Pinpoint Test X16 & X17 (Part 6 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4219 Fig. 23 Integrated Controller Pinpoint Tests X18, X19, X20 & X21 (Part 7 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4220 Fig. 23 Integrated Controller Pinpoint Test X22 (Part 8 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4221 Fig. 23 Integrated Controller Pinpoint Tests X23 & X25 (Part 9 Of 26) Fig. 23 Integrated Controller Pinpoint Tests X26, X27 & X30 (Part 10 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4222 Fig. 23 Integrated Controller Pinpoint Tests X31 & X32 (Part 11 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4223 Fig. 23 Integrated Controller Pinpoint Tests X33 & X35 (Part 12 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4224 Fig. 23 Integrated Controller Pinpoint Tests X36 & X37 (Part 13 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4225 Fig. 23 Integrated Controller Pinpoint Tests X40, X41, X42 & X43 (Part 14 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4226 Fig. 23 Integrated Controller Pinpoint Tests X44, X45 & X46 (Part 15 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4227 Fig. 23 Integrated Controller Pinpoint Tests X50, X51 & X52 (Part 16 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4228 Fig. 23 Integrated Controller Pinpoint Tests X53, X54 & X55 (Part 17 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4229 Fig. 23 Integrated Controller Pinpoint Tests X56, X57 & X58 (Part 18 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4230 Fig. 23 Integrated Controller Pinpoint Tests X59, X60 & X80 (Part 19 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4231 Fig. 23 Integrated Controller Pinpoint Tests X81, X82 & X83 (Part 20 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4232 Fig. 23 Integrated Controller Pinpoint Tests X84, X90 & X91 (Part 21 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4233 Fig. 23 Integrated Controller Pinpoint Tests X92, X93 & X94 (Part 22 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4234 Fig. 23 Integrated Controller Pinpoint Tests X95 & X96 (Part 23 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4235 Fig. 23 Integrated Controller Pinpoint Tests X100 & X101 (Part 24 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4236 Fig. 23 Integrated Controller Pinpoint Tests X102 & X103 (Part 25 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Testing and Inspection > Test Steps Description > Page 4237 Fig. 23 Integrated Controller Pinpoint Test X104 (Part 26 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions Integrated Control Relay Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4242 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4243 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4244 Integrated Control Relay Module: Electrical Diagrams Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Integrated Control Relay Module > Component Information > Diagrams > Diagram Information and Instructions > Page 4245 Integrated Controller Pin Usage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel Delivery and Air Induction > Main Relay (Computer/Fuel System) > Component Information > Locations Main Relay (Computer/Fuel System): Locations Inside Power Distribution Box Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Technical Service Bulletins > Recalls for Rollover Valve: > NHTSA88V165000 > Oct > 88 > Recall 88V165000: Fuel Tank Leaks Rollover Valve: Recalls Recall 88V165000: Fuel Tank Leaks PLASTIC ROLL-OVER VALVE MOUNTING PLATE MAY NOT BE PROPERLY SEALED TO THE PLASTIC FUEL TANK. FUEL OR VAPOR COULD LEAK, WHICH COULD RESULT IN A VEHICLE FIRE. REPLACE FUEL TANK. SYSTEM: FUEL TANK. VEHICLE DESCRIPTION: PASSENGER CARS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rollover Valve: > NHTSA88V165000 > Oct > 88 > Recall 88V165000: Fuel Tank Leaks Rollover Valve: All Technical Service Bulletins Recall 88V165000: Fuel Tank Leaks PLASTIC ROLL-OVER VALVE MOUNTING PLATE MAY NOT BE PROPERLY SEALED TO THE PLASTIC FUEL TANK. FUEL OR VAPOR COULD LEAK, WHICH COULD RESULT IN A VEHICLE FIRE. REPLACE FUEL TANK. SYSTEM: FUEL TANK. VEHICLE DESCRIPTION: PASSENGER CARS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications Air Flow Meter/Sensor: Specifications Mass or Vane Airflow Sensor Engines with multi-port injection. 1.6L MFI, 1.9L MFI, 2.3L MFI: Vane Airflow Sensors, measured between second upper terminal (W/BK wire) and ground. 3.0L SHO, 3.8L Supercharged, 5.0L MFI H.O.: Mass Airflow Sensors, measured between terminal D (upper most) and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 4266 Air Flow Meter/Sensor: Locations Engine Compartment Component Locations RH Front Of Engine Compartment, In Air Duct Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Air Flow Meter/Sensor > Component Information > Specifications > Page 4267 Air Flow Meter/Sensor: Description and Operation The vane air flow meter measures air flowing into the engine and is mounted between the air cleaner and the throttle body assembly. The meter contains a movable vane directly connected to a potentiometer. Air rushing through the vane air flow meter, changes the position of the vane and potentiometer. The potentiometer relays vane position information to the EEC-IV module. The EEC-IV module, translates vane position information into the amount of air flowing into the engine. An air temperature sensor is incorporated within the engine and also transmits the information to the EEC-IV module. The EEC-IV module receives, then computes the air flow and air temperature information and adjusts the fuel flow to obtain the optimum air/fuel mixture required. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Locations Fuel Pump Inertia Switch: Locations FUEL INJECTORS: The fuel injectors are mounted in the lower intake manifold. FUEL PRESSURE REGULATOR: The fuel pressure regulator is attached to the fuel supply manifold. FUEL FILTER: The filter is located downstream of the electric electric fuel pump and is mounted on the underbody. FUEL PUMP: The fuel pump is mounted on the fuel sender assembly inside of the fuel tank. FUEL PUMP RELAY: LH side of trunk, behind wheelwell. INERTIA SWITCH: The inertia switch is located on the LH side of trunk, behind wheelwell. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions Fuel Pump Inertia Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4273 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Diagram Information and Instructions > Page 4274 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Fuel Pump Inertia Switch <--> [Inertia Fuel Shutoff Switch] > Component Information > Diagrams > Page 4275 Fuel Pump Inertia Switch: Description and Operation Typical Inertia Fuel Shut-Off Switch PURPOSE The inertia switch is used to shut the fuel pump "Off" in the event of a collision. CONSTRUCTION The inertia switch consists of a steel ball held in place by a magnet. OPERATION When a sharp impact occurs, the ball breaks loose from the magnet, rolls up a conical ramp and strikes a target plate. This opens the electrical contacts of the switch and disrupts power to the electric fuel pump. The engine will quit running within a few seconds after the fuel pump loses power. The inertia switch must then be manually reset before the engine can be restarted. WARNING: DO NOT reset the inertia switch button if you see or smell fuel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4280 Technical Service Bulletin # 88265 Date: 881221 EEC IV Pinpoint - Test Manual Correction EEC IV - PINPOINT TESTS A, N AND P - 3.0L "SHO" AND 3.8L "SUPERCHARGED" ENGINES SHOP MANUAL CORRECTION Article No. 88-26-5 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: EEC IV pinpoint test "A" EEC IV No Start, "N" Ignition/Erratic and "P" Spark Timing Check are incorrect as published in the 1989 Engine/Emissions Diagnosis Manual, Section 17-5, 17-310 and 17-322. The Diagnostic schematics did not include the 3.0L "SHO" and 3.8L "Supercharged" crankshaft sensor connectors or the ignition coil connectors. ACTION: Use the pinpoint diagnostic information on pages 15 through 20 of this TSB article. This information should be inserted in your 1989 Engine/Emission Diagnosis Shop Manual, Section 17-5, 17-310 and 17-322 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODE: 680000 EEC-IV No Start EEC-IV-Pinpoint Tests - All Vehicles 1989 17-5 EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4281 Pinpoint Test Schematic 17-6 1989 EEC-IV-Pinpoint Tests - All Vehicles EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4282 WARNING STOP THIS TEST AT THE FIRST SIGN OF A FUEL LEAK AND SERVICE AS REQUIRED. CAUTION No open flame - No smoking during fuel delivery checks. Ignition/Erratic Diagnostic Monitor (IDM) EEC-IV - Pinpoint Tests - All Vehicles 1989 17-309 Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4283 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4284 Pinpoint Test Schematic 17-310 1989 EEC-IV - Pinpoint Tests - All Vehicles Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Spark Timing Check EEC-IV - Pinpoint Tests - All Vehicles 1989 17-321 Spark Timing Check Pinpoint P Note Test You should enter this Pinpoint Test only when directed here from Quick Test Step 4.0, when a Service Code 18 is received in Quick Test Step 5.0 or a code 49 is received in Quick Test Step 6.0. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4285 Remember To prevent the replacement of good components, be aware that the following non-EEC areas may be at fault: ^ Base Engine ^ Camshaft Sensor (CID) ^ Distributor ^ Single Hall Crankshaft Sensor (PIP) ^ TFI or DIS Module ^ Dual Hall Sensor This Pinpoint Test is intended to diagnose only the following: ^ Harness Spout Circuit ^ Base Timing ^ Processor Assembly (-12A650-) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4286 Pinpoint Test Schematic 17-322 1989 EEC-IV - Pinpoint Tests - All Vehicles Pinpoint Spark Timing Check Test P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications Throttle Position Sensor (TPS) Engines with EEC III: Turn ignition to RUN position and remove vacuum hose from throttle kicker as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV: Connect positive (+) probe of DVOM along the DG/LG wire of TPS. Connect negative (-) probe along the BK/W wire and turn ignition on but do not start engine. Adjust TPS to specified value. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 4289 Throttle Position Sensor: Mechanical Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4290 Throttle Position Sensor: Description and Operation The throttle position sensor is used by the EEC computer to determine the operating mode (closed throttle, part throttle or wide open throttle) for selection of the proper air/fuel mixture, spark and EGR. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4291 Throttle Position Sensor: Adjustments Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Description and Operation Intercooler: Description and Operation Supercharger System The intercooler cools the pressurized air from the supercharger, increasing the air density, which improves combustion efficiency, engine horsepower and torque. At low throttle, the engine runs under vacuum due to normal intake restrictions. To prevent supercharger cavitation, reduced performance and increased temperatures, a vacuum-controlled bypass valve is installed at the supercharger outlet. The bypass valve allows a controlled amount of the airflow from the supercharger outlet back into the supercharger. As the throttle opening is increased, the actuator closes the bypass valve, directing all the air from the supercharger to the intake manifold. This occurs as soon as the throttle opens, resulting in immediate response. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Supercharger > Intercooler, Supercharger > Component Information > Description and Operation > Page 4296 Intercooler: Service and Repair Supercharger System REMOVAL 1. Remove four retaining nuts connecting upper and lower intercooler tubes to intercooler. 2. Slightly loosen upper intercooler tube (inlet tube) nut at alternator-power steering pump bracket. 3. Remove intercooler retaining screw and washer assemblies. 4. Push down slightly on intercooler to release retaining clips. 5. Remove intercooler from vehicle. INSTALLATION 1. Apply gasket sealant tape (Teflon) to intercooler tubes as outlined in INLET TUBE and OUTLET TUBE. 2. Position intercooler in retaining clips and align with outlet tube. 3. Install intercooler retaining screw and washer assemblies. Tighten to 4-6 Nm (3-5 lb-ft). NOTE: Ensure air boot fits squarely to intercooler with no gaps. 4. Connect outlet tube and connect inlet tube as outlined in INLET TUBE and OUTLET TUBE. 5. START engine and check for proper operation and leaks using propane. For procedure See: Testing and Inspection/Component Tests and General Diagnostics Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Recalls: > 93B31 > Dec > 93 > Campaign - Throttle Lever Grommet Replacement Technical Service Bulletin # 93B31 Date: 931201 Overview of Program 93B31 December, 1993 TO: All Ford and Lincoln-Mercury Dealers SUBJECT: Owner Notification Program 93B31 - Replacement of Throttle Body Lever Grommet on Certain 1987 Through 1993 Passenger Cars Equipped With Automatic Overdrive Transmissions OASIS - YES OWNER LIST - YES PARTS RETURN - NO PROGRAM TIMING - For 1987-1991 vehicles: Through 12 month/12,000 mile basic vehicle warranty, or through December 31, 1994, whichever provides greater coverage. For 1992-1993 vehicles: Through 36 month/36,000 mile Bumper-to-Bumper warranty, or through December 31, 1994, whichever provides greater coverage. AFFECTED VEHICLES Vehicles involved in this program are certain 1987-1993 passenger cars equipped with automatic overdrive transmissions that were originally sold or are currently registered in counties of the extreme southern states which experience both high humidity and high temperatures. This area is generally in a band extending approximately 100 miles north from the Gulf of Mexico coastline in the following states plus the entire state of Hawaii and Florida: Alabama, Georgia, Louisiana, Mississippi and Texas. Affected vehicles can be identified by checking OASIS. Specific vehicle information - See illustration. REASONS FOR THIS PROGRAM The urethane grommet that holds the transmission throttle valve cable in the throttle body lever may deteriorate and fall out allowing the cable to disconnect from the lever. Should the cable become disconnected during normal vehicle operation, the transmission bands and clutches will immediately begin to slip. Under this condition, the bands and clutches will wear out within several miles, rendering the vehicle inoperative. SERVICE ACTION To correct this condition, dealers are to replace the urethane throttle lever grommet with a brass bushing and steel retaining clip. In instances where an owner whose vehicle is not listed in OASIS believes the vehicle should have been included or this condition is observed in a vehicle not covered by this action, obtain prior FCSD District Office approval and submit an 1863 claim via DWE in the normal manner for reimbursement. REFUNDS Only for owner-paid repairs made before date of Owner Letter. ATTACHMENTS Attachment I Administrative Information - Refund Codes Attachment II Labor Allowances - Parts Ordering Information Attachment III Technical Information Attachment I - Administrative Information Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Recalls: > 93B31 > Dec > 93 > Campaign - Throttle Lever Grommet Replacement > Page 4305 ATTACHMENT I B Program OASIS YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS PROGRAM. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. - Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. FCSD CONTACT Talk with your FCSD Service Zone Manager about program concerns. FORM 1863 Enter 1863 claims using DWE (or mail direct) See Warranty and Policy Manual: - Section 5.6 - 1/Section 6.1 - 24 (Owner Notification Programs) OWNER REFUNDS See Warranty and Policy Manual: - Section 6.1 - Pages 25 through 26 (Owner Refund) For owner-paid repairs made before date of Owner Letter: - Submit on separate Form 1863 using the codes shown below: Program Code Box - 93B31 Causal Basic Part Number - 7F330 Condition Code - 08 Labor Operation (1st line) - REFUND Labor Operation (2nd line) - ALLOW Administrative Allowance - 0.2 Hrs. Customer Concern Code - N99 Attachment II - Labor and Parts Information ATTACHMENT II B Program OWNER NOTIFICATION PROGRAM 93B31 AOD Transmission - Throttle Body Lever Grommet PARTS REQUIREMENTS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Recalls: > 93B31 > Dec > 93 > Campaign - Throttle Lever Grommet Replacement > Page 4306 Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Parts prices current until next issue of Master Price Book. For latest prices, check or call your: - Order Processing Center - DOES II - Updated Price Book CLAIMS PREPARATIONS Use Form 1863 - Enter using DWE (or mail) - Use code information shown below: Program Code - 93B31 Causal Basic Part Number - 7F330 Condition Code - 08 Labor Operation - B31B Customer Concern Code - N99 Attachment III - Technical Instructions ATTACHMENT III B Program OWNER NOTIFICATION PROGRAM 93B31 AOD Transmission - Throttle Body Lever Grommet TECHNICAL INSTRUCTIONS THROTTLE BODY LEVER GROMMET REPLACEMENT PROCEDURES 1. Pull the TV cable/rod trunnion out of the throttle body lever grommet. 2. Remove and discard the urethane grommet from the throttle body lever. 3. Place the new brass bushing in the throttle body lever by inserting the smaller diameter section into the lever. The large diameter should be on the TV cable side of the throttle body lever 4. Insert the trunnion of the TV rod completely into the brass bushing and install the retaining clip in the groove of the TV rod trunnion. Owner Letter Serial Number 1FMCA11S6XYZ12345 Date here Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a no-charge Service Program, Number 93B31, to owners of certain 1987 through 1993 passenger cars equipped with automatic overdrive transmissions. REASON FOR THIS PROGRAM The urethane grommet that holds the transmission throttle valve cable in the throttle body lever may deteriorate and fall out allowing the cable to disconnect from the lever. Should the cable become disconnected during normal vehicle operation, the transmission bands and clutches will immediately begin to slip. Under this condition, the transmission bands and clutches will wear out within several miles, rendering the vehicle inoperative. NO COST SERVICE At no charge to you, your dealer will replace the urethane throttle lever grommet with a brass bushing and steel retaining clip. For model year 1987-1991 vehicles, this no charge service is available through the 12 month/12,000 mile basic vehicle warranty period, or through December 31, 1994, whichever provides greater coverage. For model year 1992-1993 vehicles, this no charge service is available through the 36 month/36,000 mile Bumper-to-Bumper vehicle warranty period, or through December 31, 1994, whichever provides greater coverage. HOW LONG WILL IT TAKE? The time needed for this service is less than one hour. However, due to service scheduling times, your dealer may need your car for one full working day. CALL YOUR DEALER Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Recalls: > 93B31 > Dec > 93 > Campaign - Throttle Lever Grommet Replacement > Page 4307 Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS If you paid to have this service done before the date of this letter, Ford is offering a full refund. For the refund, please show your paid work-order to your Ford or Lincoln-Mercury dealer. CHANGED ADDRESS OR SOLD THE CAR? Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the car. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4313 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4314 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4315 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4316 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4317 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4318 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4319 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4320 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4321 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4322 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4323 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4324 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4325 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4326 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4327 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4328 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > Customer Interest: > 91257 > Dec > 91 > Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4329 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 93B31 > Dec > 93 > Campaign - Throttle Lever Grommet Replacement Technical Service Bulletin # 93B31 Date: 931201 Overview of Program 93B31 December, 1993 TO: All Ford and Lincoln-Mercury Dealers SUBJECT: Owner Notification Program 93B31 - Replacement of Throttle Body Lever Grommet on Certain 1987 Through 1993 Passenger Cars Equipped With Automatic Overdrive Transmissions OASIS - YES OWNER LIST - YES PARTS RETURN - NO PROGRAM TIMING - For 1987-1991 vehicles: Through 12 month/12,000 mile basic vehicle warranty, or through December 31, 1994, whichever provides greater coverage. For 1992-1993 vehicles: Through 36 month/36,000 mile Bumper-to-Bumper warranty, or through December 31, 1994, whichever provides greater coverage. AFFECTED VEHICLES Vehicles involved in this program are certain 1987-1993 passenger cars equipped with automatic overdrive transmissions that were originally sold or are currently registered in counties of the extreme southern states which experience both high humidity and high temperatures. This area is generally in a band extending approximately 100 miles north from the Gulf of Mexico coastline in the following states plus the entire state of Hawaii and Florida: Alabama, Georgia, Louisiana, Mississippi and Texas. Affected vehicles can be identified by checking OASIS. Specific vehicle information - See illustration. REASONS FOR THIS PROGRAM The urethane grommet that holds the transmission throttle valve cable in the throttle body lever may deteriorate and fall out allowing the cable to disconnect from the lever. Should the cable become disconnected during normal vehicle operation, the transmission bands and clutches will immediately begin to slip. Under this condition, the bands and clutches will wear out within several miles, rendering the vehicle inoperative. SERVICE ACTION To correct this condition, dealers are to replace the urethane throttle lever grommet with a brass bushing and steel retaining clip. In instances where an owner whose vehicle is not listed in OASIS believes the vehicle should have been included or this condition is observed in a vehicle not covered by this action, obtain prior FCSD District Office approval and submit an 1863 claim via DWE in the normal manner for reimbursement. REFUNDS Only for owner-paid repairs made before date of Owner Letter. ATTACHMENTS Attachment I Administrative Information - Refund Codes Attachment II Labor Allowances - Parts Ordering Information Attachment III Technical Information Attachment I - Administrative Information Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 93B31 > Dec > 93 > Campaign - Throttle Lever Grommet Replacement > Page 4335 ATTACHMENT I B Program OASIS YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS PROGRAM. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. - Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. FCSD CONTACT Talk with your FCSD Service Zone Manager about program concerns. FORM 1863 Enter 1863 claims using DWE (or mail direct) See Warranty and Policy Manual: - Section 5.6 - 1/Section 6.1 - 24 (Owner Notification Programs) OWNER REFUNDS See Warranty and Policy Manual: - Section 6.1 - Pages 25 through 26 (Owner Refund) For owner-paid repairs made before date of Owner Letter: - Submit on separate Form 1863 using the codes shown below: Program Code Box - 93B31 Causal Basic Part Number - 7F330 Condition Code - 08 Labor Operation (1st line) - REFUND Labor Operation (2nd line) - ALLOW Administrative Allowance - 0.2 Hrs. Customer Concern Code - N99 Attachment II - Labor and Parts Information ATTACHMENT II B Program OWNER NOTIFICATION PROGRAM 93B31 AOD Transmission - Throttle Body Lever Grommet PARTS REQUIREMENTS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 93B31 > Dec > 93 > Campaign - Throttle Lever Grommet Replacement > Page 4336 Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Parts prices current until next issue of Master Price Book. For latest prices, check or call your: - Order Processing Center - DOES II - Updated Price Book CLAIMS PREPARATIONS Use Form 1863 - Enter using DWE (or mail) - Use code information shown below: Program Code - 93B31 Causal Basic Part Number - 7F330 Condition Code - 08 Labor Operation - B31B Customer Concern Code - N99 Attachment III - Technical Instructions ATTACHMENT III B Program OWNER NOTIFICATION PROGRAM 93B31 AOD Transmission - Throttle Body Lever Grommet TECHNICAL INSTRUCTIONS THROTTLE BODY LEVER GROMMET REPLACEMENT PROCEDURES 1. Pull the TV cable/rod trunnion out of the throttle body lever grommet. 2. Remove and discard the urethane grommet from the throttle body lever. 3. Place the new brass bushing in the throttle body lever by inserting the smaller diameter section into the lever. The large diameter should be on the TV cable side of the throttle body lever 4. Insert the trunnion of the TV rod completely into the brass bushing and install the retaining clip in the groove of the TV rod trunnion. Owner Letter Serial Number 1FMCA11S6XYZ12345 Date here Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a no-charge Service Program, Number 93B31, to owners of certain 1987 through 1993 passenger cars equipped with automatic overdrive transmissions. REASON FOR THIS PROGRAM The urethane grommet that holds the transmission throttle valve cable in the throttle body lever may deteriorate and fall out allowing the cable to disconnect from the lever. Should the cable become disconnected during normal vehicle operation, the transmission bands and clutches will immediately begin to slip. Under this condition, the transmission bands and clutches will wear out within several miles, rendering the vehicle inoperative. NO COST SERVICE At no charge to you, your dealer will replace the urethane throttle lever grommet with a brass bushing and steel retaining clip. For model year 1987-1991 vehicles, this no charge service is available through the 12 month/12,000 mile basic vehicle warranty period, or through December 31, 1994, whichever provides greater coverage. For model year 1992-1993 vehicles, this no charge service is available through the 36 month/36,000 mile Bumper-to-Bumper vehicle warranty period, or through December 31, 1994, whichever provides greater coverage. HOW LONG WILL IT TAKE? The time needed for this service is less than one hour. However, due to service scheduling times, your dealer may need your car for one full working day. CALL YOUR DEALER Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 93B31 > Dec > 93 > Campaign - Throttle Lever Grommet Replacement > Page 4337 Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS If you paid to have this service done before the date of this letter, Ford is offering a full refund. For the refund, please show your paid work-order to your Ford or Lincoln-Mercury dealer. CHANGED ADDRESS OR SOLD THE CAR? Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the car. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4342 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4343 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4344 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4345 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4346 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4347 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4348 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4349 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4350 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4351 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4352 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4353 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4354 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4355 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4356 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4357 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4358 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up Technical Service Bulletin # 91257 Date: 911213 Engine - Hard Cold Starts/Hesitation/Stalls On Start-Up Article No. 91-25-7 12/13/91 ^ HARD COLD START - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE ^ HESITATION/STALLS - DURING INITIAL START-UP, IDLE OR DECEL - EFI ENGINES SLUDGE IN THROTTLE BODY AND/OR IDLE AIR BY-PASS VALVE FORD: 1983-87 EXP 1983-91 ESCORT 1984-90 MUSTANG, THUNDERBIRD 1986-90 TAURUS 1986-91 CROWN VICTORIA 1988-90 TEMPO LINCOLN-MERCURY: 1983-85 LN7 1983-87 LYNX 1984-88 CAPRI 1984-90 COUGAR 1986-90 CONTINENTAL, MARK VII, SABLE 1986-91 GRAND MARQUIS, TOWN CAR 1988-90 TOPAZ 1991 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO 1985-91 ECONOLINE, F-150-350 SERIES 1985-92 RANGER 1986-91 AEROSTAR 1991 EXPLORER ISSUE: Hard cold starts, hesitation and stalls on initial start-up or during idle or decel may be caused by sludge in the throttle body and/or idle by-pass valve. Sludge deposits or oil film on the throttle body bore and plate or the idle air by-pass valve may cause one or more of the following conditions. ^ Hard Cold Start ^ Stall On Initial Start-Up ^ Stall During Idle ^ Stall During Decel ^ Rough Idle ^ Rolling Idle ^ Hesitation During Acceleration ACTION: A new idle air by-pass service kit (F2PZ-9F939-A) is now available for service use to correct sludge contamination concerns of the throttle bore and plate only. It eliminates the need to clean the majority of past model throttle body applications. Cleaning is not required on sludge tolerant throttle body designs released for 1991 and newer model years. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4364 Figure 1 Install an idle air by-pass service kit (F2PZ-9F939-A) as applicable to provide a permanent correction for symptoms caused by throttle body sludge deposits. Refer to the instruction sheet included in the kit for installation details. Refer to Figure 1 for a specific application list of EFI (port fuel Injection) engines involved in this TSB article. The idle air by-pass service kit (F2PZ-9F939-A) includes the following items. ^ One (1) Idle Adjust Spacer ^ Two (2) Gaskets Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4365 ^ Two (2) Attaching Bolts ^ One (1) "Attention" Sticker ^ One (1) Instruction Sheet Figure 2 Refer to Figure 2 for a pictorial of the kits components. NOTE: EFFECTIVE WITH THIS TSB, THROTTLE BODY CLEANING IS NO LONGER COVERED UNDER 5/50 EMISSIONS WARRANTY, UNLESS AS SPECIFIED IN THE FOLLOWING APPLICATION CHARTS. FAILURE TO FOLLOW THE CORRECT PROCEDURE MAY RESULT IN THE CLAIM BEING DISALLOWED. The idle air adjust spacer incorporates sludge tolerant design features that eliminate throttle body sludge related conditions. Once installed, throttle body cleaning is not allowed and periodic adjustment of the throttle body is not required. Procedures, Warranty and Labor CHECKS TO MAKE PRIOR TO SERVICE KIT INSTALLATION Confirm that the following items are not causing the idle quality concern before proceeding with the service kit installation. ^ Contamination within the idle air by-pass solenoid ^ Lack of fuel system control (excessively rich or lean) ^ Ignition timing change ^ Incorrect or malfunctioning EGR system ^ Incorrect or malfunctioning cooling system ^ Vacuum leaks (air intake manifold, vacuum hoses, vacuum reservoirs, power brake booster where applicable) ^ EEC diagnostics have been performed and vehicle malfunction indicated service output codes have been resolved and cleared. If any of the areas listed above are found to be at fault, correct them before proceeding with the service kit installation. Idle Speed Adjustment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4366 WARNING: BEFORE PROCEEDING WITH THE IDLE SPEED ADJUSTMENT, VERIFY THAT THE FOLLOWING ITEMS ARE TAKEN CARE OF PROPERLY. ^ The transmission is in PARK or Neutral. ^ The parking brake is applied. ^ The wheels are properly blocked. ^ The engine is at operating temperature. ^ The heater, A/C, cooling fan and other accessories are OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4367 Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4368 Figure 4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4369 Figure 5 The EFI throttle body idle speed adjustment procedures for the various model year passenger cars and light trucks are outlined in step-by-step procedures featured in Figures 3, 4 and 5. Select the appropriate procedure for the vehicle involved and adjust the throttle body idle RPM accordingly, after service kit installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4370 Figure 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4371 Figure 7 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4372 Figure 8 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4373 Figure 9 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4374 Figure 10 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4375 Figure 11 THROTTLE BODY AND IDLE AIR BY-PASS SOLENOID SERVICE PROCEDURE Detailed application charts for throttle body and idle air by-pass solenoid service procedures by engine VIN # /engine displacement/vehicle application and model year are shown in Figures 6 through 11. Refer to these charts to see if the service kit is to be installed and which service cleaning procedure, if any, is to be used. SERVICE CLEANING PROCEDURES The following items should be noted prior to beginning the service cleaning procedure. ^ Confirm that the correct service cleaning procedure is identified in the Application Charts, Figures 6-11, for the vehicle/engine combination being Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4376 serviced. ^ Do not clean throttle bodies identified to accept service kit (F2PZ-9F939-A), IDLE AIR ADJUST SPACER. ^ Use a 1" (25.4 mm) to 1-1/2" (38.1 mm) wire stemmed horse hair or nylon bottle cleaner type brush. ^ Use rubber gloves and eye protection. ^ Do not clean throttle bodies identified with a yellow/black "ATTENTION" label. ^ Do not clean "Black" plastic air by-pass valves. Refer to TSB 89-13-8 for service details. ^ Do not run vehicles with air flow meters when the air duct is removed. ^ Do not use carburetor cleaner as a cleaning solvent. Use Carburetor Tune-up Cleaner (D9AZ-19579-AA). Procedure # 1 THROTTLE BODY AND IDLE AIR BY-PASS VALVE CLEANING CAUTION: DO NOT RUN VEHICLES EQUIPPED WITH AIR FLOW METERS DURING THE CLEANING PROCEDURE. IF THERE IS A YELLOW/BLACK "ATTENTION" LABEL ON THE THROTTLE BODY ADVISING NOT TO CLEAN, OR IF THE VEHICLE IS IDENTIFIED AS ACCEPTING SERVICE KIT (F2PZ-9F939-A), USE PROCEDURE # 2 FOR IDLE AIR BY-PASS VALVE CLEANING ONLY. 1. Plug the actuator into the connector in the Rotunda Cleaner/Tester, Tool 113-00009. 2. Remove the air duct to the throttle body inlet. 3. Disoonnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. Do not start engines that have air flow meters. 6. Spray just enough Carburetor Tune-up Cleaner (D9AZ-19579-AA) into the throttle bore to wet the bore and throttle plate. 7. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. 8. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 9. After a fifteen (15) minute soak, saturate the cleaning brush with solvent and scrub between the throttle body bore and plate while holding the throttle wide open. NOTE: IT IS NECESSARY TO APPLY SOME PRESSURE ON THE BRUSH WHILE SCRUBBING. 10. Repeat saturating the brush and scrubbing for one (1) to two (2) minutes, making sure to reach into the corners where the throttle shaft meets the bore wall. 11. Start the actuator and the start the engine. Do not start engines that have air flow meters. 12. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute to wash away residue. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 13. Spray Carburetor Tune-up Cleaner into the idle by-pass valve passage leading to the inlet of the valve for up to one (1) minute. Do not spray for longer than six (6) continuous seconds on engines that have air flow meters and are not running. 14. Stop actuator and stop engine, if running. NOTE: MAKE SURE THE THROTTLE PLATES OPERATE FREELY AND CLOSE PROPERLY. 15. Reinstall the air duct. 16. Start and run the engine for about one (1) minute to dry out the solvent residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4377 17. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 18. Disconnect the actuator from the idle air by-pass valve. 19. Reattach the control signal lead to the air by-pass valve. 20. Check engine for normal operation. It may be necessary to reset the idle speed due to a previous adjustment for an idle concern. (Refer to the respective Powertrain/Emissions Diagnosis Service Manual, Throttle Body Section, for idle speed adjust procedure.) Procedure # 2 Idle Air By-Pass Valve Cleaning Only CAUTION: THIS CLEANING PROCEDURE MAY BE USED WITH SLUDGE TOLERANT THROTTLE BODIES WHICH ARE IDENTIFIED WITH A YELLOW/BLACK "ATTENTION" LABEL AND THOSE USING SERVICE KIT (F2PZ-9F939-A). NO ATTEMPT SHOULD BE MADE TO CLEAN THROTTLE BODY BORE/PLATE AREA BY DIRECT SPRAYING OR SCRUBBING. DO NOT RUN VEHICLES WITH AIR FLOW METERS DURING CLEANING PROCEDURE. 1. Plug the actuator into the connector in the Rotunda Air By-Pass Valve Adapter 113-00009, or equivalent. 2. Remove the air duct to the throttle body inlet. 3. Disconnect the idle air by-pass valve signal lead. 4. Attach the actuator harness plug to the idle air by-pass valve. 5. Start the actuator and then start the engine. NOTE: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 6. Spray the Carburetor Tune-up Cleaner for about five (5) seconds into the idle air by-pass valve inlet passage while the actuator is operating. CAUTION: AVOID DIRECT SPRAYING ON THROTTLE PLATE/BORE AREA. 7. Stop the engine and actuator. Let everything soak for fifteen (15) minutes. 8. Start the actuator and the start the engine. CAUTION: DO NOT START ENGINES THAT HAVE AIR FLOW METERS. 9. Spray Carburetor Tune-up Cleaner into the throttle bore for up to one (1) minute. CAUTION: DO NOT SPRAY FOR LONGER THAN SIX (6) CONTINUOUS SECONDS ON ENGINES THAT HAVE AIR FLOW METERS AND ARE NOT RUNNING. 10. Stop actuator and stop engine if running. 11. Reinstall the air duct. 12. Start and run the engine for about one (1) minute to dry out the solvent residue. 13. Operate the actuator to make sure the solvent is purged from the idle by-pass valve. 14. Disconnect the actuator from the idle air by-pass valve. 15. Reattach the control signal lead to the air by-pass valve. 16. Check engine for normal operation. NOTE: IT SHOULD NOT BE NECESSARY TO RESET THE IDLE SPEED SINCE ONLY THE IDLE AIR BY-PASS VALVE WAS SERVICED IN THIS PROCEDURE Warranty Coverage Throttle bodies and idle air by-pass valves on all EFI (Port Fuel Injection) engines through the 1992 model year that can be cleaned (as identified in the application charts) are covered under 5/50 Emissions Warranty Coverage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4378 For those throttle bodies identified as having sludge tolerant designs or using service kit (F2PZ-9F939-A) where cleaning is not allowed per the application charts, the warranty claims for cleaning will not be reimbursed even within the 12/12 warranty coverage period. Cleaning is not allowed. Service kit installation (single time) is covered under 5/50 emission warranty. Labor Standards Operations The labor operations shown in the following Operation/Description/Time columns are identified by procedure number and vehicle line. Specific engines for various vehicles are identified in the sludge cleaning procedure application charts. The throttle body cleaning operations with combinations and the air by-pass valve cleaning combinations will appear in future Labor Manuals under the following operation numbers. ^ 9926 B - Throttle body and idle air by-pass valve cleaning ^ 9926 B2 - Adjust idle speed ^ 9715 A - Air by-pass valve cleaning only ^ 9715 A1 - Adjust idle speed PART NUMBER PART NAME CLASS F2PZ-9F939-A Idle Air By-pass Service Kit B D9AZ-19579-AA Carburstor Tune-Up Cleaner BG OTHER APPLICABLE ARTICLES: 89-13-8 SUPERSEDES: 88-24-5, 88-24-6, 89-16-5, 91-10-9, 91-7-4 Operation Description WARRANTY STATUS: Eligible Under Warranty Coverage As Stated In The Text Of This Article OPERATION DESCRIPTION TIME 912507A Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1983-85 Escort, EXP, LN7, LYNX 1.6L EFI. 912507B Idle Air By-Pass Valve 0.5 Hr. Cleaning - 1986-91 Escort 1.9L EFI, 1986/87 EXP, Lynx 1.9L EFI, 1991 Tracer 1.9L EFI. 912507C Idle Air By Pass Valve 0.5 Hr. Cleaning - 1984-87 Mustang 2.3L T/C, 1986/87 Capri, Cougar 2.3L T/C, 1984-88 T-Bird 2.3L T/C, 1987/92 Mustang 2.3L EFI. 912507D Idle By-Pass Valve Cleaning 0.6 Hr. - 1988-91 Tempo, Topaz 2.3L HSC, 1985-92 Ranger 2.3L EFI. 912507E Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986/87 Aerostar 2.3L EFI, 1985 Bronco II 2.3L EFI. 912507F Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1986-90 Bronco II 2.9L EFI, 1986-92 Ranger 2.9L EFI. 912507G Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1991/92 Probe 3.0L EFI, 1986-91 Taurus 3.0L EFI, 1987-91 Sable 3.0L EFI. 912507H Idle Air By-Pass Valve 0.7 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4379 Cleaning - 1986-91 Aerostar 3.0L EFI, 1991 Ranger 3.0L EFI. 912507I Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1988 Continental, Cougar, Taurus, T-Bird, Sable 3.8L EFI. 1988 Cougar, T-Bird 3.8L S/C. 912507J Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1990-92 Aerostar 4.0L EFI, 1990 Bronco II 4.0L EFI, 1991/92 Explorer 4.0L EFI, 1990-92 Ranger 4.0L EFI. 912507K Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 Bronco 4.9L EFI, 1987-92 F-Series 4.9L EFI, 1987/90 Econoline (Without Rear Heater) 4.9L EFI, 1991/92 Econoline (All) 4.9L EFI. 912507L Idle Air By-Pass Valve 0.6 Hr. Cleaning - 1986-88 Cougar, T-Bird 5.0L EFI, 1986-87 Continental, Mark VII 5.OL EFI, 1986/91 Crn - Victoria, Grn - Marquis 5.0L EFI, 1986-92 Mark VII 5.0L HO, 1982-92 Mustang 5.0L HO. 912507M Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1985-92 Bronco, E-Series, F-Series 5.0L EFI. 912507N Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1988-90 Bronco, F-Series 5.8L. 1991 Econo, F-Series, Bronco 5.8L (Do not Clean Solenoid, Calib; 1-64E-R10, 1-64H-R10, 1-64J-R10, 1-64K-R10, 1-64M-R10, 1-64P-R10, 1-64R-R10, 1-75A-R00, 1-76A-R00, 1-76B-R00, 1-76C-R00. 912507O Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1991/92 F And B Series, 7.0L EFI. 912507P Idle Air By-Pass Valve 0.7 Hr. Cleaning - 1987-92 E-Series, F-Series 7.5L EFI. 912507Q Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1989/90 Probe 3.0L EFI. 912507R Throttle Body And Idle Air 0.8 Hr. By-Pass Valve Cleaning - 1987-90 Econoline (With Rear Heat) 4.9L EFI. 912507S Throttle Body And Idle Air 0.9 Hr. By-Pass Valve Cleaning - 1988-90 Econoline 5.8L EFI. 912507T Service Kit Install - All Cars 1.0 Hr. And Light Trucks (Except Aerostar And Econoline) - Refer To The Service Procedure Application Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 91257 > Dec > 91 > Engine Hard Cold Starts/Hesitation/Stalls On Start-Up > Page 4380 Charts, For Vehicle Application. 912507U Service Kit Install - 1.2 Hr. Aerostar, Econoline - Refer To Service Procedure Application Charts - For Vehicle Application. DEALER CODING BASIC PART NO. CONDITION CODE 9E926 49 OASIS CODES: 602300, 607000, 607400, 607700, 608400, 611500, 618400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 93B31 > Dec > 93 > Campaign Throttle Lever Grommet Replacement Technical Service Bulletin # 93B31 Date: 931201 Overview of Program 93B31 December, 1993 TO: All Ford and Lincoln-Mercury Dealers SUBJECT: Owner Notification Program 93B31 - Replacement of Throttle Body Lever Grommet on Certain 1987 Through 1993 Passenger Cars Equipped With Automatic Overdrive Transmissions OASIS - YES OWNER LIST - YES PARTS RETURN - NO PROGRAM TIMING - For 1987-1991 vehicles: Through 12 month/12,000 mile basic vehicle warranty, or through December 31, 1994, whichever provides greater coverage. For 1992-1993 vehicles: Through 36 month/36,000 mile Bumper-to-Bumper warranty, or through December 31, 1994, whichever provides greater coverage. AFFECTED VEHICLES Vehicles involved in this program are certain 1987-1993 passenger cars equipped with automatic overdrive transmissions that were originally sold or are currently registered in counties of the extreme southern states which experience both high humidity and high temperatures. This area is generally in a band extending approximately 100 miles north from the Gulf of Mexico coastline in the following states plus the entire state of Hawaii and Florida: Alabama, Georgia, Louisiana, Mississippi and Texas. Affected vehicles can be identified by checking OASIS. Specific vehicle information - See illustration. REASONS FOR THIS PROGRAM The urethane grommet that holds the transmission throttle valve cable in the throttle body lever may deteriorate and fall out allowing the cable to disconnect from the lever. Should the cable become disconnected during normal vehicle operation, the transmission bands and clutches will immediately begin to slip. Under this condition, the bands and clutches will wear out within several miles, rendering the vehicle inoperative. SERVICE ACTION To correct this condition, dealers are to replace the urethane throttle lever grommet with a brass bushing and steel retaining clip. In instances where an owner whose vehicle is not listed in OASIS believes the vehicle should have been included or this condition is observed in a vehicle not covered by this action, obtain prior FCSD District Office approval and submit an 1863 claim via DWE in the normal manner for reimbursement. REFUNDS Only for owner-paid repairs made before date of Owner Letter. ATTACHMENTS Attachment I Administrative Information - Refund Codes Attachment II Labor Allowances - Parts Ordering Information Attachment III Technical Information Attachment I - Administrative Information Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 93B31 > Dec > 93 > Campaign Throttle Lever Grommet Replacement > Page 4386 ATTACHMENT I B Program OASIS YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS PROGRAM. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. - Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. FCSD CONTACT Talk with your FCSD Service Zone Manager about program concerns. FORM 1863 Enter 1863 claims using DWE (or mail direct) See Warranty and Policy Manual: - Section 5.6 - 1/Section 6.1 - 24 (Owner Notification Programs) OWNER REFUNDS See Warranty and Policy Manual: - Section 6.1 - Pages 25 through 26 (Owner Refund) For owner-paid repairs made before date of Owner Letter: - Submit on separate Form 1863 using the codes shown below: Program Code Box - 93B31 Causal Basic Part Number - 7F330 Condition Code - 08 Labor Operation (1st line) - REFUND Labor Operation (2nd line) - ALLOW Administrative Allowance - 0.2 Hrs. Customer Concern Code - N99 Attachment II - Labor and Parts Information ATTACHMENT II B Program OWNER NOTIFICATION PROGRAM 93B31 AOD Transmission - Throttle Body Lever Grommet PARTS REQUIREMENTS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 93B31 > Dec > 93 > Campaign Throttle Lever Grommet Replacement > Page 4387 Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Parts prices current until next issue of Master Price Book. For latest prices, check or call your: - Order Processing Center - DOES II - Updated Price Book CLAIMS PREPARATIONS Use Form 1863 - Enter using DWE (or mail) - Use code information shown below: Program Code - 93B31 Causal Basic Part Number - 7F330 Condition Code - 08 Labor Operation - B31B Customer Concern Code - N99 Attachment III - Technical Instructions ATTACHMENT III B Program OWNER NOTIFICATION PROGRAM 93B31 AOD Transmission - Throttle Body Lever Grommet TECHNICAL INSTRUCTIONS THROTTLE BODY LEVER GROMMET REPLACEMENT PROCEDURES 1. Pull the TV cable/rod trunnion out of the throttle body lever grommet. 2. Remove and discard the urethane grommet from the throttle body lever. 3. Place the new brass bushing in the throttle body lever by inserting the smaller diameter section into the lever. The large diameter should be on the TV cable side of the throttle body lever 4. Insert the trunnion of the TV rod completely into the brass bushing and install the retaining clip in the groove of the TV rod trunnion. Owner Letter Serial Number 1FMCA11S6XYZ12345 Date here Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a no-charge Service Program, Number 93B31, to owners of certain 1987 through 1993 passenger cars equipped with automatic overdrive transmissions. REASON FOR THIS PROGRAM The urethane grommet that holds the transmission throttle valve cable in the throttle body lever may deteriorate and fall out allowing the cable to disconnect from the lever. Should the cable become disconnected during normal vehicle operation, the transmission bands and clutches will immediately begin to slip. Under this condition, the transmission bands and clutches will wear out within several miles, rendering the vehicle inoperative. NO COST SERVICE At no charge to you, your dealer will replace the urethane throttle lever grommet with a brass bushing and steel retaining clip. For model year 1987-1991 vehicles, this no charge service is available through the 12 month/12,000 mile basic vehicle warranty period, or through December 31, 1994, whichever provides greater coverage. For model year 1992-1993 vehicles, this no charge service is available through the 36 month/36,000 mile Bumper-to-Bumper vehicle warranty period, or through December 31, 1994, whichever provides greater coverage. HOW LONG WILL IT TAKE? The time needed for this service is less than one hour. However, due to service scheduling times, your dealer may need your car for one full working day. CALL YOUR DEALER Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Technical Service Bulletins > All Other Service Bulletins for Throttle Body: > 93B31 > Dec > 93 > Campaign Throttle Lever Grommet Replacement > Page 4388 Ask for a service date and if parts are in stock. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS If you paid to have this service done before the date of this letter, Ford is offering a full refund. For the refund, please show your paid work-order to your Ford or Lincoln-Mercury dealer. CHANGED ADDRESS OR SOLD THE CAR? Please fill out the enclosed prepaid postcard and mail it to us if you have changed your address or sold the car. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Electronic Fuel Injection - EFI Throttle Body: Specifications Electronic Fuel Injection - EFI IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Electronic Fuel Injection - EFI > Page 4391 Throttle Body: Specifications Outer Throttle Lever To Shaft 12-16 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 4392 Throttle Body: Description and Operation Throttle Body - Supercharged Engine Throttle Body The throttle body assembly controls airflow to the engine. The throttle position is controlled by a single lever and cable linkage. The body is a single piece die casting made of aluminum. It has a single bore with an air bypass channel allowing both cold and warm engine idle airflow as regulated by an Air Bypass Valve Assembly mounted directly to the throttle body. The valve assembly is an electro-mechanical device controlled by the EEC computer. It incorporates a linear actuator which positions a variable area metering valve. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 4393 Throttle Body: Service and Repair REMOVAL Fuel Charging System 1. Disconnect the Throttle Position Sensor and Air Bypass Valve connectors. 2. Remove four throttle body nuts. 3. Disconnect heater hoses. 4. Carefully separate throttle body from intake manifold. 5. Remove and discard gasket between throttle body and upper intake manifold. INSTALLATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component Information > Specifications > Page 4394 Fuel Charging system - Exploded View 1. Clean gasket mating surfaces. NOTE: If scraping is necessary, be careful not to damage gasket surfaces of allow material to drop into manifold. 2. Install throttle body gasket on the four studs of the upper intake manifold. 3. To install, reverse removal procedure. 4. Tighten attaching nuts 15-22 lb. ft. (20-30 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage > Component Information > Specifications Throttle Cable/Linkage: Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove Throttle Position Sensor: Technical Service Bulletins TPS Mounting Screws - Hard to Remove THROTTLE POSITION SENSOR-MOUNTING SCREWS HARD TO REMOVE-SERVICE TIP Article No. 89-14-7 FORD: 1983-89 CROWN VICTORIA, MUSTANG, TEMPO, THUNDERBIRD 1984-89 ESCORT 1986-89 TAURUS LINCOLN-MERCURY: 1983-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1984-87 LYNX MERKUR: 1985-89 ALL MERKUR LINES LIGHT TRUCK: 1983-89 ALL LIGHT TRUCK LINES ISSUE: All Throttle Position Sensor (TPS) mounting screws have a "Pozidrive" head. The "Pozidrive" head looks a lot like a Phillips screw head. Use of a Phillips head screwdriver to remove a "Pozidrive" screw will normally result in a rounded or damaged screw head. Many technicians think it is an overtorqued or "frozen" screw. An adhesive was also used as a thread sealant starting with the 1988 model year. This adhesive requires still more effort to loosen and remove the screw. ACTION: To prevent rounded or damages screw heads when servicing the TPS mounting screws, technicians should always use a # 2 "Pozidrive" screwdriver. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4402 Technical Service Bulletin # 88265 Date: 881221 EEC IV Pinpoint - Test Manual Correction EEC IV - PINPOINT TESTS A, N AND P - 3.0L "SHO" AND 3.8L "SUPERCHARGED" ENGINES SHOP MANUAL CORRECTION Article No. 88-26-5 FORD: 1989 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: EEC IV pinpoint test "A" EEC IV No Start, "N" Ignition/Erratic and "P" Spark Timing Check are incorrect as published in the 1989 Engine/Emissions Diagnosis Manual, Section 17-5, 17-310 and 17-322. The Diagnostic schematics did not include the 3.0L "SHO" and 3.8L "Supercharged" crankshaft sensor connectors or the ignition coil connectors. ACTION: Use the pinpoint diagnostic information on pages 15 through 20 of this TSB article. This information should be inserted in your 1989 Engine/Emission Diagnosis Shop Manual, Section 17-5, 17-310 and 17-322 for future reference. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODE: 680000 EEC-IV No Start EEC-IV-Pinpoint Tests - All Vehicles 1989 17-5 EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4403 Pinpoint Test Schematic 17-6 1989 EEC-IV-Pinpoint Tests - All Vehicles EEC-IV Pinpoint No Start Test A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4404 WARNING STOP THIS TEST AT THE FIRST SIGN OF A FUEL LEAK AND SERVICE AS REQUIRED. CAUTION No open flame - No smoking during fuel delivery checks. Ignition/Erratic Diagnostic Monitor (IDM) EEC-IV - Pinpoint Tests - All Vehicles 1989 17-309 Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4405 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4406 Pinpoint Test Schematic 17-310 1989 EEC-IV - Pinpoint Tests - All Vehicles Ignition/Erratic Pinpoint N Diagnostic Monitor (IDM) Test Spark Timing Check EEC-IV - Pinpoint Tests - All Vehicles 1989 17-321 Spark Timing Check Pinpoint P Note Test You should enter this Pinpoint Test only when directed here from Quick Test Step 4.0, when a Service Code 18 is received in Quick Test Step 5.0 or a code 49 is received in Quick Test Step 6.0. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4407 Remember To prevent the replacement of good components, be aware that the following non-EEC areas may be at fault: ^ Base Engine ^ Camshaft Sensor (CID) ^ Distributor ^ Single Hall Crankshaft Sensor (PIP) ^ TFI or DIS Module ^ Dual Hall Sensor This Pinpoint Test is intended to diagnose only the following: ^ Harness Spout Circuit ^ Base Timing ^ Processor Assembly (-12A650-) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Technical Service Bulletins > TPS Mounting Screws - Hard to Remove > Page 4408 Pinpoint Test Schematic 17-322 1989 EEC-IV - Pinpoint Tests - All Vehicles Pinpoint Spark Timing Check Test P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications Throttle Position Sensor: Electrical Specifications Throttle Position Sensor (TPS) Engines with EEC III: Turn ignition to RUN position and remove vacuum hose from throttle kicker as equipped. With engine not running, compare voltage reading against specifications and adjust as needed. Engines with EEC IV: Connect positive (+) probe of DVOM along the DG/LG wire of TPS. Connect negative (-) probe along the BK/W wire and turn ignition on but do not start engine. Adjust TPS to specified value. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Electrical Specifications > Page 4411 Throttle Position Sensor: Mechanical Specifications IDLE SPEED Automatic Transmission ...................................................................................................................... ........................................................... 550-650 RPM Manual Transmission ....................................... .............................................................................................................................................. 700-800 RPM TORQUE VALUES Air Bypass Valve to Throttle Body ......................................................................................................................................................... 87 lb. in. (10 N-m) Air Supply Tube Clamps ............................................................................................. ........................................................................... 19 lb. in. (2.2 N-m) Fuel Pressure Regulator to Fuel Rail Assembly .......................................................................................................................................... 4 lb. in. (4 N-m) Fuel Rail Assembly to Intake Manifold ................................................................................................................................................... 87 lb. in. (10 N-m) Intake Elbow Bolts ........................................................................................................... ...................................................................... 6-9 lb-ft (8-13 Nm) Intercooler Outlet Tube to Bracket Bolt ......................................................................................................................................... 30-40 lb-ft (40-55 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Stud ................................................................................................................ 17-88 lb-in (2-10 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Bolt ............................................................................................................... 52-70 lb-ft (70-95 N-m) Intercooler Outlet Tube Bracket (to cylinder block) Nut ................................................................................................................ 15-22 lb-ft (20-30 N-m) Intercooler Retaining (to radiator airboot) Screw and Washer Assy. ...................................................................................................... 3-5 lb-ft (4-6 N-m) Intercooler Tube Retaining Nuts ..................................................................................................................................................... 15-22 lb-ft (20-30 N-m) Lower Intake Manifold to Head....................................................................... ............................................................................................23 lb. ft. (32 N-m) Throttle Body Assembly Retaining Nuts ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Throttle Body to Upper Intake Manifold............................................................................ .........................................................................19 lb. ft. (25 N-m) Throttle Cable Bracket to Manifold. ............................................................................................................................................................1 3 lb. ft. (17 N-m) Throttle Position Sensor to Throttle Body.................................................................................................................................................14 lb. in. (1.5 N-m) Supercharger Retaining Bolts - 8mm ............................................................................................................................................. 15-22 lb-ft (20-30 N-m) Supercharger Retaining Bolts - 12mm .......................................................................................................................................... 52-70 lb-ft (70-95 N-m) Supercharger Outlet Adapter Bolts/Stud ......................................................................................................................................... 15-22 lb-ft (20-30 N-m) Supercharger Adapter Collar Nut .......................................................................................................................................................... 148 lb-ft (200 N-m) Upper Intake Manifold to Lower Intake Manifold Bolts ......................................................................................................................... 24 lb. ft. (32 N-m) Worm Gear Clamp ............................................................................................................................... ....................................... 15-25 lb. in. (1.7-2.8 N-m) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4412 Throttle Position Sensor: Description and Operation The throttle position sensor is used by the EEC computer to determine the operating mode (closed throttle, part throttle or wide open throttle) for selection of the proper air/fuel mixture, spark and EGR. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Specifications > Page 4413 Throttle Position Sensor: Adjustments Throttle Position Sensor NOTE: This procedure can be used to check and adjust level "C" sensor only. 1. Install an EEC-IV breakout box (Rotunda part# T83-50 EEC-IV, or equivalent) to the vehicle. 2. Set a DVOM (Rotunda part# 014-00407, or equivalent) to the 20 volt scale. Insert the positive lead into test socket 47 and the negative lead into socket 46 of the breakout box. 3. Turn the ignition ON, but DO NOT start the vehicle. 4. Check the reading on the DVOM. If it is not 0.9-1.1 volts, loosen the Throttle Position (TP) sensor mounting screws and rotate the sensor until the voltage falls within this range. 5. Tighten the mounting screws to 11-16 lb. in. (1.2-1.8 N-m). 6. While observing the DVOM, move the throttle through the entire range of motion. The reading should go from 1.0 volt to at least 4.0 volts and back to 1.0 volt. 7. If the TP sensor cannot be adjusted, replace the sensor. 8. Perform an EEC-IV quick test on the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > Customer Interest: > 89257 > Dec > 89 > Air Induction System Propane Leak Test Procedure Intercooler: Customer Interest Air Induction System - Propane Leak Test Procedure ^ AIR INDUCTION SYSTEM - 3.8L "SUPERCHARGED" - PROCEDURE FOR LOCATING INDUCTION SYSTEM LEAKS BY USING PROPANE ^ IDLE - ROUGH - 3.8L "SUPERCHARGED" - INDUCTION SYSTEM LEAKS - LOCATING PROCEDURE USING PROPANE ^ STALLS - 3.8L "SUPERCHARGED II - INDUCTION SYSTEM LEAKS - LOCATING PROCEDURE USING PROPANE Article No. 89-25-7 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Air leaks in the air induction system can cause the engine to run lean. This may cause a rough idle condition or a stalling condition at idle. Proper assembly of the intercooler system is very important to prevent air leaks. ACTION: Use the following propane testing and service procedure check for air leaks. Also use the following service procedure to seal any leaking connections. The intercooler system should be checked for leaks whenever the following occur. ^ The intercooler system is reassembled after any service procedure. ^ There is a drive concern with symptoms typical of an air leak. (A leak may also be indicated by Self-Test Codes 41 and 91 - system always lean.) PROPANE TESTING PROCEDURE 1. Inspect all flange joints for signs of leaks. 2. Bring the engine to normal operating temperature. 3. Connect an EEC-IV Monitor Tester to read the rich/lean state of the EGO sensors (Code 41 or 91 on EEC-IV Star Test). WARNING: MAKE SURE THE CAR IS IN A WELL VENTILATED AREA AWAY FROM ANY SOURCE OF SPARK OR FLAME WHEN USING PROPANE. 4. With the engine idling in Neutral or Park and the parking brake set, spray small amounts of propane around the following areas: ^ Flange joint at the rear of the supercharger ^ By-pass hose connections at the rear of the supercharger ^ Flange joint at the supercharger outlet adapter ^ Tube joint at supercharger outlet to the upper tube ^ Tube joint at upper intercooler inlet ^ Tube joint at lower intercooler outlet ^ Tube joint at intake manifold adapter inlet ^ Intake manifold adapter to intake manifold flange 5. The EGO monitor box will indicate "RICH" Red Light for one or two seconds, then return to normal switching when propane is sprayed near an induction system air leak. The EGO monitor box will indicate "LEAN" Green Light after one or two seconds when the propane is removed from the leak. 6. If a leak is found, retighten the nuts at all tube flange locations and at the supercharger outlet adapter "collar". Refer to the following "Mini-Sealing Procedure". NOTE: SPANNER NUT WRENCH, T89P-6634-A IS REQUIRED TO PERFORM THE MINI-SEALING PROCEDURE. 7. If a leak is still present after performing the "Mini-Sealing Procedure", the entire induction system must be disassembled and the sealing surfaces Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > Customer Interest: > 89257 > Dec > 89 > Air Induction System Propane Leak Test Procedure > Page 4423 cleaned. Refer to the 1990 Thunderbird/Cougar Shop Manual, Section 24-43 for service details. 8. If no leak is found, refer to the 1989 Engine/Emissions Diagnosos Manual, Volume H, Section 2, Diagnostic Routines. MINI-SEALING PROCEDURES LEAK AT INTERCOOLER/TUBE CONNECTIONS For leaks at the joint between the intercooler and the inlet or outlet tube, proceed as follows: 1. Slightly loosen the nut that attaches the inlet tube to the alternator-power steering bracket. 2. Re-torque the nuts at the intercooler flanges to 15-22 lb.ft. (20-30 N-m). 3. Re-torque the nuts at the alternator-power steering pump bracket to 30-40 lb.ft. (40-55 N-m). 4. Test all joints with propane. LEAK AT SUPERCHARGER OUTLET ADAPTOR/TUBE CONNECTION For leaks at the supercharger outlet adapter "collar" and the inlet tube joint, proceed as follows: 1. Slightly loosen the nut that attaches the inlet tube to the alternator-power steering pump bracket. 2. Re-torque the "collar" to 148 lb.ft. (200 N-m). 3. Wait a minimum of ten (10) minutes and re-torque the "collar" to 148 lb.ft. (200 N-m). NOTE: WHEN COMPRESSED, THE SEALANT TAPE FLOWS AND FORMS TO THE SEALING SURFACE. IF THE "COLLAR" IS NOT RE-TORQUED, THE TORQUE OF THE "COLLAR" WILL DROP CAUSING A LEAK AT THIS JOINT. 4. Re-torque the nut at the alternator-power steering pump bracket to 30-40 lb.ft. (40-55 N-m). 5. Test all joints with propane. LEAK AT INTAKE ELBOW ADAPTOR/OUTLET TUBE CONNECTION For leaks at the intake elbow adapter to outlet tube joint, proceed as follows: 1. Slightly loosen the nut that attaches the outlet tube to the alternator-power steering pump bracket. 2. Loosen the bolt that attaches the outlet tube to the cylinder block support bracket (bottom). 3. Re-torque the nuts at the intake elbow adapter to 15-22 lb.ft. (20-30 N-m). 4. Re-torque the nut at the alternator-power steering pump bracket to 30-40 lb.ft. (40-55 N-m). 5. Re-torque the bolt that attaches the outlet tube to the cylinder block support bracket to 30-40 lb.ft. (40-55 N-m). 6. Test all joints with propane. PART NUMBER PART NAME CLASS E9PZ-6F091-A Propane Leak Testing Kit CG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 892507A Locate Induction System 1.2 Hrs. Leak 892507B Seal Air Leak 1.0 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 6F072 48 OASIS CODES: 4700, 4800, 620100, 620800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intercooler: > 906B32 > Mar > 90 > Intercooler/Components - Manual Revision Intercooler: All Technical Service Bulletins Intercooler/Components - Manual Revision ^ SHOP MANUAL - 1989 - PAGE 24-43-2 - ILLUSTRATION REVISED TO INCLUDE INTERCOOLER AND RELATED COMPONENTS ^ SHOP MANUAL-1990-PAGE 24-43-2- ILLUSTRATION REVISED TO INCLUDE INTERCOOLER AND RELATED COMPONENTS Article No. 90-6B-32 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intercooler: > 906B32 > Mar > 90 > Intercooler/Components - Manual Revision > Page 4429 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intercooler: > 906B32 > Mar > 90 > Intercooler/Components - Manual Revision > Page 4430 ISSUE: The illustration for the intercooler description on page 24-43-2 does not show the intercooler and related components. ACTION: Refer to the pages following this TSB article for the updated illustration. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intercooler: > 89257 > Dec > 89 > Air Induction System - Propane Leak Test Procedure Intercooler: All Technical Service Bulletins Air Induction System - Propane Leak Test Procedure ^ AIR INDUCTION SYSTEM - 3.8L "SUPERCHARGED" - PROCEDURE FOR LOCATING INDUCTION SYSTEM LEAKS BY USING PROPANE ^ IDLE - ROUGH - 3.8L "SUPERCHARGED" - INDUCTION SYSTEM LEAKS - LOCATING PROCEDURE USING PROPANE ^ STALLS - 3.8L "SUPERCHARGED II - INDUCTION SYSTEM LEAKS - LOCATING PROCEDURE USING PROPANE Article No. 89-25-7 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Air leaks in the air induction system can cause the engine to run lean. This may cause a rough idle condition or a stalling condition at idle. Proper assembly of the intercooler system is very important to prevent air leaks. ACTION: Use the following propane testing and service procedure check for air leaks. Also use the following service procedure to seal any leaking connections. The intercooler system should be checked for leaks whenever the following occur. ^ The intercooler system is reassembled after any service procedure. ^ There is a drive concern with symptoms typical of an air leak. (A leak may also be indicated by Self-Test Codes 41 and 91 - system always lean.) PROPANE TESTING PROCEDURE 1. Inspect all flange joints for signs of leaks. 2. Bring the engine to normal operating temperature. 3. Connect an EEC-IV Monitor Tester to read the rich/lean state of the EGO sensors (Code 41 or 91 on EEC-IV Star Test). WARNING: MAKE SURE THE CAR IS IN A WELL VENTILATED AREA AWAY FROM ANY SOURCE OF SPARK OR FLAME WHEN USING PROPANE. 4. With the engine idling in Neutral or Park and the parking brake set, spray small amounts of propane around the following areas: ^ Flange joint at the rear of the supercharger ^ By-pass hose connections at the rear of the supercharger ^ Flange joint at the supercharger outlet adapter ^ Tube joint at supercharger outlet to the upper tube ^ Tube joint at upper intercooler inlet ^ Tube joint at lower intercooler outlet ^ Tube joint at intake manifold adapter inlet ^ Intake manifold adapter to intake manifold flange 5. The EGO monitor box will indicate "RICH" Red Light for one or two seconds, then return to normal switching when propane is sprayed near an induction system air leak. The EGO monitor box will indicate "LEAN" Green Light after one or two seconds when the propane is removed from the leak. 6. If a leak is found, retighten the nuts at all tube flange locations and at the supercharger outlet adapter "collar". Refer to the following "Mini-Sealing Procedure". NOTE: SPANNER NUT WRENCH, T89P-6634-A IS REQUIRED TO PERFORM THE MINI-SEALING PROCEDURE. 7. If a leak is still present after performing the "Mini-Sealing Procedure", the entire induction system must be disassembled and the sealing surfaces Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Intercooler: > 89257 > Dec > 89 > Air Induction System - Propane Leak Test Procedure > Page 4435 cleaned. Refer to the 1990 Thunderbird/Cougar Shop Manual, Section 24-43 for service details. 8. If no leak is found, refer to the 1989 Engine/Emissions Diagnosos Manual, Volume H, Section 2, Diagnostic Routines. MINI-SEALING PROCEDURES LEAK AT INTERCOOLER/TUBE CONNECTIONS For leaks at the joint between the intercooler and the inlet or outlet tube, proceed as follows: 1. Slightly loosen the nut that attaches the inlet tube to the alternator-power steering bracket. 2. Re-torque the nuts at the intercooler flanges to 15-22 lb.ft. (20-30 N-m). 3. Re-torque the nuts at the alternator-power steering pump bracket to 30-40 lb.ft. (40-55 N-m). 4. Test all joints with propane. LEAK AT SUPERCHARGER OUTLET ADAPTOR/TUBE CONNECTION For leaks at the supercharger outlet adapter "collar" and the inlet tube joint, proceed as follows: 1. Slightly loosen the nut that attaches the inlet tube to the alternator-power steering pump bracket. 2. Re-torque the "collar" to 148 lb.ft. (200 N-m). 3. Wait a minimum of ten (10) minutes and re-torque the "collar" to 148 lb.ft. (200 N-m). NOTE: WHEN COMPRESSED, THE SEALANT TAPE FLOWS AND FORMS TO THE SEALING SURFACE. IF THE "COLLAR" IS NOT RE-TORQUED, THE TORQUE OF THE "COLLAR" WILL DROP CAUSING A LEAK AT THIS JOINT. 4. Re-torque the nut at the alternator-power steering pump bracket to 30-40 lb.ft. (40-55 N-m). 5. Test all joints with propane. LEAK AT INTAKE ELBOW ADAPTOR/OUTLET TUBE CONNECTION For leaks at the intake elbow adapter to outlet tube joint, proceed as follows: 1. Slightly loosen the nut that attaches the outlet tube to the alternator-power steering pump bracket. 2. Loosen the bolt that attaches the outlet tube to the cylinder block support bracket (bottom). 3. Re-torque the nuts at the intake elbow adapter to 15-22 lb.ft. (20-30 N-m). 4. Re-torque the nut at the alternator-power steering pump bracket to 30-40 lb.ft. (40-55 N-m). 5. Re-torque the bolt that attaches the outlet tube to the cylinder block support bracket to 30-40 lb.ft. (40-55 N-m). 6. Test all joints with propane. PART NUMBER PART NAME CLASS E9PZ-6F091-A Propane Leak Testing Kit CG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 892507A Locate Induction System 1.2 Hrs. Leak 892507B Seal Air Leak 1.0 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 6F072 48 OASIS CODES: 4700, 4800, 620100, 620800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intercooler: > 906B32 > Mar > 90 > Intercooler/Components - Manual Revision Intercooler: All Technical Service Bulletins Intercooler/Components - Manual Revision ^ SHOP MANUAL - 1989 - PAGE 24-43-2 - ILLUSTRATION REVISED TO INCLUDE INTERCOOLER AND RELATED COMPONENTS ^ SHOP MANUAL-1990-PAGE 24-43-2- ILLUSTRATION REVISED TO INCLUDE INTERCOOLER AND RELATED COMPONENTS Article No. 90-6B-32 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intercooler: > 906B32 > Mar > 90 > Intercooler/Components - Manual Revision > Page 4441 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Turbocharger > Intercooler > Component Information > Technical Service Bulletins > All Other Service Bulletins for Intercooler: > 906B32 > Mar > 90 > Intercooler/Components - Manual Revision > Page 4442 ISSUE: The illustration for the intercooler description on page 24-43-2 does not show the intercooler and related components. ACTION: Refer to the pages following this TSB article for the updated illustration. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 4800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information > Specifications Firing Order: Specifications V6 Firing Order: 1 4 2 5 3 6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures Technical Service Bulletin # 9111B6 Date: 910614 Octane Adjust Shorting Bar - Revised Procedures Article No. 91-11B-6 ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1989 - PAGE 17-289 - PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1990 - PAGE 17-329 - PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1991 - PAGE 5-22 - EEC-IV QUICK TEST STEP 12.0 - CAR DIAGNOSIS BY SYMPTOM CHART REVISED ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1991 - PAGES 6-305 THROUGH 6-307 PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR FORD: 1989-91 TAURUS, THUNDERBIRD 1991 ESCORT, MUSTANG LINCOLN-MERCURY: 1989-90 COUGAR 1991 TRACER LIGHT TRUCK: 1989-91 RANGER 1991 AEROSTAR, EXPLORER ISSUE: Additional information regarding removal of the Octane Adjust Shorting Bar is required to assure compliance with Federal (EPA) Emission Standards. The following Manuals are affected on the pages indicated: ^ 1989 Engine/Emissions Diagnosis Page 17-289 ^ 1990 Engine/Emissions Diagnosis Page 17-329 ^ 1991 Engine/Emissions Diagnosis Page 5-22 and Pages 6-305 through 307 ACTION: Refer to the pages in this TSB article for the additional information. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4452 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4453 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4454 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4455 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4456 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4457 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4458 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Locations > Component Locations Ignition Timing Connector: Component Locations Engine Compartment Component Locations RH Front Of Engine Compartment, Below VIP Test Connector Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Ignition Timing Connector > Component Information > Locations > Component Locations > Page 4461 Component Location - Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder > Component Information > Locations Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators > System Information > Diagrams Timing Mark 3.8L Supercharged Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair Camshaft Synchronizer Assembly: Service and Repair CAUTION: Prior to starting this procedure, set cylinder number one to 26 degrees After Top Dead Center (ATDC) of the compression stroke. Then note the position of the camshaft sensor electrical connector. The installation procedure requires that the connector be located in the same position. Removal 1. Disconnect negative battery cable. 2. Remove camshaft sensor assembly. 3. Remove synchronizer clamp (bolt and washer assembly). 4. Remove synchronizer from front engine cover assembly. NOTE: The intermediate oil pump driveshaft should be removed with the synchronizer assembly. Installation CAUTION: If the replacement synchronizer does not contain a plastic locator cover tool, a special service tool such as Syncro Positioner T89P-12200-A or equivalent must be obtained prior to installation of the replacement synchronizer. Failure to follow this procedure will result in improper synchronizer alignment. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. 1. If the plastic locator cover tool is not attached to the replacement synchronizer assembly, attach Syncro Positioner Tool T89P-12200-A or equivalent as follows: a. Engage synchronizer vane into the radial slot of the tool. b. Rotate tool on synchronizer base until tool boss engages the base notch. The cover tool should be square and in contact with entire top surface of synchronizer base. 2. Transfer intermediate oil pump driveshaft from old synchronizer to replacement synchronizer assembly. 3. Install synchronizer assembly so that gear engagement occurs when arrow on locator tool is pointed approximately 30 degrees counterclockwise from the front face of the engine block. This step will locate camshaft sensor electrical connector in the pre-removal position. 4. Install synchronizer base clamp (washer and bolt) and tighten bolt to 20-30 Nm (15-22 lb-ft). 5 Remove Syncro Positioner Tool T89P-12200-A or equivalent. 6. Install and connect camshaft sensor. CAUTION: If camshaft sensor electrical connector is not positioned properly (i.e. contacting the A/C bracket or forward of the supercharger drive belt), DO NOT reposition the connector by rotating the synchronizer base. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer and repeat installation procedure, beginning with Step 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair > Page 4472 7. Connect negative battery cable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Top Front Of Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4478 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4479 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4480 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft timing sensor is a single Hall effect magnetic switch, actuated by three vanes on the crankshaft damper and pulley assembly. The signal generated by this sensor the Profile Ignition Pick-up (PIP). It provides base timing and RPM information to the DIS module and EEC IV module. Initial or base, timing is set at 10 degrees BTDC and is not adjustable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4481 Crankshaft Position Sensor: Adjustments INITIAL TIMING Initial timing is preset at 10~ plus or minus 2~ BTDC and is not adjustable. PIP SENSOR 1. Install Crankshaft Sensor Gauge T89P-AH or equivalent to outside surface of one vane of shutter. Gauge is magnetic and will conform to the shape of the vane. 2. Rotate crankshaft by HAND to align shutter vane with gauge into sensor air gap. Push sensor housing inward to contact gauge and tighten screws to 22-31 lb-in. CAUTION: Over tightening can cause damage to timing sensor. 3. Rotate crankshaft by HAND to position shutter vane with gauge outside of air gap. Remove magnetic gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4482 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect negative battery cable. 2. If necessary, loosen tensioner pulleys for A/C compressor and supercharger idler pulley belts, as well as removing belts from crankshaft pulley. 3. Disconnect sensor electrical connectors from engine wiring harness. 4. Raise vehicle and suitably support. Then remove upper and lower damper shield assemblies. 5. ON 89 MODELS: Remove crankshaft damper and pulley assembly using Universal Puller T67L-3600-A or equivalent. 6. Remove crankshaft sensor mounting screws and remove sensor. Installation 1. Position crankshaft sensor assembly on bracket. 2. Install two sensor attaching screws and tighten to 22-31 lb-in. 3. Install crankshaft damper and pulley assembly using crank gear and damper replacer T83T-6316-B or equivalent. Tighten pulley bolt to 103-132 lb-ft. 4. Install upper and lower damper shields and tighten fasteners to specification. Lower vehicle. 5. Route sensor wiring harness and connect both electrical connectors. Then install A/C and power steering belts and adjust to proper tension. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Description and Operation > TFI IV Distributor: Description and Operation TFI IV Distributor (Typical) - Exploded View This distributor directs high voltage to the spark plugs and supplies crankshaft position and frequency information to the control module using a Profile Ignition Pick-up. Hall Effect Device The universal distributor operates by using a Hall Effect vane switch assembly, which causes the ignition coil to be switched off and on by the EEC IV and TFI-IV modules. The vane switch consists of a Hall Sensor on one side and a permanent magnet on the other. Rotary Vane Cup A rotary vane cup is used to trigger the signal off and on. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Description and Operation > TFI IV > Page 4487 Figure 7 - Magnetic Flux Field When the window of the vane cup is between the magnet and the Hall Effect device, a magnetic field is completed from the magnet through the Hall Effect device and back to the magnet. Hall Effect Device Response To Vane As the vane passes through this opening, the flux lines are shunted through the vane and back to the magnet. At this time, a voltage is produced as the vane passes through the opening. When the vane clears the opening, the window edge causes the signal to go to zero volts. The signal is then used by the EEC system for Crankshaft position Sensing and the Desired Spark Advance based on engine demand and calibration. The spark advance and voltage distribution is accomplished through a conventional rotor, cap and ignition wires. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Distributor, Ignition > Component Information > Description and Operation > TFI IV > Page 4488 Distributor: Description and Operation TFI Octane Rod Distributor (Typical) - Exploded View The octane rod adds a provision for a fixed octane adjustment. The adjustment is done by replacing the standard zero-degree rod located in the distributor bowl with a three degree or six degree retard rod. This is done only if the engine is experiencing a pinging or engine knocking condition and can not be repaired with the conventional methods (timing adjusted, proper operating temperature, higher gasoline octane rating....etc). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams Component Location Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Page 4492 Ignition Cable: Testing and Inspection Spark Plug Wire Resistance *** UPDATED BY TSB #85-9-33 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information > Diagrams > Page 4493 Ignition Cable: Service and Repair When removing spark plug wires from plugs, use spark plug wire remover T74P-6666-A or equivalent. Grasp and twist the boot back and forth on the plug until boot is loose. Remove boot and wire from plug. Pull on boot only. Do not pull on wire. When removing wires from the ignition coil, squeeze the locking tabs of coil wire retainer by hand. Twist and pull on boot until free. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications Ignition coil Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 4497 Ignition Coil: Locations Top LH Front Of Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 4498 Pinpoint Test N - Ignition Diagnostic Monitor (IDM) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 4499 Component Location - Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information > Specifications > Page 4500 Ignition Coil: Service and Repair Removal 1. Disconnect spark plug wires from ignition coils. 2. Disconnect engine harness electrical connector from ignition coil. 3. Remove four ignition coil assembly retaining screws, then the coil. On vehicles with power steering, it may be necessary to remove lefthand (intake) coil and bracket as an assembly. Installation 1. Mount ignition coil to bracket, tightening four retaining screws. 2. Connect engine harness electrical connector to ignition coil. 3. Install spark plug wires. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations Component Location - Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4504 Ignition Control Module: Description and Operation Module And Pin-Out The main function of the DIS module is to switch between ignition coils and cause these coils to spark. The module receives the PIP and CID signals as well as the SPOUT signal from the ECA. During normal operation, PIP is sent to the ECA to provide base timing and engine RPM information. The CID signal provides the DIS ignition module with the information required to synchronize the ignition coils so that they are fired in the proper order. The SPOUT signal contains the optimum spark timing and dwell information. The spark angle is determined by the rising edge of the SPOUT signal. The falling edge controls the ON or dwell time of the coil current. The dwell time is controlled by varying the duty cycle of the SPOUT signal. With the proper inputs from PIP, CID, and SPOUT the DIS module turns the coils On and Off in the proper order for spark control. PIN 1 VBAT (BATTERY VOLTAGE) PIN 2 CID PIN 3 NOT USED PIN 4 PIP IN PIN 5 SPOUT PIN 6 NOT USED PIN 7 IGND (MODULE GROUND) PIN 8 COIL 1 PIN 9 COIL 3 PIN 10 NOT USED PIN 11 COIL 2 PIN 12 IDM (IGNITION DIAGNOSTIC MODULE) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Control Module > Component Information > Locations > Page 4505 Ignition Control Module: Service and Repair Removal 1. Identify, then disconnect electrical connectors from DIS ignition module assembly by pushing down on the connector locking tabs. Tabs are marked PUSH. 2. Remove three retaining screws, then the ignition module from the lower intake manifold. Installation 1. Apply a 1/32 inch coat of silicone dielectric compound or equivalent to the mounting surface of the DIS module. 2. Mount the DIS module to the intake manifold. Torque bolts to 22-31 ft. lbs. 3. Connect electrical connectors to ignition module. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures Technical Service Bulletin # 9111B6 Date: 910614 Octane Adjust Shorting Bar - Revised Procedures Article No. 91-11B-6 ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1989 - PAGE 17-289 - PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1990 - PAGE 17-329 - PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1991 - PAGE 5-22 - EEC-IV QUICK TEST STEP 12.0 - CAR DIAGNOSIS BY SYMPTOM CHART REVISED ^ ENGINE/EMISSIONS DIAGNOSIS MANUAL - 1991 - PAGES 6-305 THROUGH 6-307 PINPOINT TEST KP REVISED TO PROVIDE ADDITIONAL INFORMATION CONCERNING REMOVAL OF OCTANE ADJUST SHORTING BAR FORD: 1989-91 TAURUS, THUNDERBIRD 1991 ESCORT, MUSTANG LINCOLN-MERCURY: 1989-90 COUGAR 1991 TRACER LIGHT TRUCK: 1989-91 RANGER 1991 AEROSTAR, EXPLORER ISSUE: Additional information regarding removal of the Octane Adjust Shorting Bar is required to assure compliance with Federal (EPA) Emission Standards. The following Manuals are affected on the pages indicated: ^ 1989 Engine/Emissions Diagnosis Page 17-289 ^ 1990 Engine/Emissions Diagnosis Page 17-329 ^ 1991 Engine/Emissions Diagnosis Page 5-22 and Pages 6-305 through 307 ACTION: Refer to the pages in this TSB article for the additional information. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 690000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4510 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4511 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4512 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4513 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4514 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4515 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Technical Service Bulletins > Octane Adjust Shorting Bar - Revised Procedures > Page 4516 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Locations > Component Locations Ignition Timing Connector: Component Locations Engine Compartment Component Locations RH Front Of Engine Compartment, Below VIP Test Connector Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing Connector > Component Information > Locations > Component Locations > Page 4519 Component Location - Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Rear Of Engine Lower RH Side Of Engine, Under Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information > Locations > Page 4523 Knock Sensor: Description and Operation Knock Sensor The knock sensor is a piezoelectric accelerator accelerometer. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5 - 6 KHz). The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations Component Location - Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4528 Ignition Control Module: Description and Operation Module And Pin-Out The main function of the DIS module is to switch between ignition coils and cause these coils to spark. The module receives the PIP and CID signals as well as the SPOUT signal from the ECA. During normal operation, PIP is sent to the ECA to provide base timing and engine RPM information. The CID signal provides the DIS ignition module with the information required to synchronize the ignition coils so that they are fired in the proper order. The SPOUT signal contains the optimum spark timing and dwell information. The spark angle is determined by the rising edge of the SPOUT signal. The falling edge controls the ON or dwell time of the coil current. The dwell time is controlled by varying the duty cycle of the SPOUT signal. With the proper inputs from PIP, CID, and SPOUT the DIS module turns the coils On and Off in the proper order for spark control. PIN 1 VBAT (BATTERY VOLTAGE) PIN 2 CID PIN 3 NOT USED PIN 4 PIP IN PIN 5 SPOUT PIN 6 NOT USED PIN 7 IGND (MODULE GROUND) PIN 8 COIL 1 PIN 9 COIL 3 PIN 10 NOT USED PIN 11 COIL 2 PIN 12 IDM (IGNITION DIAGNOSTIC MODULE) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Relays and Modules - Ignition System > Ignition Control Module > Component Information > Locations > Page 4529 Ignition Control Module: Service and Repair Removal 1. Identify, then disconnect electrical connectors from DIS ignition module assembly by pushing down on the connector locking tabs. Tabs are marked PUSH. 2. Remove three retaining screws, then the ignition module from the lower intake manifold. Installation 1. Apply a 1/32 inch coat of silicone dielectric compound or equivalent to the mounting surface of the DIS module. 2. Mount the DIS module to the intake manifold. Torque bolts to 22-31 ft. lbs. 3. Connect electrical connectors to ignition module. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair Camshaft Synchronizer Assembly: Service and Repair CAUTION: Prior to starting this procedure, set cylinder number one to 26 degrees After Top Dead Center (ATDC) of the compression stroke. Then note the position of the camshaft sensor electrical connector. The installation procedure requires that the connector be located in the same position. Removal 1. Disconnect negative battery cable. 2. Remove camshaft sensor assembly. 3. Remove synchronizer clamp (bolt and washer assembly). 4. Remove synchronizer from front engine cover assembly. NOTE: The intermediate oil pump driveshaft should be removed with the synchronizer assembly. Installation CAUTION: If the replacement synchronizer does not contain a plastic locator cover tool, a special service tool such as Syncro Positioner T89P-12200-A or equivalent must be obtained prior to installation of the replacement synchronizer. Failure to follow this procedure will result in improper synchronizer alignment. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. 1. If the plastic locator cover tool is not attached to the replacement synchronizer assembly, attach Syncro Positioner Tool T89P-12200-A or equivalent as follows: a. Engage synchronizer vane into the radial slot of the tool. b. Rotate tool on synchronizer base until tool boss engages the base notch. The cover tool should be square and in contact with entire top surface of synchronizer base. 2. Transfer intermediate oil pump driveshaft from old synchronizer to replacement synchronizer assembly. 3. Install synchronizer assembly so that gear engagement occurs when arrow on locator tool is pointed approximately 30 degrees counterclockwise from the front face of the engine block. This step will locate camshaft sensor electrical connector in the pre-removal position. 4. Install synchronizer base clamp (washer and bolt) and tighten bolt to 20-30 Nm (15-22 lb-ft). 5 Remove Syncro Positioner Tool T89P-12200-A or equivalent. 6. Install and connect camshaft sensor. CAUTION: If camshaft sensor electrical connector is not positioned properly (i.e. contacting the A/C bracket or forward of the supercharger drive belt), DO NOT reposition the connector by rotating the synchronizer base. This will result in the ignition system and fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer and repeat installation procedure, beginning with Step 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Camshaft Position Sensor > Camshaft Synchronizer Assembly <--> [Cam Position Sensor Mount] > Component Information > Service and Repair > Page 4535 7. Connect negative battery cable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Locations Crankshaft Position Sensor: Locations Top Front Of Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions Crankshaft Position Sensor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4541 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4542 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4543 Crankshaft Position Sensor: Description and Operation Crankshaft Position Sensor The crankshaft timing sensor is a single Hall effect magnetic switch, actuated by three vanes on the crankshaft damper and pulley assembly. The signal generated by this sensor the Profile Ignition Pick-up (PIP). It provides base timing and RPM information to the DIS module and EEC IV module. Initial or base, timing is set at 10 degrees BTDC and is not adjustable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4544 Crankshaft Position Sensor: Adjustments INITIAL TIMING Initial timing is preset at 10~ plus or minus 2~ BTDC and is not adjustable. PIP SENSOR 1. Install Crankshaft Sensor Gauge T89P-AH or equivalent to outside surface of one vane of shutter. Gauge is magnetic and will conform to the shape of the vane. 2. Rotate crankshaft by HAND to align shutter vane with gauge into sensor air gap. Push sensor housing inward to contact gauge and tighten screws to 22-31 lb-in. CAUTION: Over tightening can cause damage to timing sensor. 3. Rotate crankshaft by HAND to position shutter vane with gauge outside of air gap. Remove magnetic gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 4545 Crankshaft Position Sensor: Service and Repair Removal 1. Disconnect negative battery cable. 2. If necessary, loosen tensioner pulleys for A/C compressor and supercharger idler pulley belts, as well as removing belts from crankshaft pulley. 3. Disconnect sensor electrical connectors from engine wiring harness. 4. Raise vehicle and suitably support. Then remove upper and lower damper shield assemblies. 5. ON 89 MODELS: Remove crankshaft damper and pulley assembly using Universal Puller T67L-3600-A or equivalent. 6. Remove crankshaft sensor mounting screws and remove sensor. Installation 1. Position crankshaft sensor assembly on bracket. 2. Install two sensor attaching screws and tighten to 22-31 lb-in. 3. Install crankshaft damper and pulley assembly using crank gear and damper replacer T83T-6316-B or equivalent. Tighten pulley bolt to 103-132 lb-ft. 4. Install upper and lower damper shields and tighten fasteners to specification. Lower vehicle. 5. Route sensor wiring harness and connect both electrical connectors. Then install A/C and power steering belts and adjust to proper tension. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: Customer Interest Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations Knock Sensor: Locations Rear Of Engine Lower RH Side Of Engine, Under Exhaust Manifold Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 4563 Knock Sensor: Description and Operation Knock Sensor The knock sensor is a piezoelectric accelerator accelerometer. The sensor uses the resonant frequency to mechanically amplify the engine knock frequency (5 - 6 KHz). The sensor has a thin circular piezoelectric ceramic disk which is bonded to a metal diaphragm. Electrical connections are made through a two pin integral connector. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Specifications Spark Plug: Specifications SPARK PLUG Tightening Torque ............................................................................................................................... .................................................................... 5-11 ft lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Ignition System > Vacuum Restrictor > Component Information > Description and Operation Vacuum Restrictor: Description and Operation Fig. 29 Vacuum restrictor The orifice type flow restrictor, Fig. 29, is used on some systems to control the flow rate and or timing characteristics to the following systems: a. EGR valve timing (opening and closing). b. Part throttle spark advance. c. Purge system. d. Thermactor system. The flow rate through the restrictor is the same in both directions. If blocked, it should be replaced. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Technical Service Bulletins > Customer Interest for Shift Indicator: > 89139 > Jun > 89 > A/T - PRNDL Bulb Socket Melted Shift Indicator: Customer Interest A/T - PRNDL Bulb Socket Melted LAMP-TRANSMISSION PRNDL BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 TRANSMISSION-PRNDL LIGHT BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 Article No. 89-13-9 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Heat from the transmission "PRNDL" light bulb may soften and melt the plastic bulb socket. This is caused by the two (2) candlepower bulb. ACTION: Install a new bulb and socket assembly. The new assembly has a one (1) candlepower bulb which will operate cooler. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 17-02 for service details. NOTE: THE NEW BULB AND SOCKET ASSEMBLY ALSO HAS A LIGHTER GREEN FILTER SO THE LESS BRIGHT BULB WILL STILL SUPPLY THE CORRECT GREEN COLOR AND INTENSITY. PART NUMBER PART NAME CLASS E9SZ-15A808-C Bulb and Socket Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891309A Install Bulb & Socket 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 15A808 46 OASIS CODES: 2100, 2150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Indicator: > 89139 > Jun > 89 > A/T - PRNDL Bulb Socket Melted Shift Indicator: All Technical Service Bulletins A/T - PRNDL Bulb Socket Melted LAMP-TRANSMISSION PRNDL BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 TRANSMISSION-PRNDL LIGHT BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 Article No. 89-13-9 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Heat from the transmission "PRNDL" light bulb may soften and melt the plastic bulb socket. This is caused by the two (2) candlepower bulb. ACTION: Install a new bulb and socket assembly. The new assembly has a one (1) candlepower bulb which will operate cooler. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 17-02 for service details. NOTE: THE NEW BULB AND SOCKET ASSEMBLY ALSO HAS A LIGHTER GREEN FILTER SO THE LESS BRIGHT BULB WILL STILL SUPPLY THE CORRECT GREEN COLOR AND INTENSITY. PART NUMBER PART NAME CLASS E9SZ-15A808-C Bulb and Socket Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891309A Install Bulb & Socket 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 15A808 46 OASIS CODES: 2100, 2150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Gear Sensor/Switch, M/T > Component Information > Locations Gear Sensor/Switch: Locations LH Side Of Manual Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Technical Service Bulletins > A/T - AOD 3/4 Shift Accumulator No Longer Required Accumulator: Technical Service Bulletins A/T - AOD 3/4 Shift Accumulator No Longer Required TRANSMISSION - AOD - 3/4 SHIFT ACCUMULATOR NO LONGER REQUIRED IN SOME 1989 BUILT TRANSMISSIONS Article No. 89-4-6 FORD: 1989 MUSTANG, THUNDERBIRD, CROWN VICTORIA LINCOLN-MERCURY: 1989 COUGAR, GRAND MARQUIS, MARK VII, LINCOLN TOWN CAR LIGHT TRUCK: 1989 E & F-SERIES, BRONCO ISSUE: The 3-4 shift accumulator used in prior model year "AOD" transmissions is no longer required in 1989 "AOD" transmissons except on vehicles with 5.8L engines. The accumulator feed hole in the main control assembly has been blocked so a 3-4 shift accumulator must not be installed. ACTION: Only use a 1989 main control assembly to service a 1989 "AOD" transmission. NOTE: DO NOT ATTEMPT TO INSTALL A 3-4 SHIFT ACCUMULATOR PISTON. THE ACCUMULATOR FEED HOLE IN THE MAIN CONTROL ASSEMBLY HAS BEEN BLOCKED, AND THE 3-4 SHIFT ACCUMULATOR IS NOT REQUIRED. OTHER APPLICABLE ARTICLES: None ARTICLES SUPERSEDED: 88-24-3, date 11/23/88. WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 5200, 5300, 5970 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 2-3 Accumulator Piston Accumulator: Service and Repair 2-3 Accumulator Piston REMOVAL 1. Remove valve body. 2. Compress 2-3 accumulator piston cover, then remove snap ring retainer. 3. Release cover slowly, then remove piston cover, return spring, and piston. Some models do not use a spring. 4. Remove seal from 2-3 accumulator cover and piston and inspect for damage and wear. INSTALLATION 1. Install new seals on 2-3 accumulator cover, if necessary. Lubricate cover pocket of case with transmission fluid. 2. Install 2-3 accumulator piston and return spring into case, then the cover. 3. Compress cover using suitable tool, then install snap ring. Ensure cover is reseated snugly against snap ring. 4. Install valve body, filter, pan, and gasket. Refill transmission pan to proper fluid level. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Accumulator, A/T > Component Information > Service and Repair > 2-3 Accumulator Piston > Page 4599 Accumulator: Service and Repair 3-4 Accumulator Piston REMOVAL 1. Remove valve body. 2. Compress 3-4 accumulator piston cover, then remove snap ring retainer. 3. Release cover slowly, then remove piston cover, return spring, and piston. Some models do not use a spring. 4. Remove seal from 3-4 accumulator cover and piston and inspect for damage and wear. INSTALLATION 1. Install new seals on 3-4 accumulator cover, if necessary. Lubricate cover pocket of case with transmission fluid. 2. Install 3-4 accumulator piston and return spring into case, then the cover. 3. Compress cover using suitable tool, then install snap ring. Ensure cover is reseated snugly against snap ring. 4. Install valve body, filter, pan, and gasket. Refill transmission pan to proper fluid level. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times Band: Customer Interest A/T - AOD Delayed Shift Times Article No. 91-16-12 08/07/91 TRANSMISSION - AUTOMATIC - AOD - DELAYED 3-4/4-3 SHIFTS OR OVERDRIVE BAND/FORWARD CLUTCH REPEAT REPAIRS FORD: 1989-90 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989-90 BRONCO, E-150, E-250, F-150 This TSB article is being republished in its entirety to include Bronco and E-250 in the Light Truck application line. ISSUE: Increased shift times may be experienced during certain continuous driving conditions. When frequent 3-4/4-3 shifts or high ambient temperatures are encountered, overdrive band engagement or release times may increase. This slip at the friction surface creates excessive heat and may eventually fail the band. Forward clutch failure may also occur as the forward clutch operation is synchronized with the overdrive band during 3-4/4-3 shifting. ACTION: Whenever servicing the overdrive band or forward clutch, also replace the main control assembly with a 1991 service main control. Refer to the following AOD Main Control Application Chart. This chart reflects shift calibration revisions to the 1991 main control level. AOD MAIN CONTROL COMPLEXITY CHART MAIN DELETE ADD SERVICE CONTROL SERVICE PART PART NO. I.D. NO. MAIN CONTROL I.D. F1TZ-7A100-C GNO F0TZ-7A100-G DOA, MPA E9TZ-7A100-J MRA F1TZ-7A100-B GNN F0TZ-7A100-F DOX, MPX E9TZ-7A100-H MRX F1AZ-7A100-D JNF E9AZ-7A100-B COH, VPH, VRH, RRH F1SZ-7A100-B BNJ E9SZ-7A100-B URL, URY, SRY F0SZ-7A100-B GPJ, UPJ F1AZ-7A100-E JFK F0AZ-7A100-D CJH E9AZ-7A100-G VGH, RGH, WFR E5AZ-7A100-D BER, OER, ODR F1LY-7A-A DNX F0LY-7A100-B BOC, BOX, PPC E9LY-7A100-A PRX E9LY-7A100-B PRC F1SZ-TA100-A ANV F0SZ-7A100-A TPM E9SZ-7A100-D TRM, TRF PART NUMBER PART NAME CLASS F1TZ-7A100-C Main Control B F1TZ-7A100-B Main Control B F1AZ-7A100-D Main Control B F1SZ-7A100-B Main Control C F1AZ-7A100-E Main Control C F1LY-7A100-A Main Control B F1SZ-7A100-A Main Control C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-5-6 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 911612A Replace Main Control Valve 0.6 Hr. Body To AOD - Cars 911612B Remove And Install AOD 3.1 Hr. Transmission Assembly - Crown Victoria, Grand Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > Customer Interest for Band: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times > Page 4608 Marquis And Town Car 911612C Remove And Install AOD 3.5 Hr. Transmission Assembly - Thunderbird, Cougar, Mustang And Mark VII 911612D Overhaul Time For AOD 4.9 Hr. Transmission 911612E Remove And Install 2.8 Hr. Transmission - F-150, 4X2 Models, E-150, E-250 911612F Remove And Install 4.4 Hr. Transmission - F-150 And Bronco, 4X4 Models 911612G Remove And Install 2.6 Hr. Transmission - Econoline 911612H Overhaul Of AOD - Trucks 5.2 Hr. 9116121 Replace Main Control Valve 1.3 Hr. Body - Trucks DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times Band: All Technical Service Bulletins A/T - AOD Delayed Shift Times Article No. 91-16-12 08/07/91 TRANSMISSION - AUTOMATIC - AOD - DELAYED 3-4/4-3 SHIFTS OR OVERDRIVE BAND/FORWARD CLUTCH REPEAT REPAIRS FORD: 1989-90 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989-90 BRONCO, E-150, E-250, F-150 This TSB article is being republished in its entirety to include Bronco and E-250 in the Light Truck application line. ISSUE: Increased shift times may be experienced during certain continuous driving conditions. When frequent 3-4/4-3 shifts or high ambient temperatures are encountered, overdrive band engagement or release times may increase. This slip at the friction surface creates excessive heat and may eventually fail the band. Forward clutch failure may also occur as the forward clutch operation is synchronized with the overdrive band during 3-4/4-3 shifting. ACTION: Whenever servicing the overdrive band or forward clutch, also replace the main control assembly with a 1991 service main control. Refer to the following AOD Main Control Application Chart. This chart reflects shift calibration revisions to the 1991 main control level. AOD MAIN CONTROL COMPLEXITY CHART MAIN DELETE ADD SERVICE CONTROL SERVICE PART PART NO. I.D. NO. MAIN CONTROL I.D. F1TZ-7A100-C GNO F0TZ-7A100-G DOA, MPA E9TZ-7A100-J MRA F1TZ-7A100-B GNN F0TZ-7A100-F DOX, MPX E9TZ-7A100-H MRX F1AZ-7A100-D JNF E9AZ-7A100-B COH, VPH, VRH, RRH F1SZ-7A100-B BNJ E9SZ-7A100-B URL, URY, SRY F0SZ-7A100-B GPJ, UPJ F1AZ-7A100-E JFK F0AZ-7A100-D CJH E9AZ-7A100-G VGH, RGH, WFR E5AZ-7A100-D BER, OER, ODR F1LY-7A-A DNX F0LY-7A100-B BOC, BOX, PPC E9LY-7A100-A PRX E9LY-7A100-B PRC F1SZ-TA100-A ANV F0SZ-7A100-A TPM E9SZ-7A100-D TRM, TRF PART NUMBER PART NAME CLASS F1TZ-7A100-C Main Control B F1TZ-7A100-B Main Control B F1AZ-7A100-D Main Control B F1SZ-7A100-B Main Control C F1AZ-7A100-E Main Control C F1LY-7A100-A Main Control B F1SZ-7A100-A Main Control C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-5-6 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 911612A Replace Main Control Valve 0.6 Hr. Body To AOD - Cars 911612B Remove And Install AOD 3.1 Hr. Transmission Assembly - Crown Victoria, Grand Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Band: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times > Page 4614 Marquis And Town Car 911612C Remove And Install AOD 3.5 Hr. Transmission Assembly - Thunderbird, Cougar, Mustang And Mark VII 911612D Overhaul Time For AOD 4.9 Hr. Transmission 911612E Remove And Install 2.8 Hr. Transmission - F-150, 4X2 Models, E-150, E-250 911612F Remove And Install 4.4 Hr. Transmission - F-150 And Bronco, 4X4 Models 911612G Remove And Install 2.6 Hr. Transmission - Econoline 911612H Overhaul Of AOD - Trucks 5.2 Hr. 9116121 Replace Main Control Valve 1.3 Hr. Body - Trucks DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo - With A4LD Band Apply Servo: Service and Repair Low/Reverse Servo - With A4LD 1. Raise and support vehicle. 2. Loosen pan attaching bolts and allow transmission fluid to drain. 3. Remove all pan attaching bolts except two bolts at the front to allow fluid to drain further. 4. Remove oil filter screen and gasket. 5. Remove retaining screws, low/reverse servo cover, piston and spring and gasket. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo - With A4LD > Page 4619 Band Apply Servo: Service and Repair Overdrive Servo Assembly REMOVAL 1. Remove valve body. 2. Compress overdrive servo piston cover with a suitable tool, then remove snap ring retainer. 3. Apply compressed air to servo piston release passage and remove the overdrive servo piston cover and spring. Remove piston from cover, then the rubber seal from piston and cover. INSTALLATION 1. Install new servo piston and cover seals on the servo piston and cover. 2. Lubricate all seals, piston, and piston bore with transmission fluid. 3. Install servo piston into cover, then the return spring into servo piston. 4. Install overdrive piston assembly into overdrive servo bore. 5. Compress overdrive piston using suitable tool, then install snap ring retainer. 6. Install valve body, filter, pan, and gasket. Refill transmission to proper fluid level. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Band Apply Servo, A/T > Component Information > Service and Repair > Low/Reverse Servo - With A4LD > Page 4620 Band Apply Servo: Service and Repair Reverse Servo Assembly WITH AOD REMOVAL 1. Remove valve body. 2. Compress reverse servo piston cover with a suitable tool, then remove snap ring retainer. 3. Apply compressed air to servo piston release passage and remove the reverse servo piston cover and spring. Remove piston from cover, then the rubber seal from piston and cover. CAUTION: Reverse servo piston is under spring pressure. Use caution when removing servo piston cover. INSTALLATION 1. Install new servo piston and cover seals on the servo piston and cover. 2. Lubricate all seals, piston, and piston bore with transmission fluid. 3. Install servo piston into cover, then the return spring into servo piston. 4. Install reverse piston assembly into reverse servo bore. 5. Compress reverse piston using suitable tool, then install snap ring retainer. 6. Install valve body, filter, pan, and gasket. Refill transmission to proper fluid level. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times Clutch: Customer Interest A/T - AOD Delayed Shift Times Article No. 91-16-12 08/07/91 TRANSMISSION - AUTOMATIC - AOD - DELAYED 3-4/4-3 SHIFTS OR OVERDRIVE BAND/FORWARD CLUTCH REPEAT REPAIRS FORD: 1989-90 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989-90 BRONCO, E-150, E-250, F-150 This TSB article is being republished in its entirety to include Bronco and E-250 in the Light Truck application line. ISSUE: Increased shift times may be experienced during certain continuous driving conditions. When frequent 3-4/4-3 shifts or high ambient temperatures are encountered, overdrive band engagement or release times may increase. This slip at the friction surface creates excessive heat and may eventually fail the band. Forward clutch failure may also occur as the forward clutch operation is synchronized with the overdrive band during 3-4/4-3 shifting. ACTION: Whenever servicing the overdrive band or forward clutch, also replace the main control assembly with a 1991 service main control. Refer to the following AOD Main Control Application Chart. This chart reflects shift calibration revisions to the 1991 main control level. AOD MAIN CONTROL COMPLEXITY CHART MAIN DELETE ADD SERVICE CONTROL SERVICE PART PART NO. I.D. NO. MAIN CONTROL I.D. F1TZ-7A100-C GNO F0TZ-7A100-G DOA, MPA E9TZ-7A100-J MRA F1TZ-7A100-B GNN F0TZ-7A100-F DOX, MPX E9TZ-7A100-H MRX F1AZ-7A100-D JNF E9AZ-7A100-B COH, VPH, VRH, RRH F1SZ-7A100-B BNJ E9SZ-7A100-B URL, URY, SRY F0SZ-7A100-B GPJ, UPJ F1AZ-7A100-E JFK F0AZ-7A100-D CJH E9AZ-7A100-G VGH, RGH, WFR E5AZ-7A100-D BER, OER, ODR F1LY-7A-A DNX F0LY-7A100-B BOC, BOX, PPC E9LY-7A100-A PRX E9LY-7A100-B PRC F1SZ-TA100-A ANV F0SZ-7A100-A TPM E9SZ-7A100-D TRM, TRF PART NUMBER PART NAME CLASS F1TZ-7A100-C Main Control B F1TZ-7A100-B Main Control B F1AZ-7A100-D Main Control B F1SZ-7A100-B Main Control C F1AZ-7A100-E Main Control C F1LY-7A100-A Main Control B F1SZ-7A100-A Main Control C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-5-6 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 911612A Replace Main Control Valve 0.6 Hr. Body To AOD - Cars 911612B Remove And Install AOD 3.1 Hr. Transmission Assembly - Crown Victoria, Grand Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times > Page 4629 Marquis And Town Car 911612C Remove And Install AOD 3.5 Hr. Transmission Assembly - Thunderbird, Cougar, Mustang And Mark VII 911612D Overhaul Time For AOD 4.9 Hr. Transmission 911612E Remove And Install 2.8 Hr. Transmission - F-150, 4X2 Models, E-150, E-250 911612F Remove And Install 4.4 Hr. Transmission - F-150 And Bronco, 4X4 Models 911612G Remove And Install 2.6 Hr. Transmission - Econoline 911612H Overhaul Of AOD - Trucks 5.2 Hr. 9116121 Replace Main Control Valve 1.3 Hr. Body - Trucks DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times Clutch: All Technical Service Bulletins A/T - AOD Delayed Shift Times Article No. 91-16-12 08/07/91 TRANSMISSION - AUTOMATIC - AOD - DELAYED 3-4/4-3 SHIFTS OR OVERDRIVE BAND/FORWARD CLUTCH REPEAT REPAIRS FORD: 1989-90 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989-90 BRONCO, E-150, E-250, F-150 This TSB article is being republished in its entirety to include Bronco and E-250 in the Light Truck application line. ISSUE: Increased shift times may be experienced during certain continuous driving conditions. When frequent 3-4/4-3 shifts or high ambient temperatures are encountered, overdrive band engagement or release times may increase. This slip at the friction surface creates excessive heat and may eventually fail the band. Forward clutch failure may also occur as the forward clutch operation is synchronized with the overdrive band during 3-4/4-3 shifting. ACTION: Whenever servicing the overdrive band or forward clutch, also replace the main control assembly with a 1991 service main control. Refer to the following AOD Main Control Application Chart. This chart reflects shift calibration revisions to the 1991 main control level. AOD MAIN CONTROL COMPLEXITY CHART MAIN DELETE ADD SERVICE CONTROL SERVICE PART PART NO. I.D. NO. MAIN CONTROL I.D. F1TZ-7A100-C GNO F0TZ-7A100-G DOA, MPA E9TZ-7A100-J MRA F1TZ-7A100-B GNN F0TZ-7A100-F DOX, MPX E9TZ-7A100-H MRX F1AZ-7A100-D JNF E9AZ-7A100-B COH, VPH, VRH, RRH F1SZ-7A100-B BNJ E9SZ-7A100-B URL, URY, SRY F0SZ-7A100-B GPJ, UPJ F1AZ-7A100-E JFK F0AZ-7A100-D CJH E9AZ-7A100-G VGH, RGH, WFR E5AZ-7A100-D BER, OER, ODR F1LY-7A-A DNX F0LY-7A100-B BOC, BOX, PPC E9LY-7A100-A PRX E9LY-7A100-B PRC F1SZ-TA100-A ANV F0SZ-7A100-A TPM E9SZ-7A100-D TRM, TRF PART NUMBER PART NAME CLASS F1TZ-7A100-C Main Control B F1TZ-7A100-B Main Control B F1AZ-7A100-D Main Control B F1SZ-7A100-B Main Control C F1AZ-7A100-E Main Control C F1LY-7A100-A Main Control B F1SZ-7A100-A Main Control C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-5-6 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 911612A Replace Main Control Valve 0.6 Hr. Body To AOD - Cars 911612B Remove And Install AOD 3.1 Hr. Transmission Assembly - Crown Victoria, Grand Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times > Page 4635 Marquis And Town Car 911612C Remove And Install AOD 3.5 Hr. Transmission Assembly - Thunderbird, Cougar, Mustang And Mark VII 911612D Overhaul Time For AOD 4.9 Hr. Transmission 911612E Remove And Install 2.8 Hr. Transmission - F-150, 4X2 Models, E-150, E-250 911612F Remove And Install 4.4 Hr. Transmission - F-150 And Bronco, 4X4 Models 911612G Remove And Install 2.6 Hr. Transmission - Econoline 911612H Overhaul Of AOD - Trucks 5.2 Hr. 9116121 Replace Main Control Valve 1.3 Hr. Body - Trucks DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision Clutch: All Technical Service Bulletins A/T - AOD Disassembly/Assembly Revision ^ SHOP MANUAL - 1987 - PAGE 17-20-50 AND 17-20-51-POSITION OF ILLUSTRATIONS REVISED ^ SHOP MANUAL - 1988 - PAGE 17-20-80 AND 17-20-81 - POSITION OF ILLUSTRATIONS REVISED ^ SHOP MANUAL - 1989 - PAGE 17-20-73 - INTERMEDIATE CLUTCH CLEARANCE UPDATED AND POSITION OF ILLUSTRATIONS REVISED Article No. 90-6B-12 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The Disassembly And Assembly procedures for the: AOD Automatic Transmission have been revised. The new information shows the correct illustrations for checking intermediate clutch clearance and the depth measurement at the reverse clutch drum thrust face. The affected shop manual pages are: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4640 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4641 ^ 17-20-50 and 17-20-51 of the 1987 Thunderbird/Cougar Shop Manual Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4642 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4643 ^ 17-20-80 and 17-20-81 of the 1988 Thunderbird/Cougar Shop Manual Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4644 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4645 ^ 17-20-73 of the 1989 Thunderbird/Cougar Shop Manual ^ Page 17-20-73 of the 1989 Manual also has the intermediate clutch clearance under step 22 updated to read 41.5-41.8 mm (1.628-1.640 inches) ACTION: Refer to the pages following this TSB article for the revised illustrations and updated clearance specifications. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clutch: > 89915 > May > 89 > A/T - AOD New Design Components Clutch: All Technical Service Bulletins A/T - AOD New Design Components TRANSMISSION - AOD - STAMPED CLUTCH CYLINDERS - IDENTIFICATION AND SERVICE TIPS Article No. 89-9-15 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A limited number of AOD transmissions built in early 1989 have some unique internal components. The new design components are: ^ A new design stamped forward clutch cylinder assembly. ^ An updated reverse sungear and shell assembly. ^ A carryover cast iron reverse clutch assembly. On the outside this AOD transmission looks identical to all other AOD transmissions. ACTION: If service is required, these transmissions can be identified by the service I.D. tag located on the extension housing. The unique model number on the service I.D. tag is PKA-DV 89. Please call the Livonia Transmission Plant, toll-free telephone number 1-800-237-3160, if transmission service is required. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5100, 5101, 5102, 5200, 5300, 5500, 5800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision Clutch: All Technical Service Bulletins A/T - AOD Disassembly/Assembly Revision ^ SHOP MANUAL - 1987 - PAGE 17-20-50 AND 17-20-51-POSITION OF ILLUSTRATIONS REVISED ^ SHOP MANUAL - 1988 - PAGE 17-20-80 AND 17-20-81 - POSITION OF ILLUSTRATIONS REVISED ^ SHOP MANUAL - 1989 - PAGE 17-20-73 - INTERMEDIATE CLUTCH CLEARANCE UPDATED AND POSITION OF ILLUSTRATIONS REVISED Article No. 90-6B-12 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The Disassembly And Assembly procedures for the: AOD Automatic Transmission have been revised. The new information shows the correct illustrations for checking intermediate clutch clearance and the depth measurement at the reverse clutch drum thrust face. The affected shop manual pages are: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4655 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4656 ^ 17-20-50 and 17-20-51 of the 1987 Thunderbird/Cougar Shop Manual Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4657 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4658 ^ 17-20-80 and 17-20-81 of the 1988 Thunderbird/Cougar Shop Manual Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4659 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 906B12 > Mar > 90 > A/T - AOD Disassembly/Assembly Revision > Page 4660 ^ 17-20-73 of the 1989 Thunderbird/Cougar Shop Manual ^ Page 17-20-73 of the 1989 Manual also has the intermediate clutch clearance under step 22 updated to read 41.5-41.8 mm (1.628-1.640 inches) ACTION: Refer to the pages following this TSB article for the revised illustrations and updated clearance specifications. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Clutch: > 89915 > May > 89 > A/T - AOD New Design Components Clutch: All Technical Service Bulletins A/T - AOD New Design Components TRANSMISSION - AOD - STAMPED CLUTCH CYLINDERS - IDENTIFICATION AND SERVICE TIPS Article No. 89-9-15 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A limited number of AOD transmissions built in early 1989 have some unique internal components. The new design components are: ^ A new design stamped forward clutch cylinder assembly. ^ An updated reverse sungear and shell assembly. ^ A carryover cast iron reverse clutch assembly. On the outside this AOD transmission looks identical to all other AOD transmissions. ACTION: If service is required, these transmissions can be identified by the service I.D. tag located on the extension housing. The unique model number on the service I.D. tag is PKA-DV 89. Please call the Livonia Transmission Plant, toll-free telephone number 1-800-237-3160, if transmission service is required. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5100, 5101, 5102, 5200, 5300, 5500, 5800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch Clutch: Service and Repair Direct Clutch DISASSEMBLE Exploded View Of Direct Clutch 1. Remove No. 7 direct clutch hub inner needle bearing. 2. Remove bearing support. 3. Remove clutch pack selective retaining snap ring. 4. Remove clutch pack from drum. 5. Using suitable tools, compress piston return springs and remove piston retaining ring. 6. Note position and direction of lip seals, then remove spring retainer assembly and piston from drum, using air pressure as necessary. ASSEMBLE 1. Install inner piston seal on clutch drum hub as follows: a. Position direct clutch lip seal protector T80L-77234-A or equivalent over clutch drum hub. b. Lubricate seal and seal protector with petroleum jelly. c. Position seal over installer tool with sealing lip facing down. d. Push seal down until it snaps off end of protector onto clutch hub. e. Remove seal protector from clutch hub. f. Slide seal up until it seats in seal groove. 2. Ensure piston check ball is present and moves freely. 3. Install outer clutch piston seal, ensuring sealing lip points away from spring posts. 4. Install clutch apply piston as follows: a. Coat piston seals, clutch drum sealing area, and piston inner seal area with petroleum jelly. b. Install piston in lip seal protector T80L-77254-A or equivalent. c. Position tool in clutch drum and push piston to bottom of drum using even thumb pressure. 5. Using suitable tool, install piston spring and retainer assembly and the retaining ring. 6. Install clutch pack. 7. Install clutch pack selective retaining ring and check clearance between ring and pressure plate, holding pressure plate downward while checking clearance. Direct Clutch Clearance Chart Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4667 8. If clearance is not within specifications, as shown in the Direct Clutch Clearance Chart image, install correct replacement snap ring and recheck clearance. Snap rings are available in inch thicknesses 0.050-0.054, 0.064-0.068, 0.078-0.082, and 0.092-0.096. 9. Check clutch for proper operation using air pressure. The clutch should be heard and felt to apply smoothly and without leakage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4668 Clutch: Service and Repair Forward Clutch DISASSEMBLE Exploded View Of Forward Clutch 1. Remove clutch hub and No. 3 needle bearing, if not previously removed. 2. Remove clutch pack selective retaining ring. 3. Remove clutch pack. 4. Using suitable tools, compress piston return spring and remove retaining ring and spring retainer. 5. Note position and direction of lip seals, then remove clutch piston and ensure check balls in piston are free. ASSEMBLE 1. Install new seals on clutch piston, noting direction of sealing lips. 2. Install clutch piston as follows: a. Coat piston seals and clutch drum sealing area with petroleum jelly. b. Install forward clutch inner lip seal protector T80L-7714-A or equivalent over clutch cylinder hub. c. Install piston in forward clutch outer lip seal protector T68P-7D158-A or equivalent. d. Position seal protector and piston in clutch drum and push piston to bottom of drum using even thumb pressure. 3. Using suitable tools, install piston return spring, spring retainer, and the retaining ring. 4. Install clutch pack, wave plate first 5. Install clutch pack retaining ring and check clearance between ring and pressure plate, holding pressure plate downward while checking clearance. Forward Clutch Clearance Chart 6. If clearance is not within specifications, as shown in the Forward Clutch Clearance Chart image, install correct replacement snap ring and recheck clearance. Snap rings are available in inch thicknesses 0.060-0.064, 0.074-0.078, 0.088-0.092, and 0.102-0.106. 7. Check clutch for proper operation using air pressure clutch should be heard and felt to apply smoothly without leakage. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4669 Clutch: Service and Repair Intermediate Clutch REMOVAL Exploded View Of Intermediate One-Way Clutch 1. Using suitable tool, remove clutch retaining ring. 2. Remove clutch retaining plate. 3. Remove clutch outer race by lifting on race while turning counterclockwise. 4. Carefully lift one-way clutch from inner race. INSTALLATION 1. Reverse procedure to assemble. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4670 Clutch: Service and Repair One-Way Clutch, A/T DISASSEMBLE Exploded View Of Center Support And Planetary One-Way Cutch Assembly 1. Remove center support from planetary carrier by rotating center support counterclockwise and lifting. 2. Carefully remove planetary one-way clutch from planetary assembly. ASSEMBLE Exploded View Of Planetary One-Way Clutch 1. Assemble one-way clutch. 2. Install one-way clutch in planetary carrier. 3. Lubricate clutch races and clutch assembly with petroleum jelly. 4. Install center support into one-way clutch by rotating center support counterclockwise. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4671 Clutch: Service and Repair Reverse Clutch DISASSEMBLE Exploded View Of Reverse Clutch 1. Remove No. 2 thrust washer or needle bearing. NOTE: Passenger car and four-wheel drive truck applications use thrust washer while two-wheel drive truck applications use a needle bearing. 2. Remove clutch pack retaining ring. 3. Remove clutch pack. 4. Using suitable tools, remove wave snap ring. 5. Remove piston return spring and thrust ring. 6. Remove clutch piston, applying air pressure, if necessary, while blocking opposite hole with finger. ASSEMBLE 1. Install new seals on clutch piston and ensure check ball moves freely. 2. Install clutch piston as follows: a. Coat piston seals and clutch drum seating area with petroleum jelly. b. Install reverse clutch inner seal protector T80L-77403-B and reverse clutch outer seal protector T80L-77403-A, or equivalents, in clutch drum. c. Coat piston seals, clutch drum sealing area, and seal protector with petroleum jelly. d. Position piston and push it to bottom of drum using even thumb pressure 3. Install piston thrust ring and piston return spring. 4. Using suitable tools, install wave snap ring, points down. 5. Install clutch pack, installing apply plate first with dished side facing piston. 6. Install clutch pack retaining ring and check clearance between ring and pressure plate, hold in pressure plate downward while checking clearance Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component Information > Service and Repair > Direct Clutch > Page 4672 Reverse Clutch Clearance Chart 7. If clearance is not within specifications, as shown in the Reverse Clutch Clearance Chart image, install correct replacement snap ring. Snap rings are available in inch thicknesses of 0.060-0.064, 0.074-0.078, 0.088-0.092, and 0.102-0.1O6. 8. Check clutch for proper operation using air pressure. The clutch should be heard and felt to apply smoothly without air leakage. 9. Install No. 2 thrust washer or needle bearing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T > Component Information > Service and Repair Extension Housing: Service and Repair REMOVAL 1. Raise and support vehicle. 2. Disconnect parking brake cable from equalizer, if necessary. 3. Disconnect driveshaft from rear axle flange, then remove driveshaft from transmission. 4. Disconnect speedometer cable from extension housing. 5. Remove engine rear support to extension housing attaching bolts. 6. Support transmission with suitable jack and raise transmission enough to remove weight from rear engine support. 7. Remove engine rear support from crossmember, then lower transmission and remove extension housing attaching bolts. Slide extension housing from output shaft and allow fluid to drain. INSTALLATION 1. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage Fluid - A/T: Technical Service Bulletins A/T - Mercon V ATF Usage TSB 06-14-4 07/24/06 MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID. FORD: 1980-1997 Crown Victoria 1981-1997 Mustang, Thunderbird 1981-2003 Escort 1986-1993 Festiva 1986-1997 Taurus 1989-1997 Probe 1994-1997 Aspire 1995-2000 Contour 1980-1996 Bronco 1981-2003 F-150 1981-2004 E-Series, F-Super Duty 1983-1996 Ranger 1986-1996 Aerostar 1991-1997 Explorer 1993-2004 F-53 Motorhome Chassis 1995-1998 Windstar 1997-2004 Expedition 2000-2005 Excursion 2001-2007 Escape 1987-2000 F-B-Series 2000-2007 F-650, F-750 LINCOLN: 1980-1997 Town Car 1981-1997 Continental 1993-1997 Mark VIII 1998-2004 Navigator 2002-2003 Blackwood MERCURY: 1980-1997 Grand Marquis 1981-1997 Cougar 1986-1997 Sable 1987-1999 Tracer 1995-2000 Mystique 1999-2002 Cougar 1993-2002 Villager 1997 Mountaineer 2005-2007 Mariner MERKUR: 1985-1989 XR4TI This article supersedes TSB 01-15-7 to update the vehicle application chart. ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid. ACTION Beginning immediately all automatic transmission / transaxle applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will only continue for however long it takes to deplete what remains in inventory. SERVICE PROCEDURE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4680 Service automatic transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V For proper fluid application on current and past model vehicles equipped with automatic transmissions I transaxles refer to the fluid usage chart. (Figure 1) CAUTION AUTOMATIC TRANSMISSIONS / TRANSAXLES THAT REQUIRE MERCON® V SHOULD STILL ONLY USE MERCON(R) V OR DUAL USAGE FLUID LABELED MERCON(R) / MERCON(R) V. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Technical Service Bulletins > A/T - Mercon V ATF Usage > Page 4681 CAUTION MERCON(R) SP, MOTORCRAFT PREMIUM AUTOMATIC TRANSMISSION FLUID AND MOTORCRAFT M5 ATFS ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR TRANSMISSION DAMAGE. CAUTION THE FUNCTIONAL CHARACTERISTICS OF FLUIDS FOR CVT TRANSMISSIONS ARE VERY DIFFERENT THAN THOSE OF OTHER AUTOMATIC TRANSMISSION FLUIDS (ATFS). USE OF A FLUID OTHER THAN MOTORCRAFT CONTINUOUSLY VARIABLE CHAIN TYPE TRANSMISSION FLUID OR ONE LABELED AS MEETING MERCON(R) C WILL CAUSE FUNCTIONALITY CONCERNS AND INTERNAL TRANSMISSION DAMAGE. CAUTION DO NOT USE AUTOMATIC TRANSMISSION FLUID SUPPLEMENTS, ADDITIVES, TREATMENTS OR CLEANING AGENTS. Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Refill Capacity Fluid - A/T: Specifications Type MA(MERCON (R) V Automatic Transmission Fluid) CAPACITY, Initial Refill*: 3.0 qt (US) With the engine at operating temperature, shift transmission through all gears. Check fluid level in PARK and add fluid as needed Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Refill Capacity > Page 4684 Fluid - A/T: Specifications Type MA(MERCON (R) V Automatic Transmission Fluid) CAPACITY, Total Fill: AXOD 12.8 qt (US) 4WD Tempo, Topaz 10.0 qt (US) Taurus ex. O.D. 8.0 qt (US) Festiva 5.6 qt (US) Tracer 6.0 qt (US) Others 8.3 qt (US) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component Information > Specifications > Page 4685 Fluid - A/T: Testing and Inspection CHECKING OIL LEVEL 1. With transmission at operating temperature, park vehicle on level surface. 2. Operate engine at idle speed with parking brake applied and move selector lever through each detent position. Return selector lever to PARK. 3. With engine idling, remove dipstick and check fluid level. Fluid level should be between arrows on dipstick. 4. Add fluid as necessary to bring fluid to proper level. Use only fluid meeting Ford Qualification No. M2C-138-CJ, Dexron II or Mercon. MERCON(R) automatic Transmission Fluid is being replaced by MERCON(R) V as a service fluid, as per TSB 06-14-4. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4690 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4691 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T > Component Information > Application and ID Ford AOD & AOD-E Overdrive Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T > Component Information > Service and Repair Fluid Pump: Service and Repair DISASSEMBLE 1. Remove No. 1 thrust washer. 2. Remove four pump seal rings. The reverse clutch rings are larger than the forward clutch rings. Exploded View Of Pump And Intermediate Clutch Piston 3. Remove and discard pump body to case seal. 4. Remove spring retainer assembly by carefully dislodging tabs. 5. Remove clutch piston. 6. Remove five stator support bolts. 7. Remove stator support. 8. Remove drive and driven pump gears from pump body. ASSEMBLE 1. Install drive and driven pump gears in pump body with chamfers on both gears facing pump body. 2. Position stator support to pump body and install and torque attaching bolts. 3. Install new pump to case seal. 4. Install new seals on clutch piston, ensuring sealing lips point away from spring posts. 5. Install clutch piston as follows: a. Coat piston seals and pump body sealing area with petroleum jelly. b. Install piston in seal protector T80L-77005-A or equivalent. c. Install piston in pump body and push to bottom of bore by exerting even thumb pressure on piston. Ensure piston bleed is located at 12 o'clock position. 6. Snap spring retainer assembly into place on pump body, using even pressure. 7. Install pump seal rings. NOTE: Stator support seal rings are largest rings and are for reverse clutch. These rings are closest to pump. Stator support seal rings are for the forward clutch. These rings are furthest from pump body. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal and Installation Governor: Service and Repair Removal and Installation REMOVAL 1. Remove extension housing. If governor body only is being removed, proceed to step 4. 2. Remove governor to output shaft retaining snap ring. 3. Remove governor assembly from output shaft using suitable tool. Remove 4. Remove governor to counterweight attaching screws. Remove governor from counterweight. INSTALLATION 1. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Governor, A/T > Component Information > Service and Repair > Removal and Installation > Page 4702 Governor: Service and Repair Disassembly and Assembly DISASSEMBLE Exploded View Of Governor Assembly 1. Remove screws attaching counterweight to governor body. 2. Remove cover screws and cover. 3. Remove plug, sleeve, and governor valve from governor body. 4. Remove screen from governor body. ASSEMBLE 1. Install clip and spring on governor valve. 2. Install governor valve in governor body. 3. Install sleeve in governor body with points outward. 4. Install plug in sleeve with knurled face inward. 5. Position cover and install and torque attaching screws. 6. Install screen in body with brass colored steel band inward and top of screen facing outward. 7. Position governor body on counterweight and install and torque attaching screws. CAUTION: Finished face of body should be flush with face of counterweight. Otherwise, body is installed backward. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Technical Service Bulletins > Customer Interest for Shift Indicator: > 89139 > Jun > 89 > A/T - PRNDL Bulb Socket Melted Shift Indicator: Customer Interest A/T - PRNDL Bulb Socket Melted LAMP-TRANSMISSION PRNDL BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 TRANSMISSION-PRNDL LIGHT BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 Article No. 89-13-9 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Heat from the transmission "PRNDL" light bulb may soften and melt the plastic bulb socket. This is caused by the two (2) candlepower bulb. ACTION: Install a new bulb and socket assembly. The new assembly has a one (1) candlepower bulb which will operate cooler. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 17-02 for service details. NOTE: THE NEW BULB AND SOCKET ASSEMBLY ALSO HAS A LIGHTER GREEN FILTER SO THE LESS BRIGHT BULB WILL STILL SUPPLY THE CORRECT GREEN COLOR AND INTENSITY. PART NUMBER PART NAME CLASS E9SZ-15A808-C Bulb and Socket Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891309A Install Bulb & Socket 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 15A808 46 OASIS CODES: 2100, 2150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Lamps and Indicators - A/T > Shift Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Indicator: > 89139 > Jun > 89 > A/T - PRNDL Bulb Socket Melted Shift Indicator: All Technical Service Bulletins A/T - PRNDL Bulb Socket Melted LAMP-TRANSMISSION PRNDL BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 TRANSMISSION-PRNDL LIGHT BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 Article No. 89-13-9 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Heat from the transmission "PRNDL" light bulb may soften and melt the plastic bulb socket. This is caused by the two (2) candlepower bulb. ACTION: Install a new bulb and socket assembly. The new assembly has a one (1) candlepower bulb which will operate cooler. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 17-02 for service details. NOTE: THE NEW BULB AND SOCKET ASSEMBLY ALSO HAS A LIGHTER GREEN FILTER SO THE LESS BRIGHT BULB WILL STILL SUPPLY THE CORRECT GREEN COLOR AND INTENSITY. PART NUMBER PART NAME CLASS E9SZ-15A808-C Bulb and Socket Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891309A Install Bulb & Socket 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 15A808 46 OASIS CODES: 2100, 2150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > A/T - A4LD Output Shaft Snap Ring and Application Output Shaft: Technical Service Bulletins A/T - A4LD Output Shaft Snap Ring and Application TRANSMISSION - A4LD - SNAP RING AND OUTPUT SHAFT - SERVICE PART PACKAGING AND APPLICATION Article No. 88-20-7 FORD: 1989 MUSTANG, THUNDERBIRD LIGHT TRUCK: 1989 AEROSTAR, BRONCO II, RANGER ISSUE: 1989 Aerostar extended vans require the use of a (2.0 mm) snap ring and matching output shaft. During the 1989 model year some A4LD transmissions, used in other car and light truck applications, will be built with either the (1.2 mm) snap ring and matching output shaft or the (2.0 mm) snap ring and matching output shaft. The snap rings and output shafts are not interchangeable because of the difference in size. ACTION: If service is required on the snap ring or output shaft, it will be necessary to determine which size snap ring is needed. The (1.2 mm) and (2.0 mm) snap rings will be packaged together for service. NOTE: THE 2.0 mm SNAP RING AND MATCHING OUTPUT SHAFT CAN BE USED TO SERVICE PRIOR MODEL YEAR A4LD TRANSMISSIONS. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Output Shaft, A/T > Component Information > Technical Service Bulletins > Page 4721 Output Shaft: Service and Repair REMOVAL Exploded View Of Output Shaft 1. Remove ring gear retaining output shaft hub to ring gear. 2. Separate output shaft and hub assembly from ring gear. 3. Remove direct clutch from ring gear and the No. 8 needle bearing from back of direct clutch. 4. Remove four output shaft seal rings and the hub to output shaft retaining ring and separate hub from output shaft. 5. Remove two direct clutch seal rings from output shaft. INSTALLATION 1. Reverse procedure to assemble. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Parking Pawl, A/T > Component Information > Service and Repair Parking Pawl: Service and Repair REMOVAL Removing Or Installing Parking Pawl 1. Slide park pawl shaft out of rear of case and remove parking pawl. 2. Remove return spring. INSTALLATION 1. Hook squared end of spring into notch on park pawl. 2. Hold pawl and spring in place and hook curved end of spring into recess in case. 3. Install park pawl shaft. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T > Component Information > Service and Repair Planetary Gears: Service and Repair DISASSEMBLE Exploded View Of Sun Gear And Drive Shell 1. Remove No. 4 needle bearing from drive shell. 2. Remove forward sun gear and No. 5 needle bearing from drive shell. 3. Remove No. 5 needle bearing from forward sun gear. ASSEMBLE 1. The sun gear and drive shell is assembled during assembly of transmission. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > Customer Interest for Shift Cable: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Shift Cable: Customer Interest Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift Cable, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Cable: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Shift Cable: All Technical Service Bulletins Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component Information > Technical Service Bulletins > A/T - AOD New Design Components Sun Gear: Technical Service Bulletins A/T - AOD New Design Components TRANSMISSION - AOD - STAMPED CLUTCH CYLINDERS - IDENTIFICATION AND SERVICE TIPS Article No. 89-9-15 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A limited number of AOD transmissions built in early 1989 have some unique internal components. The new design components are: ^ A new design stamped forward clutch cylinder assembly. ^ An updated reverse sungear and shell assembly. ^ A carryover cast iron reverse clutch assembly. On the outside this AOD transmission looks identical to all other AOD transmissions. ACTION: If service is required, these transmissions can be identified by the service I.D. tag located on the extension housing. The unique model number on the service I.D. tag is PKA-DV 89. Please call the Livonia Transmission Plant, toll-free telephone number 1-800-237-3160, if transmission service is required. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5100, 5101, 5102, 5200, 5300, 5500, 5800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve, A/T > Component Information > Adjustments > Vehicles With Throttle Valve Cable Linkage Throttle Valve: Adjustments Vehicles With Throttle Valve Cable Linkage ADJUST 1. Attach Throttle Valve (TV) pressure gauge with hose, No. T86L-70002-A, or equivalent, to TV port on transmission, using enough hose to make gauge accessible while operating engine. 2. If necessary, remove air cleaner cover and inlet tube from throttle body inlet. Installing Cable TV Gauge Tool (Typical) 3. Insert tapered end of cable TV gauge tool No. T86L-70332-A or equivalent between crimped slug on end of cable and plastic cable fitting that attaches to throttle lever. 4. Push gauge tool in, forcing the crimped slug away from the plastic fitting, ensuring gauge block is pushed in as far as it will go. 5. Run engine until it reaches normal operating temperature and temperature of transmission fluid is 100-150° F. 6. Apply parking brake and place shift selector in Neutral. TV pressure should be 30-40 psi. For best results, set TV pressure as close to 33 psi as possible as follows: a. Using suitable tool, pry up white toggle lever on cable adjuster located immediately behind throttle body cable mounting bracket. The adjuster preload spring should cause the adjusting slider to move away from the throttle body and TV pressure should increase. b. Push on slider from behind bracket until TV pressure is 33 psi and, while still holding slider, push down on toggle lever as far as it will go, locking slider in position. 7. Remove gauge tool, allowing cable to return to its normal idle position. 8. If TV pressure is not less than 5 psi, reinstall gauge block and repeat step 6, setting pressure to a pressure of less than 33 psi but not less than 28 psi. 9. Remove gauge block and ensure TV pressure is less than 5 psi. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Assembly, A/T > Throttle Valve, A/T > Component Information > Adjustments > Vehicles With Throttle Valve Cable Linkage > Page 4751 Throttle Valve: Adjustments Vehicles With Throttle Valve Rod Linkage ADJUSTMENT 1. Check curb idle speed, adjusting as necessary. Ensure curb idle speed is set to specification with and without the throttle solenoid positioner (anti-diesel solenoid) energized, if equipped. 2. Using adapter fitting D80L-77001-A or equivalent, attach suitable pressure gauge to Throttle Valve (TV) port on transmission, using enough flexible hose so that gauge can be read while operating engine. TV Control Pressure Gauge Block Tool 3. Obtain TV control pressure gauge block No. D84P-70332-A or fabricate a block 0.390-0.404 inch thick. 4. Run engine until it reaches normal operating temperature and the throttle lever is off fast idle, or the Idle Speed Control (ISC) plunger, if equipped, is at its normal idle position. Ensure transmission fluid temperature is approximately 100-150° F. 5. Apply parking brake, place shift selector in Neutral, remove air cleaner, and shut off air conditioner. If equipped with a vacuum operated throttle modulator, disconnect and plug vacuum line to this unit. If equipped with a throttle solenoid positioner or an idle speed control, do not disconnect either of these units. 6. With engine idling in Neutral and no accessory load on engine, insert gauge block between carburetor throttle lever and adjustment screw on the TV linkage lever at the carburetor, as shown in the TV Control Pressure Gauge Block Tool image. The TV pressure should be 28-88 psi. For optimum setting, use adjusting screw to set pressure as close to 33 psi as possible. Turning the screw in will raise the pressure 1.5 psi per turn and backing out the screw will lower the pressure. If equipped with idle speed control, some hunting may occur and an average pressure reading will have to be determined. If the adjusting screw does not have enough adjustment range to bring TV pressure within specification, first adjust rod at transmission as previously described. 7. Remove gauge block, allowing TV lever to return to idle. With engine still idling in Neutral, TV pressure must be less than 5 psi. If not, back out adjusting screw until TV pressure is less than 5 psi, then reinstall gauge block and ensure TV pressure is still 28-38 psi. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Cable/Linkage: > 911114 > May > 91 > A/T - AOD Harsh/Rough Shifts Throttle Valve Cable/Linkage: Customer Interest A/T - AOD Harsh/Rough Shifts Article No. 91-11-14 05/30/91 TRANSMISSION - AUTOMATIC - AOD - HARSH/ROUGH 3-4/4-3 SHIFTS FORD: 1989-90 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989-90 BRONCO, E-150, F-150 ISSUE: Harsh or rough transmission shifts in certain vehicles may be calibration characteristics of the AOD transmission split torque feature. However some customer transmission shifting concerns could be the result of improper (TV) pressure or sticking control valves. ACTION: Diagnose and repair the transmission. Using the following procedures which have proven to be an effective sequence of repair and significantly reduces the potential for unnecessary replacement of major components. Before performing any transmission repairs, test drive the vehicle to verify the 3-4 shift concern. Some of these concerns may be related to "tip-out" clunk due to an engine processor strategy and may be repaired as specified in TSB 90-17-4. If the referenced TSB does not eliminate the concern, refer to the following repair procedure. Diagnose and Adjust (TV) pressure. Refer to Section 17 of the appropriate Car or Truck Shop Manual for service details in performing the following adjustment. 1. Check throttle valve (TV) pressure and verify 33-34 PSI for passenger vehicles and 29-30 PSI for trucks. If TV pressure is not as specified, adjust TV pressure as outlined in the appropriate Car or Truck Shop Manual. 2. With TV pressure properly set, test drive the vehicle to verify if symptom still exists. If the vehicle has not been corrected, proceed as follows: Inspect and Clean Main Control Refer to Section 17 of the appropriate Car or Truck Shop Manual for service details in performing the following repair. 1. Throughly drain the transmission and converter. 2. Remove the oil pan and main control assembly. 3. Disassemble the main control and check for stuck valves. With the separating plate removed, check each valve for free movement, pay special attention to the 2-3 capacity modulator, 2-3 TV modulator, and the 3-4 TV modulator valve. Using crocus cloth, clean and polish lands as required and reassemble. 4. Install new upper and lower main control gaskets. 5. Torque main control attaching bolts to 85 in.lbs. +/- 5 in.lbs. NOTE: Target 85 in.lbs. 6. Install oil pan using a new pan gasket and fill with Mercon/R transmission fluid to the proper level. 7. Recheck TV pressure and re-adjust as required to establish 33-34 PSI for passenger cars and 29-30 PSI for trucks. 8. Test drive to verify repair. As indicated, the above repair procedure has proven to be effective with over 90% of the 3-4/4-3 shift concerns. However, in some circumstances, the above procedure may not completely satisfy the customer concerns. In those instances, the 1991 Main Control may provide the required shift improvements. Refer to the following AOD Main Control Complexity Chart for the 1989-1990 Main Controls and their equivalent 1991 replacements. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Customer Interest for Throttle Valve Cable/Linkage: > 911114 > May > 91 > A/T - AOD Harsh/Rough Shifts > Page 4760 AOD MAIN CONTROL COMPLEXITY CHART ADD SERVICE MAIN DELETE PART CONTROL SERVICE NUMBER I.D. PART NUMBER MAIN CONTROL I.D. F1TZ-7A100-C GNO F0TZ-7A100-G DOA, MPA E9TZ-7A100-J MRA F1TZ-7A100-B GNN F0TZ-7A100-F DOX, MPX E9TZ-7A100-H MRX F1AZ-7A100-D JNF E9AZ-7A100-B COH, VPH, VRH RRH F1SZ-7A100-B BNJ E9SZ-7A100-B URL, URY, SRY F0SZ-7A100-B GPJ, UPJ F1AZ-7A100-E JFK F0AZ-7A100-D CJH E9AZ-7A100-G VGH, RGH, WFR E5AZ-7A100-D BER, OER, ODR F1LY-7A100-A DNX F0LY-7A100-B BOC, BOX, PPC E9LY-7A100-A PRX E9LY-7A100-B PRC F1SZ-7A100-A ANV F0SZ-7A100-A TPM E9SZ-7A100-D TRM, TRF PART NUMBER PART NAME CLASS D9AZ-7D100-B Gasket Lower Control C E9SZ-7C155-A Gasket Upper Control B E0AZ-7A191-B Gasket Transmission Pan AM XT-2-QDX Mercon/R Fluid VG OTHER APPLICABLE ARTICLES: 91-5-5 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911114A Adjust TV Pressure 0.7 Hrs 911114B Inspect And Clean Control 2.6 Hrs Valves 911114C Replace Main Control Valve 1.3 Hrs DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Cable/Linkage: > 911114 > May > 91 > A/T - AOD Harsh/Rough Shifts Throttle Valve Cable/Linkage: All Technical Service Bulletins A/T - AOD Harsh/Rough Shifts Article No. 91-11-14 05/30/91 TRANSMISSION - AUTOMATIC - AOD - HARSH/ROUGH 3-4/4-3 SHIFTS FORD: 1989-90 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989-90 BRONCO, E-150, F-150 ISSUE: Harsh or rough transmission shifts in certain vehicles may be calibration characteristics of the AOD transmission split torque feature. However some customer transmission shifting concerns could be the result of improper (TV) pressure or sticking control valves. ACTION: Diagnose and repair the transmission. Using the following procedures which have proven to be an effective sequence of repair and significantly reduces the potential for unnecessary replacement of major components. Before performing any transmission repairs, test drive the vehicle to verify the 3-4 shift concern. Some of these concerns may be related to "tip-out" clunk due to an engine processor strategy and may be repaired as specified in TSB 90-17-4. If the referenced TSB does not eliminate the concern, refer to the following repair procedure. Diagnose and Adjust (TV) pressure. Refer to Section 17 of the appropriate Car or Truck Shop Manual for service details in performing the following adjustment. 1. Check throttle valve (TV) pressure and verify 33-34 PSI for passenger vehicles and 29-30 PSI for trucks. If TV pressure is not as specified, adjust TV pressure as outlined in the appropriate Car or Truck Shop Manual. 2. With TV pressure properly set, test drive the vehicle to verify if symptom still exists. If the vehicle has not been corrected, proceed as follows: Inspect and Clean Main Control Refer to Section 17 of the appropriate Car or Truck Shop Manual for service details in performing the following repair. 1. Throughly drain the transmission and converter. 2. Remove the oil pan and main control assembly. 3. Disassemble the main control and check for stuck valves. With the separating plate removed, check each valve for free movement, pay special attention to the 2-3 capacity modulator, 2-3 TV modulator, and the 3-4 TV modulator valve. Using crocus cloth, clean and polish lands as required and reassemble. 4. Install new upper and lower main control gaskets. 5. Torque main control attaching bolts to 85 in.lbs. +/- 5 in.lbs. NOTE: Target 85 in.lbs. 6. Install oil pan using a new pan gasket and fill with Mercon/R transmission fluid to the proper level. 7. Recheck TV pressure and re-adjust as required to establish 33-34 PSI for passenger cars and 29-30 PSI for trucks. 8. Test drive to verify repair. As indicated, the above repair procedure has proven to be effective with over 90% of the 3-4/4-3 shift concerns. However, in some circumstances, the above procedure may not completely satisfy the customer concerns. In those instances, the 1991 Main Control may provide the required shift improvements. Refer to the following AOD Main Control Complexity Chart for the 1989-1990 Main Controls and their equivalent 1991 replacements. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Throttle Valve Cable/Linkage: > 911114 > May > 91 > A/T - AOD Harsh/Rough Shifts > Page 4766 AOD MAIN CONTROL COMPLEXITY CHART ADD SERVICE MAIN DELETE PART CONTROL SERVICE NUMBER I.D. PART NUMBER MAIN CONTROL I.D. F1TZ-7A100-C GNO F0TZ-7A100-G DOA, MPA E9TZ-7A100-J MRA F1TZ-7A100-B GNN F0TZ-7A100-F DOX, MPX E9TZ-7A100-H MRX F1AZ-7A100-D JNF E9AZ-7A100-B COH, VPH, VRH RRH F1SZ-7A100-B BNJ E9SZ-7A100-B URL, URY, SRY F0SZ-7A100-B GPJ, UPJ F1AZ-7A100-E JFK F0AZ-7A100-D CJH E9AZ-7A100-G VGH, RGH, WFR E5AZ-7A100-D BER, OER, ODR F1LY-7A100-A DNX F0LY-7A100-B BOC, BOX, PPC E9LY-7A100-A PRX E9LY-7A100-B PRC F1SZ-7A100-A ANV F0SZ-7A100-A TPM E9SZ-7A100-D TRM, TRF PART NUMBER PART NAME CLASS D9AZ-7D100-B Gasket Lower Control C E9SZ-7C155-A Gasket Upper Control B E0AZ-7A191-B Gasket Transmission Pan AM XT-2-QDX Mercon/R Fluid VG OTHER APPLICABLE ARTICLES: 91-5-5 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911114A Adjust TV Pressure 0.7 Hrs 911114B Inspect And Clean Control 2.6 Hrs Valves 911114C Replace Main Control Valve 1.3 Hrs DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Page 4767 Throttle Valve Cable/Linkage: Description and Operation Throttle Valve (TV) Control Cable System Components The Throttle Valve (TV) control cable system consists of a cable attaching grommet on the throttle body throttle lever, the TV control cable assembly, the external TV control lever on the transmission, and the cable mounting brackets at the throttle body and transmission. Operation As the throttle is moved from idle to Wide-Open Throttle (WOT), the TV control cable pulls the transmission TV control lever from idle to WOT. Return of the cable and transmission lever toward idle is accomplished by the return spring on the transmission end of the cable assembly. This spring and the end of the cable assembly is protected by a flexible rubber boot. The transmission external TV control lever actuates the internal TV control mechanism which regulates the TV control pressure. The travel of this lever is controlled by stops internal to the transmission. TV Control Cable Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Technical Service Bulletins > Page 4768 The TV control cable is set and locked to its proper length during initial assembly when the grooved pin on the upper end of the cable assembly is inserted in the grommet on the throttle body lever. To release the cable locking mechanism, it is necessary to pry the grooved pin out of the grommet and push out the white locking pin. The take-up spring at the end of the cable assembly tensions the cable and takes up the slack in the system. When the grooved pin is reinserted in the grommet, the white locking tab is pushed in, automatically locking the cable to its correct length. When the cable is locked, the take-up spring plays no part in the operation of the system. Situations Requiring Readjustment Under normal circumstances, it should not be necessary to alter or readjust the initial setting of the TV control cable. Situations requiring readjustment of the TV control cable include maintenance involving the removal and/or replacement of the throttle body, transmission, TV cable assembly, or installing a new main control assembly. Readjustment of the TV control cable would also be necessary to correct complaints of poor transmission shift quality that would have been caused by a misadjustment of the TV control cable. When the TV control cable is properly set, the transmission TV control lever will be at its internal idle stop (lever to rear as far as it will travel) when the throttle lever is at its idle stop. Idle Speed Affect on TV Control Cable The Sequential Electronic Fuel Injection (SEFI) engine uses an air bypass type Idle Speed Control (ISC) that does not affect throttle position. Therefore, idle automatic setting does not affect TV cable adjustment. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Testing and Inspection > Throttle Valve Cable Diagnosis - With AOD Throttle Valve Cable/Linkage: Testing and Inspection Throttle Valve Cable Diagnosis - With AOD Transmission Lever Stuck In Wide 0pen or Part Throttle Position TRANSMISSION LEVER STUCK IN WIDE 0PEN OR PART THROTTLE POSITION 1. Delayed and harsh upshifts, particularly at light to moderate acceleration. 2. Harsh idle engagement. TV Control Cable Broken or Disconnected at Throttle Body TV CONTROL CABLE BROKEN OR DISCONNECTED AT THROTTLE BODY 1. Excessively early and/or soft upshifts. 2. Harsh light throttle shift into and out of overdrive. 3. No forced downshift at proper speeds. TV Control Cable Disconnected at Transmission TV CONTROL CABLE DISCONNECTED AT TRANSMISSION 1. Delayed and harsh upshifts, particularly at light to moderate acceleration. 2. Harsh idle engagement. TV Control Cable Improperly Attached at One End TV CONTROL CABLE IMPROPERLY ATTACHED AT ONE END 1. Clunking when throttle is backed off after full or heavy throttle acceleration. 2. Harsh coasting downshifts out of overdrive. TV Control Cable Not Locked TV CONTROL CABLE NOT LOCKED 1. Clunking when throttle is backed off after full or heavy throttle acceleration. 2. Harsh coasting downshifts out of overdrive. TV Control Cable Set Too Long TV CONTROL CABLE SET TOO LONG 1. Excessively early and/or soft upshifts. 2. Harsh light throttle shift into and out of overdrive. 3. No forced downshift at proper speeds. TV Control Cable Set Too Short TV CONTROL CABLE SET TOO SHORT 1. Clunking when throttle is backed off after full or heavy throttle acceleration. 2. Harsh coasting downshifts out of overdrive. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Testing and Inspection > Throttle Valve Cable Diagnosis - With AOD > Page 4771 Throttle Valve Cable/Linkage: Testing and Inspection Throttle Valve Linkage Diagnosis - With AOD Binding Grommets Preventing Linkage Return BINDING GROMMETS PREVENTING LINKAGE RETURN 1. Delayed or harsh upshifts. 2. Harsh idle engagement. Clamping Bolt on Trunnion at Lower End of TV Control Rod Loose CLAMPING BOLT ON TRUNNION AT LOWER END OF TV CONTROL ROD LOOSE 1. Delayed or harsh upshifts. 2. Harsh idle engagement. Interference Proventing Return of TV Control Rod INTERFERENCE PROVENTING RETURN OF TV CONTROL ROD 1. Delayed or harsh upshift. 2. Harsh idle engagement. Linkage Lever Return Spring Broken or Disconnected LINKAGE LEVER RETURN SPRING BROKEN OR DISCONNECTED 1. Delayed or harsh upshifts. 2. Harsh idle engagement. TV Control Linkage Adjusted Too Short TV CONTROL LINKAGE ADJUSTED TOO SHORT 1. Early or soft upshifts. 2. Harsh light throttle shift into and out of overdrive. 3. No forced downshift at proper speeds. TV Control Rod Disconnected TV CONTROL ROD DISCONNECTED 1. Delayed or harsh upshifts. 2. Harsh idle engagement. TV Linkage Adjusted Too Long TV LINKAGE ADJUSTED TOO LONG 1. Harsh idle engagement after engine warm up. 2. Clunking when throttle is released after heavy acceleration. 3. Harsh coasting downshifts out of overdrive. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > Throttle Valve Control Cable - With AOD Throttle Valve Cable/Linkage: Adjustments Throttle Valve Control Cable - With AOD ADJUST THROTTLE VALVE CONTROL CABLE 1. Set parking brake and place shift selector in Neutral position. 2. Remove air cleaner cover and inlet tube from throttle body inlet. 3. Using a wide blade screwdriver, pry grooved pin on cable assembly out of grommet on throttle body lever. 4. Using small screwdriver push out white locking tab. Ensure plastic block with pin and tab slides freely on notched rod. if it does not slide freely, the white tab may not be pushed out far enough. 5. while holding throttle lever firmly against its idle stop, push grooved pin into grommet on throttle lever as far as it will go. While pushing pin into grommet, do not move throttle lever away from idle stop. 6. Install air cleaner cover and air inlet tube. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Throttle Valve Cable/Linkage, A/T > Component Information > Adjustments > Throttle Valve Control Cable - With AOD > Page 4774 Throttle Valve Cable/Linkage: Adjustments Throttle Valve Linkage ADJUST THROTTLE VALVE LINKAGE At Transmission 1. On vehicles without Idle Speed Control (ISC), proceed as follows: a. Check and adjust curb idle speed to specifications with and without throttle solenoid positioner (anti-dieseling solenoid energized, if equipped). b. Shut off engine and remove air cleaner. c. De-cam fast idle cam on carburetor so that throttle lever is against idle stop or throttle solenoid positioner stop. 2. Place shift lever in Neutral and apply parking brake. 3. Set linkage lever adjustment screw at approximately mid-range. 4. If a new Throttle Valve (TV) control rod assembly is being installed, connect rod to linkage lever at carburetor. 5. Raise and support vehicle. 6. Loosen bolt on sliding trunnion block on TV control rod assembly, removing any corrosion from control rod and freeing up trunnion block so that it slides freely on control rod. 7. Push up on lower end of control rod to ensure linkage lever on carburetor is firmly against throttle lever, then release force on rod and ensure rod stays up. 8. Push TV control lever on transmission up against its internal stop with a force of approximately five lbs and tighten bolt on trunnion block. Do not relax force on lever until bolt is tightened. 9. Lower vehicle and ensure throttle lever is still against stop and if not, repeat steps 2 through 9. At Carburetor 1. Position throttle lever at idle stop, place shift lever in Neutral and apply parking brake (engine OFF). 2. Turn linkage lever adjusting screw counterclockwise until end of screw is flush with throttle lever face. 3. Turn adjusting screw clockwise to provide 0.005 inch clearance between end of screw and throttle lever. Continue turning adjusting screw an additional three turns. If screw travel is limited, one turn is acceptable. 4. If adjusting screw cannot be turned at least one turn, refer to At Transmission procedure. Idle Seed/Throttle Valve Linkage Adjustment Chart NOTE: Whenever idle speed is adjusted by more than 50 RPM, the adjustment screw on the linkage lever at the carburetor should also be adjusted as listed in the Idle Speed/Throttle Valve Linkage Adjustment Chart. 5. If idle speed was adjusted, ensure that 0.005 inch clearance exists between linkage lever adjusting screw and the throttle lever. The throttle lever should be at the idle stop and the shift lever in Neutral. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure Torque Converter: Technical Service Bulletins A/T Torque Converter - Leak Test Procedure Article No. 96-24-9 11/18/96 TORQUE CONVERTER - LEAK TEST PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1984-90 BRONCO II 1984-96 BRONCO 1984-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: A new torque converter leak test tool has been released. The current leak test tool has been discontinued by the manufacturer. The new tool will be available to all dealers in 1997. ACTION: When using the new leak test tool, a new procedure must be followed. Refer to the following Service Procedure and/or the 1997 Service/Workshop Manuals when using the new leak test tool. NEW TOOL NUMBER Description Tool Number Torque converter Leak Test Tool and Gasket 014-R1075 SERVICE PROCEDURE 1. Clean the outside surface of the torque converter. CAUTION: BE CAREFUL NOT TO DAMAGE THE CONVERTER HUB FINISH WHEN INSTALLING THE TOOL. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4779 2. Install the Torque Converter Leak Test Tool and Gasket (O14-R1075) into the converter hub. Figure 1. WARNING: ALWAYS USE PROPER SAFETY PROCEDURES WHILE USING PRESS. CAUTION: DO NOT DAMAGE THE CONVERTER BY APPLYING EXCESSIVE FORCE FROM THE PRESS. USE ONLY ENOUGH FORCE TO SEAL TOOL INTO THE CONVERTER. 3. Place the torque converter with the tool installed into press and apply enough force to seal tool into the converter. Figure 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4780 4. Using clean, dry shop air only, apply air pressure of 552 kPa (80 psi) maximum to the valve on the tool. Refer to Figure 3. 5. With air pressure applied to the valve, inspect for any air leaks at the studs, seams and pilot hub. A soap bubble solution may be applied around those areas to aid in diagnosis. If any leaks are present, replace the converter. 6. Disconnect the air line and release the air pressure from the tool by pulling on the release ring and then slowly releasing the press. Refer to Figure 4. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4781 7. Turn the torque converter and tool upside down and reinstall into the press. Repeat Steps 2-6 to check for leaks on the opposite side. Refer to Figure 5. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 501000, 502000, 504000, 510000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4782 Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4783 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > A/T Torque Converter - Leak Test Procedure > Page 4784 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter > Component Information > Technical Service Bulletins > Page 4785 Torque Converter: Specifications Converter to Flywheel Torque Converter to Flywheel Torque Converter To Flywheel 20-34 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines Technical Service Bulletin # 962612 Date: 961216 Torque Converter - Cleaning and Replacement Guidelines Article No. 96-26-12 12/16/96 ^ TRANSAXLE - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSAXLE COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP ^ TRANSMISSION - TORQUE CONVERTER REPLACEMENT GUIDELINES AND TORQUE CONVERTER/TRANSMISSION COOLING SYSTEM CLEANING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1985-86 MARQUIS 1985-87 LN7, LYNX 1985-92 MARK VII 1985-94 TOPAZ 1985-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-96 BRONCO 1985-97 ECONOLINE, F-150-350 SERIES, RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, MOUNTAINEER ISSUE: Torque converter replacement guidelines and torque converter/transmission (or transaxle) cooling-system cleaning procedures are now available to reduce repeat repairs. ACTION: Refer to the following guideline to properly diagnose and service torque converters and to properly clean the torque converter and transmission cooling system using forward flushing/backflushing. For diagnosis, service and cleaning, refer to to the appropriate model/year Service Manual, Sections 07-01, 07-02, 03-03, 307-01, 307-02, or 303-03. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4790 OASIS CODES: 501000, 502000, 503000, 504000 Diagnostic Procedure Prior to torque converter replacement, all diagnostic procedures must be followed. This is to prevent the unnecessary replacement of good torque converters. Only after a complete diagnostic evaluation can the decision be made to replace the torque converter. The normal diagnostic procedure is as follows: 1. Preliminary inspection. 2. Know and understand the customers concern. 3. Verify the concern: - Perform the Torque Converter Clutch Operation Test 4. Perform diagnostic procedures: a. Run On-Board Diagnostics - Repair all non-transmission-related Diagnostic Trouble Codes (DTCs) first. - Repair all transmission DTCs. - Rerun On-Board Diagnostic to verify repair. b. Perform Line Pressure Test c. Perform Stall Speed Test d. Diagnosis by Symptom Routines - Use the index to locate the appropriate routine that best describes the symptom(s). The routine will list all possible components that may cause or contribute to the symptom. Check each component listed, diagnose and service as required, before servicing the torque converter. Replacement The torque converter must be replaced if one or more of the following statements are true: ^ A torque converter malfunction has been determined based on completed diagnostic procedures ^ A converter stud(s), impeller hub or bushing is damaged ^ If there is discoloration of the torque converter (due to overheating) ^ The torque converter is found to be out of specification when performing the following checks (as applicable): 1. Torque Converter One-way Clutch Check 2. End Play Check 3. Stator-to-Turbine Interference Check 4. Converter Leakage Check 5. Stator-to-Impeller Interference Check ^ If there is evidence of transmission assembly or fluid contamination due to the following failure modes: Torque converter Replacement Policy Failure Modes Major metallic failure Multiple clutches or clutch plate failures Sufficient component wear which results in metallic contamination Torque Converter & Transmission Cooling System Cleaning Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T > Component Information > Technical Service Bulletins > Torque Converter - Cleaning and Replacement Guidelines > Page 4791 When the torque converter is replaced, the following actions must take place: 1. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 2. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All Cooler By-Pass Valves (CBV), it equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 4. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. If the torque converter is not being replaced, the following actions must take place: 1. The torque convener must be thoroughly cleaned: a. Torque converters with drain plugs can be cleaned using the Rotunda Torque Converter Cleaner Follow the instructions included with the equipment. b. Torque converters without drain plugs can be cleaned by hand. Partially fill the converter using clean transmission fluid (as recommended for the particular transmission). Hand agitate the converter and then thoroughly drain the fluid. Refill with new fluid, specified for the transmission, and reinstall. 2. All cooler lines must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 3. All coolers (in-tank and auxiliary) must be thoroughly cleaned by Back and Forward Flushing using Service Manual procedure. 4. All Cooler By-Pass Valves (CBV), if equipped, must be removed and thoroughly cleaned using Service Manual procedures. Replace rubber coated sealing washers prior to reinstalling CBV. Replace CBV if damaged or plugged. 5. Perform Transmission Cooler Flow Test - If the Transmission Cooling System fails the Flow Test, the coolers, CBVs or lines must be replaced. If the coolers are to be replaced, use only factory approved service parts. Required Tools Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times Valve Body: Customer Interest A/T - AOD Delayed Shift Times Article No. 91-16-12 08/07/91 TRANSMISSION - AUTOMATIC - AOD - DELAYED 3-4/4-3 SHIFTS OR OVERDRIVE BAND/FORWARD CLUTCH REPEAT REPAIRS FORD: 1989-90 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989-90 BRONCO, E-150, E-250, F-150 This TSB article is being republished in its entirety to include Bronco and E-250 in the Light Truck application line. ISSUE: Increased shift times may be experienced during certain continuous driving conditions. When frequent 3-4/4-3 shifts or high ambient temperatures are encountered, overdrive band engagement or release times may increase. This slip at the friction surface creates excessive heat and may eventually fail the band. Forward clutch failure may also occur as the forward clutch operation is synchronized with the overdrive band during 3-4/4-3 shifting. ACTION: Whenever servicing the overdrive band or forward clutch, also replace the main control assembly with a 1991 service main control. Refer to the following AOD Main Control Application Chart. This chart reflects shift calibration revisions to the 1991 main control level. AOD MAIN CONTROL COMPLEXITY CHART MAIN DELETE ADD SERVICE CONTROL SERVICE PART PART NO. I.D. NO. MAIN CONTROL I.D. F1TZ-7A100-C GNO F0TZ-7A100-G DOA, MPA E9TZ-7A100-J MRA F1TZ-7A100-B GNN F0TZ-7A100-F DOX, MPX E9TZ-7A100-H MRX F1AZ-7A100-D JNF E9AZ-7A100-B COH, VPH, VRH, RRH F1SZ-7A100-B BNJ E9SZ-7A100-B URL, URY, SRY F0SZ-7A100-B GPJ, UPJ F1AZ-7A100-E JFK F0AZ-7A100-D CJH E9AZ-7A100-G VGH, RGH, WFR E5AZ-7A100-D BER, OER, ODR F1LY-7A-A DNX F0LY-7A100-B BOC, BOX, PPC E9LY-7A100-A PRX E9LY-7A100-B PRC F1SZ-TA100-A ANV F0SZ-7A100-A TPM E9SZ-7A100-D TRM, TRF PART NUMBER PART NAME CLASS F1TZ-7A100-C Main Control B F1TZ-7A100-B Main Control B F1AZ-7A100-D Main Control B F1SZ-7A100-B Main Control C F1AZ-7A100-E Main Control C F1LY-7A100-A Main Control B F1SZ-7A100-A Main Control C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-5-6 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 911612A Replace Main Control Valve 0.6 Hr. Body To AOD - Cars 911612B Remove And Install AOD 3.1 Hr. Transmission Assembly - Crown Victoria, Grand Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times > Page 4800 Marquis And Town Car 911612C Remove And Install AOD 3.5 Hr. Transmission Assembly - Thunderbird, Cougar, Mustang And Mark VII 911612D Overhaul Time For AOD 4.9 Hr. Transmission 911612E Remove And Install 2.8 Hr. Transmission - F-150, 4X2 Models, E-150, E-250 911612F Remove And Install 4.4 Hr. Transmission - F-150 And Bronco, 4X4 Models 911612G Remove And Install 2.6 Hr. Transmission - Econoline 911612H Overhaul Of AOD - Trucks 5.2 Hr. 9116121 Replace Main Control Valve 1.3 Hr. Body - Trucks DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 911114 > May > 91 > A/T - AOD Harsh/Rough Shifts Valve Body: Customer Interest A/T - AOD Harsh/Rough Shifts Article No. 91-11-14 05/30/91 TRANSMISSION - AUTOMATIC - AOD - HARSH/ROUGH 3-4/4-3 SHIFTS FORD: 1989-90 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989-90 BRONCO, E-150, F-150 ISSUE: Harsh or rough transmission shifts in certain vehicles may be calibration characteristics of the AOD transmission split torque feature. However some customer transmission shifting concerns could be the result of improper (TV) pressure or sticking control valves. ACTION: Diagnose and repair the transmission. Using the following procedures which have proven to be an effective sequence of repair and significantly reduces the potential for unnecessary replacement of major components. Before performing any transmission repairs, test drive the vehicle to verify the 3-4 shift concern. Some of these concerns may be related to "tip-out" clunk due to an engine processor strategy and may be repaired as specified in TSB 90-17-4. If the referenced TSB does not eliminate the concern, refer to the following repair procedure. Diagnose and Adjust (TV) pressure. Refer to Section 17 of the appropriate Car or Truck Shop Manual for service details in performing the following adjustment. 1. Check throttle valve (TV) pressure and verify 33-34 PSI for passenger vehicles and 29-30 PSI for trucks. If TV pressure is not as specified, adjust TV pressure as outlined in the appropriate Car or Truck Shop Manual. 2. With TV pressure properly set, test drive the vehicle to verify if symptom still exists. If the vehicle has not been corrected, proceed as follows: Inspect and Clean Main Control Refer to Section 17 of the appropriate Car or Truck Shop Manual for service details in performing the following repair. 1. Throughly drain the transmission and converter. 2. Remove the oil pan and main control assembly. 3. Disassemble the main control and check for stuck valves. With the separating plate removed, check each valve for free movement, pay special attention to the 2-3 capacity modulator, 2-3 TV modulator, and the 3-4 TV modulator valve. Using crocus cloth, clean and polish lands as required and reassemble. 4. Install new upper and lower main control gaskets. 5. Torque main control attaching bolts to 85 in.lbs. +/- 5 in.lbs. NOTE: Target 85 in.lbs. 6. Install oil pan using a new pan gasket and fill with Mercon/R transmission fluid to the proper level. 7. Recheck TV pressure and re-adjust as required to establish 33-34 PSI for passenger cars and 29-30 PSI for trucks. 8. Test drive to verify repair. As indicated, the above repair procedure has proven to be effective with over 90% of the 3-4/4-3 shift concerns. However, in some circumstances, the above procedure may not completely satisfy the customer concerns. In those instances, the 1991 Main Control may provide the required shift improvements. Refer to the following AOD Main Control Complexity Chart for the 1989-1990 Main Controls and their equivalent 1991 replacements. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 911114 > May > 91 > A/T - AOD Harsh/Rough Shifts > Page 4805 AOD MAIN CONTROL COMPLEXITY CHART ADD SERVICE MAIN DELETE PART CONTROL SERVICE NUMBER I.D. PART NUMBER MAIN CONTROL I.D. F1TZ-7A100-C GNO F0TZ-7A100-G DOA, MPA E9TZ-7A100-J MRA F1TZ-7A100-B GNN F0TZ-7A100-F DOX, MPX E9TZ-7A100-H MRX F1AZ-7A100-D JNF E9AZ-7A100-B COH, VPH, VRH RRH F1SZ-7A100-B BNJ E9SZ-7A100-B URL, URY, SRY F0SZ-7A100-B GPJ, UPJ F1AZ-7A100-E JFK F0AZ-7A100-D CJH E9AZ-7A100-G VGH, RGH, WFR E5AZ-7A100-D BER, OER, ODR F1LY-7A100-A DNX F0LY-7A100-B BOC, BOX, PPC E9LY-7A100-A PRX E9LY-7A100-B PRC F1SZ-7A100-A ANV F0SZ-7A100-A TPM E9SZ-7A100-D TRM, TRF PART NUMBER PART NAME CLASS D9AZ-7D100-B Gasket Lower Control C E9SZ-7C155-A Gasket Upper Control B E0AZ-7A191-B Gasket Transmission Pan AM XT-2-QDX Mercon/R Fluid VG OTHER APPLICABLE ARTICLES: 91-5-5 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911114A Adjust TV Pressure 0.7 Hrs 911114B Inspect And Clean Control 2.6 Hrs Valves 911114C Replace Main Control Valve 1.3 Hrs DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 89236 > Nov > 89 > A/T - AOD Buzzing At Idle/Grunting During Tip-In Valve Body: Customer Interest A/T - AOD Buzzing At Idle/Grunting During Tip-In Article No. 89-23-6 ^ NOISE - "BUZZING" AT IDLE OR "GRUNTING" DURING THROTTLE TIP-IN - VEHICLES WITH AOD TRANSMISSION ^ TRANSMISSION - AOD - "BUZZING" SOUND AT IDLE AND/OR "GRUNTING" SOUND DURING THROTTLE TIP-IN FORD: 1989 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989 BRONCO, ECONOLINE, F-150, F-250 ISSUE: A "buzzing" noise at idle or a "grunting" noise during throttle tip-in may be caused by throttle valve fluid oscillation. The "grunting" noise may be accompanied by a slight vibration felt through the accelerator pedal. ACTION: Install a main control gasket kit (E9AZ-7D100-B). The kit contains the following items. ^ A revised separator plate lower gasket (7D100) ^ Three different throttle valve springs ^ Instructions for selecting the proper throttle valve spring. PART NUMBER PART NAME CLASS E9AZ-7D100-B Main Control Gasket Kit B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 892306A Install Main Control Gasket 1.9 Hrs. Kit DEALER CODING BASIC PART NO. CONDITION CODE 7A100 56 OASIS CODES: 5104, 5500, 7100, 7113, 7210 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times Valve Body: All Technical Service Bulletins A/T - AOD Delayed Shift Times Article No. 91-16-12 08/07/91 TRANSMISSION - AUTOMATIC - AOD - DELAYED 3-4/4-3 SHIFTS OR OVERDRIVE BAND/FORWARD CLUTCH REPEAT REPAIRS FORD: 1989-90 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989-90 BRONCO, E-150, E-250, F-150 This TSB article is being republished in its entirety to include Bronco and E-250 in the Light Truck application line. ISSUE: Increased shift times may be experienced during certain continuous driving conditions. When frequent 3-4/4-3 shifts or high ambient temperatures are encountered, overdrive band engagement or release times may increase. This slip at the friction surface creates excessive heat and may eventually fail the band. Forward clutch failure may also occur as the forward clutch operation is synchronized with the overdrive band during 3-4/4-3 shifting. ACTION: Whenever servicing the overdrive band or forward clutch, also replace the main control assembly with a 1991 service main control. Refer to the following AOD Main Control Application Chart. This chart reflects shift calibration revisions to the 1991 main control level. AOD MAIN CONTROL COMPLEXITY CHART MAIN DELETE ADD SERVICE CONTROL SERVICE PART PART NO. I.D. NO. MAIN CONTROL I.D. F1TZ-7A100-C GNO F0TZ-7A100-G DOA, MPA E9TZ-7A100-J MRA F1TZ-7A100-B GNN F0TZ-7A100-F DOX, MPX E9TZ-7A100-H MRX F1AZ-7A100-D JNF E9AZ-7A100-B COH, VPH, VRH, RRH F1SZ-7A100-B BNJ E9SZ-7A100-B URL, URY, SRY F0SZ-7A100-B GPJ, UPJ F1AZ-7A100-E JFK F0AZ-7A100-D CJH E9AZ-7A100-G VGH, RGH, WFR E5AZ-7A100-D BER, OER, ODR F1LY-7A-A DNX F0LY-7A100-B BOC, BOX, PPC E9LY-7A100-A PRX E9LY-7A100-B PRC F1SZ-TA100-A ANV F0SZ-7A100-A TPM E9SZ-7A100-D TRM, TRF PART NUMBER PART NAME CLASS F1TZ-7A100-C Main Control B F1TZ-7A100-B Main Control B F1AZ-7A100-D Main Control B F1SZ-7A100-B Main Control C F1AZ-7A100-E Main Control C F1LY-7A100-A Main Control B F1SZ-7A100-A Main Control C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-5-6 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 911612A Replace Main Control Valve 0.6 Hr. Body To AOD - Cars 911612B Remove And Install AOD 3.1 Hr. Transmission Assembly - Crown Victoria, Grand Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 911612 > Aug > 91 > A/T - AOD Delayed Shift Times > Page 4815 Marquis And Town Car 911612C Remove And Install AOD 3.5 Hr. Transmission Assembly - Thunderbird, Cougar, Mustang And Mark VII 911612D Overhaul Time For AOD 4.9 Hr. Transmission 911612E Remove And Install 2.8 Hr. Transmission - F-150, 4X2 Models, E-150, E-250 911612F Remove And Install 4.4 Hr. Transmission - F-150 And Bronco, 4X4 Models 911612G Remove And Install 2.6 Hr. Transmission - Econoline 911612H Overhaul Of AOD - Trucks 5.2 Hr. 9116121 Replace Main Control Valve 1.3 Hr. Body - Trucks DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 911114 > May > 91 > A/T - AOD Harsh/Rough Shifts Valve Body: All Technical Service Bulletins A/T - AOD Harsh/Rough Shifts Article No. 91-11-14 05/30/91 TRANSMISSION - AUTOMATIC - AOD - HARSH/ROUGH 3-4/4-3 SHIFTS FORD: 1989-90 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989-90 BRONCO, E-150, F-150 ISSUE: Harsh or rough transmission shifts in certain vehicles may be calibration characteristics of the AOD transmission split torque feature. However some customer transmission shifting concerns could be the result of improper (TV) pressure or sticking control valves. ACTION: Diagnose and repair the transmission. Using the following procedures which have proven to be an effective sequence of repair and significantly reduces the potential for unnecessary replacement of major components. Before performing any transmission repairs, test drive the vehicle to verify the 3-4 shift concern. Some of these concerns may be related to "tip-out" clunk due to an engine processor strategy and may be repaired as specified in TSB 90-17-4. If the referenced TSB does not eliminate the concern, refer to the following repair procedure. Diagnose and Adjust (TV) pressure. Refer to Section 17 of the appropriate Car or Truck Shop Manual for service details in performing the following adjustment. 1. Check throttle valve (TV) pressure and verify 33-34 PSI for passenger vehicles and 29-30 PSI for trucks. If TV pressure is not as specified, adjust TV pressure as outlined in the appropriate Car or Truck Shop Manual. 2. With TV pressure properly set, test drive the vehicle to verify if symptom still exists. If the vehicle has not been corrected, proceed as follows: Inspect and Clean Main Control Refer to Section 17 of the appropriate Car or Truck Shop Manual for service details in performing the following repair. 1. Throughly drain the transmission and converter. 2. Remove the oil pan and main control assembly. 3. Disassemble the main control and check for stuck valves. With the separating plate removed, check each valve for free movement, pay special attention to the 2-3 capacity modulator, 2-3 TV modulator, and the 3-4 TV modulator valve. Using crocus cloth, clean and polish lands as required and reassemble. 4. Install new upper and lower main control gaskets. 5. Torque main control attaching bolts to 85 in.lbs. +/- 5 in.lbs. NOTE: Target 85 in.lbs. 6. Install oil pan using a new pan gasket and fill with Mercon/R transmission fluid to the proper level. 7. Recheck TV pressure and re-adjust as required to establish 33-34 PSI for passenger cars and 29-30 PSI for trucks. 8. Test drive to verify repair. As indicated, the above repair procedure has proven to be effective with over 90% of the 3-4/4-3 shift concerns. However, in some circumstances, the above procedure may not completely satisfy the customer concerns. In those instances, the 1991 Main Control may provide the required shift improvements. Refer to the following AOD Main Control Complexity Chart for the 1989-1990 Main Controls and their equivalent 1991 replacements. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 911114 > May > 91 > A/T - AOD Harsh/Rough Shifts > Page 4820 AOD MAIN CONTROL COMPLEXITY CHART ADD SERVICE MAIN DELETE PART CONTROL SERVICE NUMBER I.D. PART NUMBER MAIN CONTROL I.D. F1TZ-7A100-C GNO F0TZ-7A100-G DOA, MPA E9TZ-7A100-J MRA F1TZ-7A100-B GNN F0TZ-7A100-F DOX, MPX E9TZ-7A100-H MRX F1AZ-7A100-D JNF E9AZ-7A100-B COH, VPH, VRH RRH F1SZ-7A100-B BNJ E9SZ-7A100-B URL, URY, SRY F0SZ-7A100-B GPJ, UPJ F1AZ-7A100-E JFK F0AZ-7A100-D CJH E9AZ-7A100-G VGH, RGH, WFR E5AZ-7A100-D BER, OER, ODR F1LY-7A100-A DNX F0LY-7A100-B BOC, BOX, PPC E9LY-7A100-A PRX E9LY-7A100-B PRC F1SZ-7A100-A ANV F0SZ-7A100-A TPM E9SZ-7A100-D TRM, TRF PART NUMBER PART NAME CLASS D9AZ-7D100-B Gasket Lower Control C E9SZ-7C155-A Gasket Upper Control B E0AZ-7A191-B Gasket Transmission Pan AM XT-2-QDX Mercon/R Fluid VG OTHER APPLICABLE ARTICLES: 91-5-5 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911114A Adjust TV Pressure 0.7 Hrs 911114B Inspect And Clean Control 2.6 Hrs Valves 911114C Replace Main Control Valve 1.3 Hrs DEALER CODING BASIC PART NO. CONDITION CODE 7A100 09 OASIS CODES: 501000, 502000, 504000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 89236 > Nov > 89 > A/T - AOD Buzzing At Idle/Grunting During Tip-In Valve Body: All Technical Service Bulletins A/T - AOD Buzzing At Idle/Grunting During Tip-In Article No. 89-23-6 ^ NOISE - "BUZZING" AT IDLE OR "GRUNTING" DURING THROTTLE TIP-IN - VEHICLES WITH AOD TRANSMISSION ^ TRANSMISSION - AOD - "BUZZING" SOUND AT IDLE AND/OR "GRUNTING" SOUND DURING THROTTLE TIP-IN FORD: 1989 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR, GRAND MARQUIS, MARK VII, TOWN CAR LIGHT TRUCK: 1989 BRONCO, ECONOLINE, F-150, F-250 ISSUE: A "buzzing" noise at idle or a "grunting" noise during throttle tip-in may be caused by throttle valve fluid oscillation. The "grunting" noise may be accompanied by a slight vibration felt through the accelerator pedal. ACTION: Install a main control gasket kit (E9AZ-7D100-B). The kit contains the following items. ^ A revised separator plate lower gasket (7D100) ^ Three different throttle valve springs ^ Instructions for selecting the proper throttle valve spring. PART NUMBER PART NAME CLASS E9AZ-7D100-B Main Control Gasket Kit B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage, Powertrain Warranty Coverage OPERATION DESCRIPTION TIME 892306A Install Main Control Gasket 1.9 Hrs. Kit DEALER CODING BASIC PART NO. CONDITION CODE 7A100 56 OASIS CODES: 5104, 5500, 7100, 7113, 7210 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 89237 > Nov > 89 > A/T - AOD Separator Plate Gasket Changes Valve Body: All Technical Service Bulletins A/T - AOD Separator Plate Gasket Changes TRANSMISSION - AOD - MAIN CONTROL GASKET CHANGES AFFECTING USAGE OF SERVICE KITS Article No. 89-23-7 FORD: 1980-90 CROWN VICTORIA 1980-86 LTD 1980-90 THUNDERBIRD 1985-90 MUSTANG LINCOLN-MERCURY: 1980-87 CONTINENTAL 1980-90 COUGAR, GRAND MARQUIS 1980-83 MARK VI 1980-90 TOWN CAR 1984-90 MARK VII 1985 CAPRI, MARQUIS LIGHT TRUCK: 1981-90 BRONCO, ECONOLINE, F-150, F-250 ISSUE: The separator plate lower gasket from the current gasket service kit (7153) and overhaul service kit (7C391) cannot be used on any 1990 model vehicles. ACTION: When servicing 1990 AOD transmissions the separator plate lower gasket found in the current kits must be thrown away and replaced with a new gasket (F0AZ-7D100-A). This new gasket can only be used on 1990 vehicles. CAUTION: USE OF THE SEPARATOR PLATE LOWER GASKET CONTAINED IN THE CURRENT KITS ON 1990 VEHICLES COULD CAUSE A REDUCTION IN THROTTLE VALVE PRESSURE. THIS CAN RESULT IN POSSIBLE TRANSMISSION FAILURES. In the near future, gasket and overhaul kits will no longer contain any main control gaskets. Two main control lower separator plate gasket items will be available. Refer to the following gasket application chart for correct service part usage. PART NUMBER PART NAME CLASS E9AZ-7D100-B Main Control Gasket Kit B FOAZ-7D100-A Separator Plate Lower Gasket B E9SZ-7C155-A Main Control Upper Separator B Plate Gasket OTHER APPLICABLE ARTICLES: none SUPERSEDES: 88-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5100, 5101, 5102, 5200, 5300, 5500, 5800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 89211 > Jan > 89 > A/T - New Main Control Separator Plate Gaskets Valve Body: All Technical Service Bulletins A/T - New Main Control Separator Plate Gaskets TRANSMISSION - AOD - MAIN CONTROL SERVICE GASKET APPLICATION - VEHICLES WITH 3.8L SUPERCHARGED ENGINE BUILT AFTER 9/15/88 Article No. 89-2-11 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: New upper and lower main control separator plate gaskets for 1989 Thunderbird/Cougar units with 3.8L Supercharged engines have been released. The new gaskets have a slot instead of a hole to match the slot in the new separator plate that is required for the new 3-4 shift calibration. The new gaskets can be used to service all prior model year AOD transmissions. ACTION: Use the new "lower" main control separator plate gasket, E9SZ-7D100-A and new "upper" main control separator main control gasket, E9SZ-7C155-A if service is required. The new gaskets can be identified by one (1) white stripe. PART NUMBER PART NAME CLASS E9SZ-7D100-A Upper Separator Gasket B E9SZ-7C155-A Lower Separator Gasket B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 5200, 5300, 5800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 89237 > Nov > 89 > A/T - AOD Separator Plate Gasket Changes Valve Body: All Technical Service Bulletins A/T - AOD Separator Plate Gasket Changes TRANSMISSION - AOD - MAIN CONTROL GASKET CHANGES AFFECTING USAGE OF SERVICE KITS Article No. 89-23-7 FORD: 1980-90 CROWN VICTORIA 1980-86 LTD 1980-90 THUNDERBIRD 1985-90 MUSTANG LINCOLN-MERCURY: 1980-87 CONTINENTAL 1980-90 COUGAR, GRAND MARQUIS 1980-83 MARK VI 1980-90 TOWN CAR 1984-90 MARK VII 1985 CAPRI, MARQUIS LIGHT TRUCK: 1981-90 BRONCO, ECONOLINE, F-150, F-250 ISSUE: The separator plate lower gasket from the current gasket service kit (7153) and overhaul service kit (7C391) cannot be used on any 1990 model vehicles. ACTION: When servicing 1990 AOD transmissions the separator plate lower gasket found in the current kits must be thrown away and replaced with a new gasket (F0AZ-7D100-A). This new gasket can only be used on 1990 vehicles. CAUTION: USE OF THE SEPARATOR PLATE LOWER GASKET CONTAINED IN THE CURRENT KITS ON 1990 VEHICLES COULD CAUSE A REDUCTION IN THROTTLE VALVE PRESSURE. THIS CAN RESULT IN POSSIBLE TRANSMISSION FAILURES. In the near future, gasket and overhaul kits will no longer contain any main control gaskets. Two main control lower separator plate gasket items will be available. Refer to the following gasket application chart for correct service part usage. PART NUMBER PART NAME CLASS E9AZ-7D100-B Main Control Gasket Kit B FOAZ-7D100-A Separator Plate Lower Gasket B E9SZ-7C155-A Main Control Upper Separator B Plate Gasket OTHER APPLICABLE ARTICLES: none SUPERSEDES: 88-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5100, 5101, 5102, 5200, 5300, 5500, 5800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Valve Body: > 89211 > Jan > 89 > A/T - New Main Control Separator Plate Gaskets Valve Body: All Technical Service Bulletins A/T - New Main Control Separator Plate Gaskets TRANSMISSION - AOD - MAIN CONTROL SERVICE GASKET APPLICATION - VEHICLES WITH 3.8L SUPERCHARGED ENGINE BUILT AFTER 9/15/88 Article No. 89-2-11 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: New upper and lower main control separator plate gaskets for 1989 Thunderbird/Cougar units with 3.8L Supercharged engines have been released. The new gaskets have a slot instead of a hole to match the slot in the new separator plate that is required for the new 3-4 shift calibration. The new gaskets can be used to service all prior model year AOD transmissions. ACTION: Use the new "lower" main control separator plate gasket, E9SZ-7D100-A and new "upper" main control separator main control gasket, E9SZ-7C155-A if service is required. The new gaskets can be identified by one (1) white stripe. PART NUMBER PART NAME CLASS E9SZ-7D100-A Upper Separator Gasket B E9SZ-7C155-A Lower Separator Gasket B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 5200, 5300, 5800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Technical Service Bulletins > Page 4842 Valve Body: Specifications Valve Body Tightening Valve Body Tightening Filter To Valve Body 80-120 in.lb Reinforcing Plate to Valve Body 80-120 in.lb Valve Body to Case 80-100 in.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Solenoid Body Valve Body: Locations Solenoid Body Engine Compartment Component Locations Part Of Brake Control Unit Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Locations > Solenoid Body > Page 4845 Location Of Relief Valves And Check Balls Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation Valve Body: Service and Repair Removal and Installation REMOVAL 1. Raise and support vehicle, drain transmission fluid, then remove transmission pan, gasket, and filter. 2. Remove detent spring attaching bolt, then the spring. 3. Remove valve body to case attaching bolts, then the valve body. INSTALLATION 1. Reverse procedure to install. 2. Use suitable guide pins to align valve body to case. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4848 Valve Body: Service and Repair Disassembly and Assembly DISASSEMBLE 1. Remove and discard valve body gasket, then loosen and remove 11 bolts from reinforcement plates. Detent Spring Guide Bolt Location 2. Remove detent 5 ring guide bolt from separator plate. Location Of Separator Plate, Reinforcement Plates, And Separator Plate Gasket 3. Remove separator plate, reinforcement plates, and separator plate gasket, discarding gasket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4849 Location Of Relief Valves And Check Balls 4. Remove two relief valves and seven check balls from valve body, noting location of orange ball, as it is not interchangeable with other balls. Removing Or Installing Manual Valve Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4850 Removing Or Installing Throttle System Valves Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4851 Removing Or Installing 2-3 Backout Valve Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4852 Removing Or Installing Orifice Control And 2-3 Capacity Modulator Valves Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4853 Removing Or Installing 3-4 Shift And 3-4 TV Modulator Valves Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4854 Removing Or Installing TV Limit Valve Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4855 Removing Or Installing 1-2 Shift Valve Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4856 Removing Or Installing Overdrive Servo Regulator Valve Removing Or Installing 3-4 Shuttle Valve Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4857 Removing Or Installing 1-2 Accumulator Valve Removing Or Installing 1-2 Capacity Modulator Valve Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4858 Removing Or Installing Main Regulator And Pressure Boost Valves Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4859 Removing Or Installing 2-1 Scheduling And Low Servo Modulator Valves Removing Or Installing 3-4 Backout Valve Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4860 Removing Or Installing 2-3 Shift, 3-2 Control, And 2-3 TV Modulator Valves 5. Complete disassembly of valve body as shown, in the Valve Body images, noting the following: a. Some bore plugs have threaded hole in center to facilitate removal by using M4 metric screw. These pugs must be installed with hole facing out. b. The 1-2 accumulator valve and valve body diameter are not the same for all models. c. Components may vary in size or shape for different applications. ASSEMBLE 1. Assemble valve body components as shown, in the Valve Body images. 2. Install seven check balls as shown in the Location Of Relief Valves And Check Balls image. Orange ball is larger than the others and must be positioned as shown. 3. Install pressure relief valves. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T > Component Information > Service and Repair > Removal and Installation > Page 4861 Installing Alignment Pins In Valve Body 4. Install alignment pins T80L-7710-A, or equivalents, as shown in the Installing Alignment Pins In Valve Body image. These two holes are smaller than other bolt holes to ensure proper alignment of gasket and separator plate with valve body. These two holes also align the valve body gasket and valve body assembly with the case. 5. Using new separator plate gasket, slide gasket and separator plate over the two alignment pins, then position three reinforcement plates and loosely install the 11 attaching bolts and the detent spring guide bolt. 6. Starting at center reinforcement plate and working outward, torque 11 attaching bolts, then the detent spring guide bolt, to 80-100 in lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Disc, M/T > Component Information > Service and Repair Clutch Disc: Service and Repair REMOVAL and INSTALLATION 1. Disconnect negative battery cable. 2. Disconnect clutch cylinder from clutch pedal and dash panel. 3. Raise and support vehicle, then remove starter. 4. Disconnect hydraulic coupling at transmission, using coupling disconnect tool No. T88T-70522-A or equivalent, by sliding white sleeve toward slave cylinder, and apply a slight tug on tube. 5. Remove transmission. 6. Mark assembled position of pressure plate and cover to flywheel for reference during assembly. 7. Loosen pressure plate cover attaching bolts evenly, until pressure plate springs are expanded, then remove the bolts. Cross Sectional View Of Clutch System 8. Remove pressure plate cover assembly, then the clutch disc from flywheel. Clutch Pressure Plate Tightening Sequence 9. Reverse procedure to install. Tighten pressure plate attaching bolts in sequence shown in image. Bleed clutch hydraulic system as necessary. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Hydraulic System > Clutch Slave Cylinder > Component Information > Service and Repair Clutch Slave Cylinder: Service and Repair 1. Raise and support vehicle, then disconnect master cylinder push rod from clutch pedal. 2. Disconnect clutch hydraulic line using clutch coupling tool No. T88T-70522-A or equivalent. 3. Remove transmission. 4. Loosen retaining bolts and remove clutch slave cylinder. 5. Reverse procedure to install, noting the following: a. Position slave cylinder over input shaft, aligning bleeder screw and line coupling with holes in transmission housing. b. Tighten to specifications and bleed system. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Clutch Switch Jumper Clutch Pedal Position Switch: Locations Clutch Switch Jumper On Clutch Pedal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Clutch Switch Jumper > Page 4874 Clutch Pedal Position Switch: Locations Clutch Pedal Switch I/P Components On Clutch Pedal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Page 4875 Clutch Pedal Position Switch: Adjustments Fig. 18 Clutch Interlock Three Function Switch. Cougar & Thunderbird 1. Disconnect switch electrical connector, Fig. 18. 2. Using a volt-ohmmeter, check for continuity at the following switch terminals. a. EFI switch terminals 5 and 6 should be open with clutch pedal released. Terminals 5 and 6 should show continuity, within two inches of clutch pedal travel. b. Speed control release switch terminals 3 and 4 should be show continuity with clutch pedal released. Terminals 3 and 4 should open within two inches of clutch pedal travel. c. Clutch interlock switch terminals 1 and 2 should be open with clutch pedal released. Terminals 1 and 2 should close within one inch from full clutch pedal travel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Page 4876 Clutch Pedal Position Switch: Service and Repair Fig. 18 Clutch Interlock Three Function Switch. Cougar & Thunderbird 1. Disconnect switch electrical connector, Fig. 18. 2. Separate switch tab from clip by pulling downward on the clip. 3. Expose switch plastic retainer by rotating switch 1/2 turn. 4. Separate switch from retainer by pressing tabs together and allowing retainer to move rearward. 5. Remove switch from push rod. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Clutch Release Bearing, M/T > Component Information > Service and Repair Clutch Release Bearing: Service and Repair 1. Disconnect negative battery cable. 2. Disconnect clutch cylinder from clutch pedal and dash panel. 3. Raise and support vehicle, then remove starter. 4. Disconnect hydraulic coupling at transmission, using coupling disconnect tool No. T88T-70522-A or equivalent, by sliding white sleeve toward slave cylinder, and apply a slight tug on tube. 5. Remove transmission. 6. Mark assembled position of pressure plate and cover to flywheel for reference during assembly. 7. Loosen pressure plate cover attaching bolts evenly, until pressure plate springs are expanded, then remove the bolts. Cross Sectional View Of Clutch System 8. Remove pressure plate cover assembly, then the clutch disc from flywheel. Clutch Pressure Plate Tightening Sequence 9. Reverse procedure to install. Tighten pressure plate attaching bolts in sequence shown in example. Bleed clutch hydraulic system as necessary. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Clutch, M/T > Pressure Plate > Component Information > Service and Repair Pressure Plate: Service and Repair 1. Disconnect negative battery cable. 2. Disconnect clutch cylinder from clutch pedal and dash panel. 3. Raise and support vehicle, then remove starter. 4. Disconnect hydraulic coupling at transmission, using coupling disconnect tool No. T88T-70522-A or equivalent, by sliding white sleeve toward slave cylinder, and apply a slight tug on tube. 5. Remove transmission. 6. Mark assembled position of pressure plate and cover to flywheel for reference during assembly. 7. Loosen pressure plate cover attaching bolts evenly, until pressure plate springs are expanded, then remove the bolts. Cross Sectional View Of Clutch System 8. Remove pressure plate cover assembly, then the clutch disc from flywheel. Clutch Pressure Plate Tightening Sequence 9. Reverse procedure to install. Tighten pressure plate attaching bolts in sequence shown in example. Bleed clutch hydraulic system as necessary. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage Differential Case: Customer Interest Axle - Rear Axle Cover Vent Hose Lubricant Leakage Article No. 94-11-12 AXLE - REAR - LUBRICANT LEAKAGE THROUGH COVER VENT/HOSE FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR ISSUE: Rear axle leakage may occur through the cover vent/hose because the rear axle vent tube is not positioned properly. ACTION: If rear axle lubricant is observed to be leaking from the vent/hose, check the position of the rear axle vent tube and, if necessary, clean and reposition it. Refer to the following procedure for service details. 1. Raise the vehicle on a hoist. Refer to the appropriate model year Thunderbird/Cougar Service Manual, Section 10-04 (1988-91) or Section 00-02 (1992-94). 2. Remove and inspect vent hose to assure it is free of dirt and/or debris. If the hose is plugged, clean or replace it. 3. Check the vent to make sure it is aligned correctly with the cover, Figure 1. NOTE: NOTCH IN VENT MUST ALIGN WITH NUB IN COVER. NOTE: USE THE FOLLOWING PROCEDURE FOR 8.80 RING GEAR ONLY. THE 7.5" RING GEAR IS NOT EQUIPPED WITH A DEFLECTOR. 4. Support the axle and remove the rear axle differential rear insulator-to-crossmember retaining bolts, Figure 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4892 5. Position the drain pan under the axle. Remove axle housing cover bolts, Figure 3. 6. Remove the rear axle cover, Figure 4. 7. Remove the lubricant deflector inside of cover using 1/8" Allen wrench, Figure 5. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4893 8. If the vent is found to be misaligned, pry it out with a screwdriver, Figure 6. 9. If the vent is damaged, replace it with a new axle vent assembly (E9SZ-4022-A). 10. Thoroughly clean all sealing surfaces and cover groove, Figure 7. Make sure there is no gasket material in or near the vent hole or lubricant deflector area. 11. Install the rear axle housing vent as shown in Figure 8. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4894 NOTE: THE NOTCH IN THE REAR AXLE HOUSING VENT MUST BE ALIGNED WITH THE NUB IN THE AXLE HOUSING COVER. CAUTION: IF THE VENT IS NOT INSTALLED AS SHOWN IN FIGURE 8, IT WILL LEAK, CAUSING OVERHEATING OF THE AXLE AND POSSIBLE COMPONENT FAILURE. 12. Seat the rear axle housing vent using a 9/32" (7.144 mm) deep well socket or similar tool to drive against the rear axle housing vent lip, Figure 9. CAUTION: DO NOT HAMMER ON END OF VENT TUBE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4895 13. Install the lubricant deflector using a 1/8" (3.175 mm) Allen wrench, Figure 10. A gap of .200" to .250" MUST exist between the end of the lubricant deflector and the back-face of the cover, Figure 11. CAUTION: IF SHIELD GAP IS NOT .200" to .250", IT WILL CAUSE A VENT LEAK AND AXLE OVERHEATING. 14. Apply a continuous bead of silicone rubber (D6AZ-19562-AA; ESE-M4G195-A and ESB-M4G92-A) or equivalent to groove in axle housing cover, Figure 12. NOTE: THE AXLE HOUSING COVER ASSEMBLY MUST BE INSTALLED WITHIN 15 MINUTES OF APPLICATION OF THE SILICONE RUBBER OR NEW SILICONE RUBBER MUST BE APPLIED. CAUTION: MAKE SURE MACHINED SURFACES ON BOTH AXLE HOUSING COVER AND REAR AXLE HOUSING CARRIER ARE CLEAN BEFORE INSTALLING THE NEW SILICONE RUBBER. THE INSIDE OF REAR AXLE HOUSING MUST BE COVERED WHEN CLEANING THE MACHINED SURFACE TO PREVENT REAR AXLE HOUSING CONTAMINATION. TIGHTEN THE COVER BOLTS IN A CROSSWISE PATTERN TO ENSURE UNIFORM DRAW ON AXLE HOUSING COVER. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4896 15. Install vent house, Figure 13. 16. Position new axle housing cover retaining bolts. a. Place the service identification tag in the 12 o'clock position. b. Tighten the bolts to 27-37 N-m (20-27 lb.ft.). 17. Install the rear axle differential rear insulator-to-crossmember bolts, Figure 15. a. Tighten bolts to 108-136 N-m. (80-100 lb.ft.). b. Fill the rear axle housing with specified rear axle lubricant to 1/4" (6.35 mm) below bottom of filler hole. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > Customer Interest for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4897 18. Install filler plug, Figure 16. Tighten to 28-40 N-m (21-30 lb.ft.). 19. Ensure that vent hose is routed correctly to vehicle subframe. LUBRICANT SPECIFICATIONS FOR CONVENTIONAL DIFFERENTIAL AXLES Fill the rear axle with 3.50 pints of XY-90-QL, Premium Rear Axle Lubricant, Ford Specification ESP-M2C154-A. LUBRICANT SPECIFICATIONS FOR TRACTION-LOK (LIMITED-SLIP) DIFFERENTIAL AXLES Fill the rear axle with 3.25 pints of XY-90-QL, Premium Rear Axle Lubricant, Ford Specification ESP-M2C154-A, PLUS 4 ounces of Friction Modifier Additive (C8AZ-19B546-A), Ford Specification EST-M2C118-C. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 941112A Remove And Install 1.1 Hrs. Differential Vent Assembly DEALER CODING BASIC PART NO. CONDITION CODE 4022 51 OASIS CODES: 509000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage Differential Case: All Technical Service Bulletins Axle - Rear Axle Cover Vent Hose Lubricant Leakage Article No. 94-11-12 AXLE - REAR - LUBRICANT LEAKAGE THROUGH COVER VENT/HOSE FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR ISSUE: Rear axle leakage may occur through the cover vent/hose because the rear axle vent tube is not positioned properly. ACTION: If rear axle lubricant is observed to be leaking from the vent/hose, check the position of the rear axle vent tube and, if necessary, clean and reposition it. Refer to the following procedure for service details. 1. Raise the vehicle on a hoist. Refer to the appropriate model year Thunderbird/Cougar Service Manual, Section 10-04 (1988-91) or Section 00-02 (1992-94). 2. Remove and inspect vent hose to assure it is free of dirt and/or debris. If the hose is plugged, clean or replace it. 3. Check the vent to make sure it is aligned correctly with the cover, Figure 1. NOTE: NOTCH IN VENT MUST ALIGN WITH NUB IN COVER. NOTE: USE THE FOLLOWING PROCEDURE FOR 8.80 RING GEAR ONLY. THE 7.5" RING GEAR IS NOT EQUIPPED WITH A DEFLECTOR. 4. Support the axle and remove the rear axle differential rear insulator-to-crossmember retaining bolts, Figure 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4903 5. Position the drain pan under the axle. Remove axle housing cover bolts, Figure 3. 6. Remove the rear axle cover, Figure 4. 7. Remove the lubricant deflector inside of cover using 1/8" Allen wrench, Figure 5. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4904 8. If the vent is found to be misaligned, pry it out with a screwdriver, Figure 6. 9. If the vent is damaged, replace it with a new axle vent assembly (E9SZ-4022-A). 10. Thoroughly clean all sealing surfaces and cover groove, Figure 7. Make sure there is no gasket material in or near the vent hole or lubricant deflector area. 11. Install the rear axle housing vent as shown in Figure 8. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4905 NOTE: THE NOTCH IN THE REAR AXLE HOUSING VENT MUST BE ALIGNED WITH THE NUB IN THE AXLE HOUSING COVER. CAUTION: IF THE VENT IS NOT INSTALLED AS SHOWN IN FIGURE 8, IT WILL LEAK, CAUSING OVERHEATING OF THE AXLE AND POSSIBLE COMPONENT FAILURE. 12. Seat the rear axle housing vent using a 9/32" (7.144 mm) deep well socket or similar tool to drive against the rear axle housing vent lip, Figure 9. CAUTION: DO NOT HAMMER ON END OF VENT TUBE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4906 13. Install the lubricant deflector using a 1/8" (3.175 mm) Allen wrench, Figure 10. A gap of .200" to .250" MUST exist between the end of the lubricant deflector and the back-face of the cover, Figure 11. CAUTION: IF SHIELD GAP IS NOT .200" to .250", IT WILL CAUSE A VENT LEAK AND AXLE OVERHEATING. 14. Apply a continuous bead of silicone rubber (D6AZ-19562-AA; ESE-M4G195-A and ESB-M4G92-A) or equivalent to groove in axle housing cover, Figure 12. NOTE: THE AXLE HOUSING COVER ASSEMBLY MUST BE INSTALLED WITHIN 15 MINUTES OF APPLICATION OF THE SILICONE RUBBER OR NEW SILICONE RUBBER MUST BE APPLIED. CAUTION: MAKE SURE MACHINED SURFACES ON BOTH AXLE HOUSING COVER AND REAR AXLE HOUSING CARRIER ARE CLEAN BEFORE INSTALLING THE NEW SILICONE RUBBER. THE INSIDE OF REAR AXLE HOUSING MUST BE COVERED WHEN CLEANING THE MACHINED SURFACE TO PREVENT REAR AXLE HOUSING CONTAMINATION. TIGHTEN THE COVER BOLTS IN A CROSSWISE PATTERN TO ENSURE UNIFORM DRAW ON AXLE HOUSING COVER. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4907 15. Install vent house, Figure 13. 16. Position new axle housing cover retaining bolts. a. Place the service identification tag in the 12 o'clock position. b. Tighten the bolts to 27-37 N-m (20-27 lb.ft.). 17. Install the rear axle differential rear insulator-to-crossmember bolts, Figure 15. a. Tighten bolts to 108-136 N-m. (80-100 lb.ft.). b. Fill the rear axle housing with specified rear axle lubricant to 1/4" (6.35 mm) below bottom of filler hole. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Case: > 941112 > Jun > 94 > Axle - Rear Axle Cover Vent Hose Lubricant Leakage > Page 4908 18. Install filler plug, Figure 16. Tighten to 28-40 N-m (21-30 lb.ft.). 19. Ensure that vent hose is routed correctly to vehicle subframe. LUBRICANT SPECIFICATIONS FOR CONVENTIONAL DIFFERENTIAL AXLES Fill the rear axle with 3.50 pints of XY-90-QL, Premium Rear Axle Lubricant, Ford Specification ESP-M2C154-A. LUBRICANT SPECIFICATIONS FOR TRACTION-LOK (LIMITED-SLIP) DIFFERENTIAL AXLES Fill the rear axle with 3.25 pints of XY-90-QL, Premium Rear Axle Lubricant, Ford Specification ESP-M2C154-A, PLUS 4 ounces of Friction Modifier Additive (C8AZ-19B546-A), Ford Specification EST-M2C118-C. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 941112A Remove And Install 1.1 Hrs. Differential Vent Assembly DEALER CODING BASIC PART NO. CONDITION CODE 4022 51 OASIS CODES: 509000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Except Traction-LOK Limited Slip Differential Differential Case: Testing and Inspection Except Traction-LOK Limited Slip Differential Clean all parts in suitable solvent. Dry all parts except bearings with compressed air or shop towels. Allow bearings to air dry or dry with shop towels. Do not use compressed air to dry bearings, as damage may result. Inspect differential bearings and cups for wear, pitting, galling, flat spots or cracks. Any bearing or cup showing any signs of wear or damage must be replaced. Bearings and respective cups must be replaced as an assembly only. Do not attempt to interchange bearings and cups as bearing life will be affected. Inspect non-machined differential case surfaces for nicks and burrs which can be removed with an oil stone or fine tooth file. Inspect pinion shaft bore to ensure it is not elongated or worn. If damage is evident, differential case must be replaced. Inspect machined differential surfaces and counterbores. They must be smooth and free of nicks, gouges, cracks and other visible damage. If damage is evident, differential case must be replaced. Inspect pinion shaft for excessive wear, scoring or galling. Ensure shaft is smooth and concentric. If any wear or damage is evident, replace shaft. Inspect pinion shaft lock pin for damage and to ensure it has a snug fit in differential case. Replace lock pin or case as necessary. Inspect pinion and ring gears for worn or chipped teeth, cracks, damaged bearing journals or attaching bolt threads. If any of the above are evident, replace ring gear and pinion as a matched set. Inspect pinion and side gears. Gears must exhibit a uniform contact pattern without any signs of cracks, wear, scoring or galling. If any of the above are evident, replace all the gears. Inspect thrust washers for wear and replace as necessary. Inspect pinion and ring gears for worn or chipped teeth, cracks, damaged bearing journals or attaching bolt threads. If any of the above are evident, replace ring gear and pinion as a matched set. Inspect axle shaft C-locks (if equipped) for signs of cracks or wear and replace as necessary. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Except Traction-LOK Limited Slip Differential > Page 4911 Differential Case: Testing and Inspection Traction-LOC Limited Slip Differential Fig. 7 Measuring Shim Thickness. Ford Traction-Lok Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Testing and Inspection > Except Traction-LOK Limited Slip Differential > Page 4912 Fig. 8 Installing Tool T80P-4946-A Or Equivalent To Measure Shim Thickness. Ford Traction-Lok The cleaning and inspection of these units is the same as for conventional differentials except that cleaning solvent should not be allowed to contact the clutch plates. The clutch plates should be wiped clean only. In addition, the following steps should be performed which apply to the Traction-Loc differential only. Visually inspect clutch packs, side gears, pinion gears and pinion shaft for damage or wear and replace as necessary. Place each clutch pack without shims into tool T80P-4946-A or equivalent, Fig. 7. Torque nut to 60 inch lbs. Using feeler gauge, determine thickness of new shims by inserting thickest blade possible between clutch pack and tool, Fig. 8, and note size for use during reassembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal Differential Case: Service and Repair Removal DIFFERENTIAL CASE ASSEMBLY Fig. 4 Exploded View Of 7-1/2 & 8.8 Inch Ring Gear Rear Axle 1. Raise and support rear of vehicle, then loosen axle housing cover bolts and allow lubricant to drain into suitable container, Fig. 4. 2. Remove axle housing cover, then proceed as follows: a. Wipe excess lubricant from inside axle housing, then visually inspect parts for wear and/or damage. b. Rotate gears and check for roughness, indicating damaged bearings or gears. c. Install suitable dial indicator on axle housing cover flange, then check and record ring gear back face run-out. Maximum back face run-out is .004 inch. 3. Remove rear axles and propeller shaft. 4. Scribe reference marks on differential bearing caps for assembly reference, then loosen bearing cap bolts. Observe and record direction the arrows are facing on the bearing caps. During installation, the arrows must face in the same direction. 5. Using suitable tool, pry differential case, bearing cups and shims out of housing until loose in the bearing caps. Remove bearing caps, then the differential assembly. Mark which side cups and shims came from for reference during reassembly. DRIVE PINION 1. Scribe reference mark between drive pinion and companion flange, then hold flange with suitable tool and remove pinion nut and pinion flange. 2. Using suitable soft faced hammer, drive pinion out of front bearing cone and remove from rear of axle housing. 3. Remove oil seal and front bearing cone and roller from pinion housing. 4. Using suitable arbor press and adapters, remove rear pinion bearing. 5. Using suitable micrometer, measure and record thickness of shim which is found under rear bearing cone. 6. Remove pinion bearing cups from pinion housing with suitable brass drift. Install cups using suitable bearing cup installer. Cups are not properly installed if a .015 feeler gauge can be installed between cup and bottom of bore at any point around the cup. If any bearing cups are replaced, the respective bearing cone and roller must be replaced. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Case > Component Information > Service and Repair > Removal > Page 4915 Differential Case: Service and Repair Differential Case Except Traction-Lok Limited Slip Differential 1. Install replacement ring gear (if removed). Apply suitable locking compound to new bolts and torque to 70-85 ft. lbs. Traction-Lok Limited Slip Differential Fig. 9 Pinion Gear Removal & Installation. Ford Traction-Lok 1. Apply suitable lubricant to clutch plates, then install left side gear, clutch pack and new shim into differential case. Repeat procedure for right hand side. 2. Install pinion gears and thrust washers 180° apart and in contact with side gears. 3. Align gears with pinion shaft bore, Fig. 9, using 12 inch socket extension inserted in pinion shaft rotator. 4. Install ``S'' shaped preload spring into differential using soft faced hammer. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 96129 > Jun > 96 > Differential Chatter On Turns Differential Clutch: Customer Interest Differential - Chatter On Turns Article No. 96-12-9 06/03/96 ^ NOISE - "CHATTER" DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING - TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR REAR AXLES ^ AXLE - NEW SERVICE KIT AVAILABLE FOR TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR ^ AXLE - TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR - "CHATTER" NOISE DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING FORD: 1989-96 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-96 COUGAR, GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1989-96 AEROSTAR, BRONCO, E-150, RANGER 1989-97 F-150 1991-96 EXPLORER ISSUE: A "chatter" noise can be felt and/or heard during tight turns or turns after an extended period of highway driving. This is due to insufficient specified friction modifier, or over-shimming of the clutch packs within Traction-Lok differentials. ACTION: Install revised Clutch Pack Replacement Kit (F5ZZ-4947-BA for 7.5" ring gear and F5AZ-4947-BA for 8.8" ring gear), with improved friction material, in the differential after confirming the "chatter" concern with a road test of the vehicle. Refer to the Instruction Sheet within the kit for details. NOTE: THE CLUTCH PACK REPLACEMENT KIT INCLUDES SELECTED SHIMS. IT WILL NOT REQUIRE THE ORDERING OF INDIVIDUAL SHIMS BASED UPON TEARDOWN MEASUREMENTS. REAR AXLE ASSEMBLY IDENTIFICATION See metal Service Identification tag for rear axle ring gear size and differential type. The identification tag is attached to the rear axle cover by means of a cover bolt. The Clutch Pack Replacement kit (F5ZZ-4947-BA) for the 7.5" ring gear traction-lok rear axle contains the following: ^ Two (2) Clutch Packs ^ One (1) Pinion Shaft Lockbolt ^ One (1) 4 oz. bottle of Friction Modifier ^ Two (2) Shims - 0.025" thick ^ Two (2) Shims - 0.030" thick ^ Two (2) Shims - 0.035" thick ^ Two (2) Shims - 0.040" thick ^ Two (2) Shims - 0.045" thick ^ One (1) Instruction Sheet (I.S. # 7145) The Clutch Pack Replacement Kit (F5AZ-4947-BA) for the 8.8" ring gear traction-lok rear axle contains the following: ^ Two (2) Clutch Packs Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > Customer Interest for Differential Clutch: > 96129 > Jun > 96 > Differential Chatter On Turns > Page 4924 ^ One (1) Pinion Shaft Lockbolt ^ One (1) 4 oz. bottle of Friction Modifier ^ Two (2) Shims - 0.025" thick ^ Two (2) Shims - 0.030" thick ^ Two (2) Shims - 0.035" thick ^ Two (2) Shims - 0.040" thick ^ Two (2) Shims - 0.045" thick ^ One (1) Instruction Sheet (I.S. # 7146) Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Vehicles And Basic Warranty Coverage For All Other Vehicles OPERATION DESCRIPTION TIME 961209A Replace Traction-Lok 1.4 Hrs. Differential Clutch Packs - Crown Victoria/Grand Marquis, Mustang, Town Car, E/F-150, Bronco, Aerostar, Explorer, Ranger 961209B Replace Traction-Lok 2.9 Hrs. Differential Clutch Packs - Thunderbird/Cougar DEALER CODING CONDITION BASIC PART NO. CODE 4001 56 OASIS CODES: 509000, 597997, 702200, 702300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 96129 > Jun > 96 > Differential - Chatter On Turns Differential Clutch: All Technical Service Bulletins Differential - Chatter On Turns Article No. 96-12-9 06/03/96 ^ NOISE - "CHATTER" DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING - TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR REAR AXLES ^ AXLE - NEW SERVICE KIT AVAILABLE FOR TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR ^ AXLE - TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR - "CHATTER" NOISE DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING FORD: 1989-96 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-96 COUGAR, GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1989-96 AEROSTAR, BRONCO, E-150, RANGER 1989-97 F-150 1991-96 EXPLORER ISSUE: A "chatter" noise can be felt and/or heard during tight turns or turns after an extended period of highway driving. This is due to insufficient specified friction modifier, or over-shimming of the clutch packs within Traction-Lok differentials. ACTION: Install revised Clutch Pack Replacement Kit (F5ZZ-4947-BA for 7.5" ring gear and F5AZ-4947-BA for 8.8" ring gear), with improved friction material, in the differential after confirming the "chatter" concern with a road test of the vehicle. Refer to the Instruction Sheet within the kit for details. NOTE: THE CLUTCH PACK REPLACEMENT KIT INCLUDES SELECTED SHIMS. IT WILL NOT REQUIRE THE ORDERING OF INDIVIDUAL SHIMS BASED UPON TEARDOWN MEASUREMENTS. REAR AXLE ASSEMBLY IDENTIFICATION See metal Service Identification tag for rear axle ring gear size and differential type. The identification tag is attached to the rear axle cover by means of a cover bolt. The Clutch Pack Replacement kit (F5ZZ-4947-BA) for the 7.5" ring gear traction-lok rear axle contains the following: ^ Two (2) Clutch Packs ^ One (1) Pinion Shaft Lockbolt ^ One (1) 4 oz. bottle of Friction Modifier ^ Two (2) Shims - 0.025" thick ^ Two (2) Shims - 0.030" thick ^ Two (2) Shims - 0.035" thick ^ Two (2) Shims - 0.040" thick ^ Two (2) Shims - 0.045" thick ^ One (1) Instruction Sheet (I.S. # 7145) The Clutch Pack Replacement Kit (F5AZ-4947-BA) for the 8.8" ring gear traction-lok rear axle contains the following: ^ Two (2) Clutch Packs Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Differential Clutch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Differential Clutch: > 96129 > Jun > 96 > Differential - Chatter On Turns > Page 4930 ^ One (1) Pinion Shaft Lockbolt ^ One (1) 4 oz. bottle of Friction Modifier ^ Two (2) Shims - 0.025" thick ^ Two (2) Shims - 0.030" thick ^ Two (2) Shims - 0.035" thick ^ Two (2) Shims - 0.040" thick ^ Two (2) Shims - 0.045" thick ^ One (1) Instruction Sheet (I.S. # 7146) Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Vehicles And Basic Warranty Coverage For All Other Vehicles OPERATION DESCRIPTION TIME 961209A Replace Traction-Lok 1.4 Hrs. Differential Clutch Packs - Crown Victoria/Grand Marquis, Mustang, Town Car, E/F-150, Bronco, Aerostar, Explorer, Ranger 961209B Replace Traction-Lok 2.9 Hrs. Differential Clutch Packs - Thunderbird/Cougar DEALER CODING CONDITION BASIC PART NO. CODE 4001 56 OASIS CODES: 509000, 597997, 702200, 702300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Technical Service Bulletins > Customer Interest for Fill Plug: > 8979 > Apr > 89 > Rear Axle - Fill Plug Hard to Remove Fill Plug: Customer Interest Rear Axle - Fill Plug Hard to Remove Article No. 89-7-9 AXLE - REAR - 7.5 AND 8.8 INCH - FILL PLUG HARD TO REMOVE FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A rear axle fill plug that is hard to remove may be caused by the type of plating used on the steel fill plug. The steel fill plug has a negative reaction to the aluminum rear axle cover. ACTION: Use the following procedure if the rear axle fill plug is difficult to remove. 1. Using a heat gun, apply heat for about 60 seconds to the aluminum that surrounds the fill plug. The heat range should be 500~ to 750~ F. CAUTION: DO NOT USE AN OPEN FLAME TO HEAT THE REAR AXLE FILL PLUG. 2. Immediately remove the fill plug by using a 3/8" flex handle. 3. When the fill plug is reinstalled, tighten it to a torque of 23-25 ft.lbs. (34-47 N-m). NOTE: LUBRICANT LEVELS IN FORD DESIGN REAR AXLES ARE NOT TO BE CHECKED AT PRE-DELIVERY OR ANY OTHER TIME DURING THE LIFE OF THE AXLE UNLESS A LEAK IS SUSPECTED OR REPAIR IS REQUIRED. ALL FORD DESIGN REAR AXLES ARE LUBRICATED FOR LIFE AT THE FACTORY. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5960, 5970 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fill Plug, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fill Plug: > 8979 > Apr > 89 > Rear Axle - Fill Plug Hard to Remove Fill Plug: All Technical Service Bulletins Rear Axle - Fill Plug Hard to Remove Article No. 89-7-9 AXLE - REAR - 7.5 AND 8.8 INCH - FILL PLUG HARD TO REMOVE FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A rear axle fill plug that is hard to remove may be caused by the type of plating used on the steel fill plug. The steel fill plug has a negative reaction to the aluminum rear axle cover. ACTION: Use the following procedure if the rear axle fill plug is difficult to remove. 1. Using a heat gun, apply heat for about 60 seconds to the aluminum that surrounds the fill plug. The heat range should be 500~ to 750~ F. CAUTION: DO NOT USE AN OPEN FLAME TO HEAT THE REAR AXLE FILL PLUG. 2. Immediately remove the fill plug by using a 3/8" flex handle. 3. When the fill plug is reinstalled, tighten it to a torque of 23-25 ft.lbs. (34-47 N-m). NOTE: LUBRICANT LEVELS IN FORD DESIGN REAR AXLES ARE NOT TO BE CHECKED AT PRE-DELIVERY OR ANY OTHER TIME DURING THE LIFE OF THE AXLE UNLESS A LEAK IS SUSPECTED OR REPAIR IS REQUIRED. ALL FORD DESIGN REAR AXLES ARE LUBRICATED FOR LIFE AT THE FACTORY. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 5960, 5970 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component Information > Specifications Fluid - Differential: Specifications VIN C,R, Fluid Capacity VIN C,R, Fluid Capacity Rear Axle Oil Models W/7.5 inch ring gear, Conventional axle 3 pt (US) Note: Plus 4 oz. of friction modifier meeting Ford Motor Co. specification Traction-Lok axle 2.75 pt (US) Note: Plus 4 oz. of friction modifier meeting Ford Motor Co. specification Friction Modifier C8AZ-19B956-A 4 oz (US) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Customer Interest for Pinion Gear: > 97811 > Apr > 97 > Rear Axle Whining/Howling Noise Pinion Gear: Customer Interest Rear Axle - Whining/Howling Noise Article No. 97-8-11 04/14/97 ^ NOISE - "WHINING/HOWLING" FROM REAR AXLE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION ^ REAR AXLE - "WHINING/HOWLING" NOISE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION FORD: 1989-96 THUNDERBIRD LINCOLN-MERCURY: 1989-96 COUGAR ISSUE: Some vehicles may exhibit a rear axle "whining" or "howling" noise. This noise may be audible during light throttle at speeds between 56-72 km/h (35-45 mph) or at highway speeds during acceleration or deceleration. This may be due to the ring and pinion gear set. ACTION: Select the appropriate ring and pinion set from the Parts Block listed below and replace the ring and pinion set. The revised ring and pinion should reduce the possibility of noise. Refer to the appropriate year Thunderbird/cougar Service Manual and the following text for removal and installation procedures. REAR AXLE ASSEMBLY IDENTIFICATION Refer to the metal service identification tag for the rear axle ring gear size, ratio and differential type (Traction-Lok or conventional). The identification tag is attached to the rear axle cover by a cover bolt. CAUTION: SHEET MOLDING COMPOSITE (SMC) PLASTIC REAR AXLE COVERS CANNOT BE REUSED AFTER REMOVAL. A NEW COVER SHOULD BE ORDERED AS SOON AS POSSIBLE TO COMPLETE THE REPAIR ON A TIMELY BASIS. CAUTION: BE SURE TO MARK THE DRIVESHAFT IN RELATION TO THE COMPANION FLANGE SO IT MAY BE REINSTALLED IN ITS ORIGINAL POSITION. CAUTION: DIFFERENTIAL BEARING CAPS MUST BE INSTALLED IN THEIR ORIGINAL POSITIONS AND LOCATIONS AT ASSEMBLY TIME. CAUTION: IF LOOSENED, REMOVED OR DAMAGED, THE SPEED SENSOR RING CANNOT BE REUSED AND MUST BE REPLACED. NOTE: BE SURE TO FILL THE AXLE WITH MOTORCRAFT SAE 80W90 PREMIUM REAR AXLE LUBRICANT (XY-80W90-QL) TO THE LEVEL SPECIFIED IN THE SERVICE MANUAL. FOR TRACTION-LOK DIFFERENTIALS, ADD 118 mL (4 OZ) OF ADDITIVE FRICTION MODIFIER (C8AZ-19B546-A). ROAD TEST THE VEHICLE. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > Customer Interest for Pinion Gear: > 97811 > Apr > 97 > Rear Axle Whining/Howling Noise > Page 4955 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Powertrain Warranty Coverage For 1989-91 Vehicles OPERATION DESCRIPTION TIME 970811A Install New Gear Set 2.5 Hrs. (Includes Drain And Refill DEALER CODING CONDITION BASIC PART NO. CODE 4209 56 OASIS CODES: 509000, 597997, 702200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pinion Gear: > 97811 > Apr > 97 > Rear Axle Whining/Howling Noise Pinion Gear: All Technical Service Bulletins Rear Axle - Whining/Howling Noise Article No. 97-8-11 04/14/97 ^ NOISE - "WHINING/HOWLING" FROM REAR AXLE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION ^ REAR AXLE - "WHINING/HOWLING" NOISE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION FORD: 1989-96 THUNDERBIRD LINCOLN-MERCURY: 1989-96 COUGAR ISSUE: Some vehicles may exhibit a rear axle "whining" or "howling" noise. This noise may be audible during light throttle at speeds between 56-72 km/h (35-45 mph) or at highway speeds during acceleration or deceleration. This may be due to the ring and pinion gear set. ACTION: Select the appropriate ring and pinion set from the Parts Block listed below and replace the ring and pinion set. The revised ring and pinion should reduce the possibility of noise. Refer to the appropriate year Thunderbird/cougar Service Manual and the following text for removal and installation procedures. REAR AXLE ASSEMBLY IDENTIFICATION Refer to the metal service identification tag for the rear axle ring gear size, ratio and differential type (Traction-Lok or conventional). The identification tag is attached to the rear axle cover by a cover bolt. CAUTION: SHEET MOLDING COMPOSITE (SMC) PLASTIC REAR AXLE COVERS CANNOT BE REUSED AFTER REMOVAL. A NEW COVER SHOULD BE ORDERED AS SOON AS POSSIBLE TO COMPLETE THE REPAIR ON A TIMELY BASIS. CAUTION: BE SURE TO MARK THE DRIVESHAFT IN RELATION TO THE COMPANION FLANGE SO IT MAY BE REINSTALLED IN ITS ORIGINAL POSITION. CAUTION: DIFFERENTIAL BEARING CAPS MUST BE INSTALLED IN THEIR ORIGINAL POSITIONS AND LOCATIONS AT ASSEMBLY TIME. CAUTION: IF LOOSENED, REMOVED OR DAMAGED, THE SPEED SENSOR RING CANNOT BE REUSED AND MUST BE REPLACED. NOTE: BE SURE TO FILL THE AXLE WITH MOTORCRAFT SAE 80W90 PREMIUM REAR AXLE LUBRICANT (XY-80W90-QL) TO THE LEVEL SPECIFIED IN THE SERVICE MANUAL. FOR TRACTION-LOK DIFFERENTIALS, ADD 118 mL (4 OZ) OF ADDITIVE FRICTION MODIFIER (C8AZ-19B546-A). ROAD TEST THE VEHICLE. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Pinion Gear: > 97811 > Apr > 97 > Rear Axle Whining/Howling Noise > Page 4961 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Powertrain Warranty Coverage For 1989-91 Vehicles OPERATION DESCRIPTION TIME 970811A Install New Gear Set 2.5 Hrs. (Includes Drain And Refill DEALER CODING CONDITION BASIC PART NO. CODE 4209 56 OASIS CODES: 509000, 597997, 702200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Removal Pinion Gear: Service and Repair Removal DIFFERENTIAL CASE ASSEMBLY Fig. 4 Exploded View Of 7-1/2 & 8.8 Inch Ring Gear Rear Axle 1. Raise and support rear of vehicle, then loosen axle housing cover bolts and allow lubricant to drain into suitable container, Fig. 4. 2. Remove axle housing cover, then proceed as follows: a. Wipe excess lubricant from inside axle housing, then visually inspect parts for wear and/or damage. b. Rotate gears and check for roughness, indicating damaged bearings or gears. c. Install suitable dial indicator on axle housing cover flange, then check and record ring gear back face run-out. Maximum back face run-out is .004 inch. 3. Remove rear axles and propeller shaft. 4. Scribe reference marks on differential bearing caps for assembly reference, then loosen bearing cap bolts. Observe and record direction the arrows are facing on the bearing caps. During installation, the arrows must face in the same direction. 5. Using suitable tool, pry differential case, bearing cups and shims out of housing until loose in the bearing caps. Remove bearing caps, then the differential assembly. Mark which side cups and shims came from for reference during reassembly. DRIVE PINION 1. Scribe reference mark between drive pinion and companion flange, then hold flange with suitable tool and remove pinion nut and pinion flange. 2. Using suitable soft faced hammer, drive pinion out of front bearing cone and remove from rear of axle housing. 3. Remove oil seal and front bearing cone and roller from pinion housing. 4. Using suitable arbor press and adapters, remove rear pinion bearing. 5. Using suitable micrometer, measure and record thickness of shim which is found under rear bearing cone. 6. Remove pinion bearing cups from pinion housing with suitable brass drift. Install cups using suitable bearing cup installer. Cups are not properly installed if a .015 feeler gauge can be installed between cup and bottom of bore at any point around the cup. If any bearing cups are replaced, the respective bearing cone and roller must be replaced. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Removal > Page 4964 Pinion Gear: Service and Repair Installation 1. Lubricate pinion bearings with suitable axle lubricant, then install pinion shaft and rear bearing, collapsible spacer and front bearing. 2. Install slinger (if equipped) and pinion oil seal, then insert pinion flange in seal and hold firmly in place against front bearing. From rear of housing, insert pinion shaft into flange. 3. Install pinion nut. While holding pinion flange, tighten nut only enough to remove bearing endplay. When an increase in pinion nut turning effort is noted, stop tightening pinion nut. Rotate pinion several times in both directions to seat bearings. 4. Continue to tighten pinion nut in very small increments, then, every so often, using suitable inch lbs. torque wrench, measure pinion rotational torque. The rotating torque must not exceed specifications. Do not exceed specified preload torque. Do not loosen pinion nut if preload torque is exceeded. If preload torque is exceeded, remove pinion nut, yoke, oil seal, slinger (if equipped) and collapsible spacer. Replace collapsible spacer and oil seal with new ones and repeat procedure. ^ Minimum torque required to tighten pinion flange nut to obtain correct pinion bearing preload ........................................... 190 N.m (140 lb-ft) ^ Pinion bearing preload Original bearing ........................................................................................... ...................................................................... 11-19 N.m (8-14 lb-in) New bearing ............................. ....................................................................................................................................... 23-37 N.m (16-29 lb-in) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Pinion Gear, Differential > Component Information > Service and Repair > Removal > Page 4965 Pinion Gear: Service and Repair Determining Drive Pinion Depth Fig. 10 Rear Axle Pinion Depth Gauge Fig. 11 Pinion Depth Gauge Block Installation Prior to determining drive pinion depth, clean pinion bearing cups and differential bearing pedestals thoroughly to ensure an accurate reading. Apply only a light oil film to bearing assemblies to avoid false readings. 1. Assemble aligning adapter, gauge disc and gauge block to tool T79P-4020-A, Fig. 10. 2. Place rear pinion bearing over aligning adapter, then insert tool and bearing in rear pinion bearing cup in pinion housing bore. Place front pinion bearing over screw in front pinion bearing cup and assemble tool handle onto screw. Torque handle to 20 ft. lbs. Ensure tool is mounted securely between front and rear bearings. 3. Rotate gauge block several half turns to ensure bearings are seated properly. Rotational torque should be 20 ft. lbs. with new bearings. Set gauge block at an angle approximately 45° from horizontal, Fig. 11. 4. Install gauge tube in differential bearing mounts, then install bearing caps and bearing cap bolts. 5. Use pinion shims to determine pinion depth by inserting shims between gauge block and gauge tube. The correct shim will fit with a slight drag. Do not attempt to force a shim between block and tube. Do not use shims that are bent, dirty, nicked or mutilated as a gauge. 6. Make note of proper shim size and remove tool from axle housing. 7. Using suitable arbor press and adapters, remove rear pinion bearing. 8. Install shim determined in step 5 above on pinion shaft, then reinstall bearing using arbor press. The rear pinion bearing used to determine drive pinion depth must be used in the final assembly of the axle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Technical Service Bulletins > Customer Interest for Ring Gear: > 97811 > Apr > 97 > Rear Axle Whining/Howling Noise Ring Gear: Customer Interest Rear Axle - Whining/Howling Noise Article No. 97-8-11 04/14/97 ^ NOISE - "WHINING/HOWLING" FROM REAR AXLE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION ^ REAR AXLE - "WHINING/HOWLING" NOISE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION FORD: 1989-96 THUNDERBIRD LINCOLN-MERCURY: 1989-96 COUGAR ISSUE: Some vehicles may exhibit a rear axle "whining" or "howling" noise. This noise may be audible during light throttle at speeds between 56-72 km/h (35-45 mph) or at highway speeds during acceleration or deceleration. This may be due to the ring and pinion gear set. ACTION: Select the appropriate ring and pinion set from the Parts Block listed below and replace the ring and pinion set. The revised ring and pinion should reduce the possibility of noise. Refer to the appropriate year Thunderbird/cougar Service Manual and the following text for removal and installation procedures. REAR AXLE ASSEMBLY IDENTIFICATION Refer to the metal service identification tag for the rear axle ring gear size, ratio and differential type (Traction-Lok or conventional). The identification tag is attached to the rear axle cover by a cover bolt. CAUTION: SHEET MOLDING COMPOSITE (SMC) PLASTIC REAR AXLE COVERS CANNOT BE REUSED AFTER REMOVAL. A NEW COVER SHOULD BE ORDERED AS SOON AS POSSIBLE TO COMPLETE THE REPAIR ON A TIMELY BASIS. CAUTION: BE SURE TO MARK THE DRIVESHAFT IN RELATION TO THE COMPANION FLANGE SO IT MAY BE REINSTALLED IN ITS ORIGINAL POSITION. CAUTION: DIFFERENTIAL BEARING CAPS MUST BE INSTALLED IN THEIR ORIGINAL POSITIONS AND LOCATIONS AT ASSEMBLY TIME. CAUTION: IF LOOSENED, REMOVED OR DAMAGED, THE SPEED SENSOR RING CANNOT BE REUSED AND MUST BE REPLACED. NOTE: BE SURE TO FILL THE AXLE WITH MOTORCRAFT SAE 80W90 PREMIUM REAR AXLE LUBRICANT (XY-80W90-QL) TO THE LEVEL SPECIFIED IN THE SERVICE MANUAL. FOR TRACTION-LOK DIFFERENTIALS, ADD 118 mL (4 OZ) OF ADDITIVE FRICTION MODIFIER (C8AZ-19B546-A). ROAD TEST THE VEHICLE. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Technical Service Bulletins > Customer Interest for Ring Gear: > 97811 > Apr > 97 > Rear Axle Whining/Howling Noise > Page 4974 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Powertrain Warranty Coverage For 1989-91 Vehicles OPERATION DESCRIPTION TIME 970811A Install New Gear Set 2.5 Hrs. (Includes Drain And Refill DEALER CODING CONDITION BASIC PART NO. CODE 4209 56 OASIS CODES: 509000, 597997, 702200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ring Gear: > 97811 > Apr > 97 > Rear Axle Whining/Howling Noise Ring Gear: All Technical Service Bulletins Rear Axle - Whining/Howling Noise Article No. 97-8-11 04/14/97 ^ NOISE - "WHINING/HOWLING" FROM REAR AXLE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION ^ REAR AXLE - "WHINING/HOWLING" NOISE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION FORD: 1989-96 THUNDERBIRD LINCOLN-MERCURY: 1989-96 COUGAR ISSUE: Some vehicles may exhibit a rear axle "whining" or "howling" noise. This noise may be audible during light throttle at speeds between 56-72 km/h (35-45 mph) or at highway speeds during acceleration or deceleration. This may be due to the ring and pinion gear set. ACTION: Select the appropriate ring and pinion set from the Parts Block listed below and replace the ring and pinion set. The revised ring and pinion should reduce the possibility of noise. Refer to the appropriate year Thunderbird/cougar Service Manual and the following text for removal and installation procedures. REAR AXLE ASSEMBLY IDENTIFICATION Refer to the metal service identification tag for the rear axle ring gear size, ratio and differential type (Traction-Lok or conventional). The identification tag is attached to the rear axle cover by a cover bolt. CAUTION: SHEET MOLDING COMPOSITE (SMC) PLASTIC REAR AXLE COVERS CANNOT BE REUSED AFTER REMOVAL. A NEW COVER SHOULD BE ORDERED AS SOON AS POSSIBLE TO COMPLETE THE REPAIR ON A TIMELY BASIS. CAUTION: BE SURE TO MARK THE DRIVESHAFT IN RELATION TO THE COMPANION FLANGE SO IT MAY BE REINSTALLED IN ITS ORIGINAL POSITION. CAUTION: DIFFERENTIAL BEARING CAPS MUST BE INSTALLED IN THEIR ORIGINAL POSITIONS AND LOCATIONS AT ASSEMBLY TIME. CAUTION: IF LOOSENED, REMOVED OR DAMAGED, THE SPEED SENSOR RING CANNOT BE REUSED AND MUST BE REPLACED. NOTE: BE SURE TO FILL THE AXLE WITH MOTORCRAFT SAE 80W90 PREMIUM REAR AXLE LUBRICANT (XY-80W90-QL) TO THE LEVEL SPECIFIED IN THE SERVICE MANUAL. FOR TRACTION-LOK DIFFERENTIALS, ADD 118 mL (4 OZ) OF ADDITIVE FRICTION MODIFIER (C8AZ-19B546-A). ROAD TEST THE VEHICLE. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Ring Gear, Differential > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ring Gear: > 97811 > Apr > 97 > Rear Axle Whining/Howling Noise > Page 4980 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Powertrain Warranty Coverage For 1989-91 Vehicles OPERATION DESCRIPTION TIME 970811A Install New Gear Set 2.5 Hrs. (Includes Drain And Refill DEALER CODING CONDITION BASIC PART NO. CODE 4209 56 OASIS CODES: 509000, 597997, 702200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications Axle Shaft: Specifications Rear Axle Nut Torque .......................................................................................................................... .................................................. 340 Nm (251 ft lb) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4986 Axle Shaft: Description and Operation Rear Wheel Drive Halfshaft System This system employs Constant Velocity (CV) joints at both its inboard (differential) and outboard (wheel) ends for vehicle operating smoothness. The CV joints are connected by an interconnecting shaft which is splined at both ends and retained in the inboard and outboard CV joints by circlips. The inboard CV joint stub shaft is splined and held in the differential side gear by circlip. The outboard CV joint stub shaft is pressed into the hub and secured with a free-spinning lock nut. The CV joints are lube-for-life with a special CV joint grease and require no periodic lubrication. The CV boots should be periodically inspected and replaced immediately when damage or grease leakage is evident. Halfshaft removal from the differential is accomplished by applying a load to the back face of the inboard CV joint assembly to overcome the circlip. The outboard joint end must be pressed from the hub. The inboard tripod CV joints can be disassembled and serviced. Other then the CV boot, the outboard CV joint is serviced only as an assembly with the shaft. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4987 Axle Shaft: Service and Repair REMOVAL CAUTION: Do not begin this removal procedure unless the following parts are available: a. A new rear axle wheel hub retainer. b. A new driveshaft bearing retainer circlip. c. A new inboard Constant Velocity (CV) joint stub shaft pilot bearing housing seal. Once removed, these parts must not be reused during assembly. Their torque holding ability or retention capability is diminished during removal. Hub Retainer Nut 1. Remove wheel hub cap. Remove rear axle wheel hub retainer using 36mm socket. Loosen wheel hub bolt nuts. CAUTION: A frame contact hoist must be used to avoid damage to the halfshafts and/or rear axle CV joint boots. 2. Raise vehicle on a frame contact hoist. 3. Remove wheel and tire assembly. Antilock Sensors 4. Remove rear brake anti-lock sensors. CAUTION: Damage to the rear brake anti-lock sensors may result if they are not removed before removing the halfshafts. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4988 Parking Brake Rear Cable 5. Using needle nose pliers, slide parking brake rear cable and conduit downward until parking brake cable adjuster is free. Parking Brake 6. Remove parking brake rear cable and conduit from rear disc brake caliper. Brake Caliper 7. Remove upper and lower disc brake caliper locating pins. 8. Remove rear disc brake caliper assembly from rear disc brake rotor. CAUTION: Extreme care must be taken not to stretch, twist or kink brake hose assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4989 Brake Caliper 9. Carefully wire rear disc brake caliper to brake junction bracket as shown. Upper Arm 10. Remove rear suspension arm and bushing bolt and nuts. Suspension Arm 11. Wire rear suspension arm and bushing to upper shock absorber so that it does not interfere with or damage rear axle CV joint boots when halfshaft is removed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4990 Lower Arm 12. Using a paint marker, mark the position of the rear suspension arm and bushing in relation to the rear wheel knuckle with the lower bushings in their relaxed position. CAUTION: Failure to mark this position will result in bushing wind-up on assembly and incorrect ride height, causing misalignment and premature tire wear. NOTE: When rear suspension arm bolt is removed from the rear wheel knuckle, the lower bushings will return to their relaxed positions. Removing Hub 13. Attach Hub Remover/Replacer T81P-1104-C, Metric Hub Remover Adapter T83P-1104-BH and Hub Bearing Service Adapter T86P-1104-A1 to hub studs as shown. Turn wrench counterclockwise until halfshaft is free in rear hub. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4991 Lower Arm 14. Using Torx(r) tool T93P-5494-A hold bolt and loosen lower rear nut and remove. Lower Arm 15. Using Torx(r) tool T93P-5494-A hold bolt and loosen lower front nut and remove. Rear Hub 16. Push inboard CV joint stub shaft pilot bearing housing through rear hub while positioning CV joint and rear wheel knuckle to allow the front lower bolt to clear CV joint. Remove bolt. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4992 Washers 17. Remove and save washers (one washer for each rear suspension arm and bushing bolt). NOTE: Washers are positioned between rear suspension arm and bushing. These washers must be reinstalled. Removing Knuckle 18. Remove rear bolt, washer and rear wheel knuckle. Halfshaft 19. Remove halfshaft assembly from vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4993 Differential Plug 20. Insert Differential Plug T89P-4850-B into differential case to prevent loss of lubricant. INSTALLATION 1. Remove differential plug. 2. Replace inboard CV joint stub shaft pilot bearing housing seal. Circlip 3. Install a new driveshaft bearing retainer circlip on inboard CV joint stub shaft pilot bearing housing. NOTE: To install driveshaft bearing retainer circlip properly, start ends in groove and push driveshaft bearing retainer circlip into groove. This will prevent overexpanding of the driveshaft bearing retainer circlip. CV Joint 4. Lightly lubricate stub shaft splines with premium long-life grease XG-1-C (ESA-M1C75-B) or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4994 Installing Shaft 5. Carefully align splines of inboard CV joint stub shaft pilot bearing housing with splines in differential. NOTE: A non-metallic mallet may be used to aid in seating driveshaft bearing retainer circlip into differential side gear groove. If a mallet is necessary, tap only on the outboard CV joint stub shaft. Installing Shaft 6. Push halfshaft into differential case until driveshaft bearing retainer circlip engages with groove in differential side gear. Use care to prevent damage to inboard CV joint stub shaft pilot bearing housing seal. Knuckle 7. Engage rear hub splines with outboard CV joint splines and install rear lower bolt, washer and nut finger tight. NOTE: Proper rear wheel knuckle attaching bolt installation is with the bolt heads facing the rear of the vehicle and with the washers on each side between rear suspension arm and bushing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4995 Washers 8. Position washer between the rear suspension arm and bushing. Installing Hub 9. Push CV joint stub shaft inward through rear hub while positioning CV joint and rear wheel knuckle to allow installation of the front lower bolt, washer and nut. NOTE: Due to the rear suspension arm and bushing design, the lower bolts must be installed with the Torx(r) heads facing the rear of the vehicle. Index Marks 10. Align rear suspension arm and bushing index marks and tighten rear suspension arm and bushing retaining bolts to 128-178 Nm (94-131 ft lb) using Torx Head Holding Tool T93P-5494-A. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4996 Tightening Nut 11. With wheel hub bolt nuts installed, hold rear disc brake rotor from turning and hand tighten new rear axle wheel hub retainer. Upper Arm 12. Install rear suspension arm and bushing retaining bolt and tighten nut to 158-193 Nm (117-142 ft lb). Rear Brake 13. Position rear disc brake caliper assembly over the rear disc brake rotor and install the two disc brake caliper locating pins. Tighten to 87-119 Nm (64-88 ft lb). CAUTION: When installing rear disc brake caliper hold outer brake shoe and lining against rear disc brake rotor braking surface to avoid damaging caliper piston boot. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4997 Parking Brake 14. Insert parking brake rear cable and conduit through rear disc brake caliper lever and attach parking brake rear cable and conduits. Parking Brake Cable 15. Install parking brake cable adjuster. Antilock Sensors 16. Install rear brake anti-lock sensors. Tighten retaining bolts to 19-27 Nm (14-20 ft lb). 17. Check axle lube level and fill as necessary. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle Shaft > Component Information > Specifications > Page 4998 Axle 18. Check inboard driveshaft bearing retainer circlip engagement by attempting to pull inboard CV joint stub shaft pilot bearing housing from axle. If driveshaft bearing retainer circlip is not seated, push CV joint in until driveshaft bearing retainer circlip is fully engaged in differential side gear. 19. Install wheel and tire assembly. Tighten wheel lug nuts to 115-142 Nm (85-105 ft lb). 20. Lower vehicle. 21. Tighten rear axle wheel hub retainer to 340 Nm (251 ft lb). 22. Install wheel hub cap. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Bearing Adjusting Nut 17-25 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Specifications > Page 5002 Wheel Bearing: Adjustments These models are equipped with sealed bearing units which do not require adjustment or maintenance. If bearing is found to be defective, then hub and bearing must be replaced as an assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Fig. 3 Hub & Wheel Bearing Assembly REPLACE 1. Raise and support front of vehicle, then remove wheel and tire assembly. 2. Remove grease cap from hub. 3. Remove disc brake caliper with brake hose attached. Suspend caliper from suspension with wire. Do not allow caliper to hang from brake hose. 4. Remove brake rotor. 5. Remove hub nut, then remove hub and bearing assembly, Fig. 3. If difficulty is encountered in hub removal, use hub removal tool No. T81P-1104-C or equivalent. 6. Reverse procedure to install. Use a new hub nut and tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5005 Wheel Bearing: Service and Repair Rear NOTE: There are two approved methods for removing the hub from the bearing. Both methods are outlined. Removal 1. Remove knuckle and hub assembly from vehicle as outlined. 2. Place knuckle and hub assembly in a vise. NOTE: On drum brakes, remove shoe and linings, springs, and adjuster from backing plate. Remove four screws that retain the backing plate to the knuckle. Method One A. Position 3-Jaw Puller D88L-1 037-A and Step Plate D8OL-630-5 or equivalent, on the knuckle and press out the hub from the knuckle assembly. Method Two Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5006 A. Position Rear Hub Remover T89P-1 225-AH or equivalent between the knuckle and the backing plate. B. Assemble Hub Remover/Replacer T81 P-il 04-C and Step Plate D8OL-630-5 or equivalent. C. With forcing nut below the crossbar, hold forcing screw and turn forcing nut to remove hub. 3. Remove the backing plate. 4. Remove bearing retainer snap ring. 5. Place knuckle and bearing assembly on a press bed using Hub Support T89P-1 104-A and Bearing Remover T83P-1 1 04-AH2 or equivalent, and press bearing out of knuckle assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5007 Installation 1. Place knuckle assembly on press bed and position bearing in the bearing bore of the knuckle. 2. Using Bearing Installer T86P-1 1 04-A3 or equivalent, press the bearing into the knuckle. 3. Install bearing retainer snap ring. 4. Position the backing plate on the knuckle. Install four retaining bolts and tighten to 61-81 Nm (45-59 lb-ft). 5. Place knuckle assembly on the Hub Support T89P-1 104-A or equivalent and position on press bed plate Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5008 6. Position hub on bearing and using Hub Installer/Bearing Remover T83P-1 104-AH2 or equivalent, press hub into bearing. NOTE: If vehicle is equipped with drum brakes, install shoe linings, springs, and adjuster on backing plate 7. Prior to hub/bearing/knuckle installation replace bearing dust seal on the outboard CV joint with new seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing > Component Information > Service and Repair > Front > Page 5009 Dust Seal Installation 8. Install new dust seal, ensuring seal flange faces outboard toward bearing. Use Drive Tube T83T-31 32-Al and Bearing Dust Seal Installer T89P-l 249-A or equivalent. 9. Install hub and knuckle assembly. See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Wheel Hub: Customer Interest Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 5018 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 5019 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake Wheel Hub: All Technical Service Bulletins Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake > Page 5025 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake > Page 5026 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 90199 > Sep > 90 > Lug Nuts Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 90199 > Sep > 90 > Lug Nuts Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Page 5036 Wheel Hub: Specifications Rear Axle Hub Nut 250 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Page 5037 Wheel Hub: Service and Repair NOTE: There are two approved methods for removing the hub from the bearing. Both methods are outlined. Removal 1. Remove knuckle and hub assembly from vehicle as outlined. 2. Place knuckle and hub assembly in a vise. NOTE: On drum brakes, remove shoe and linings, springs, and adjuster from backing plate. Remove four screws that retain the backing plate to the knuckle. Method One A. Position 3-Jaw Puller D88L-1 037-A and Step Plate D8OL-630-5 or equivalent, on the knuckle and press out the hub from the knuckle assembly. Method Two Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Page 5038 A. Position Rear Hub Remover T89P-1 225-AH or equivalent between the knuckle and the backing plate. B. Assemble Hub Remover/Replacer T81 P-il 04-C and Step Plate D8OL-630-5 or equivalent. C. With forcing nut below the crossbar, hold forcing screw and turn forcing nut to remove hub. 3. Remove the backing plate. 4. Remove bearing retainer snap ring. 5. Place knuckle and bearing assembly on a press bed using Hub Support T89P-1 104-A and Bearing Remover T83P-1 1 04-AH2 or equivalent, and press bearing out of knuckle assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Page 5039 Installation 1. Place knuckle assembly on press bed and position bearing in the bearing bore of the knuckle. 2. Using Bearing Installer T86P-1 1 04-A3 or equivalent, press the bearing into the knuckle. 3. Install bearing retainer snap ring. 4. Position the backing plate on the knuckle. Install four retaining bolts and tighten to 61-81 Nm (45-59 lb-ft). 5. Place knuckle assembly on the Hub Support T89P-1 104-A or equivalent and position on press bed plate Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Page 5040 6. Position hub on bearing and using Hub Installer/Bearing Remover T83P-1 104-AH2 or equivalent, press hub into bearing. NOTE: If vehicle is equipped with drum brakes, install shoe linings, springs, and adjuster on backing plate 7. Prior to hub/bearing/knuckle installation replace bearing dust seal on the outboard CV joint with new seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Component Information > Technical Service Bulletins > Page 5041 Dust Seal Installation 8. Install new dust seal, ensuring seal flange faces outboard toward bearing. Use Drive Tube T83T-31 32-Al and Bearing Dust Seal Installer T89P-l 249-A or equivalent. 9. Install hub and knuckle assembly. See: Steering and Suspension/Suspension/Rear Knuckle/Service and Repair Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest for Propeller Shaft: > 8921 > Jan > 89 > Driveshaft - Vibration Propeller Shaft: Customer Interest Driveshaft - Vibration ^ CROSSMEMBER - CENTER SUPPORT BRACKET INSTALLATION - VEHICLES BUILT BEFORE 2/01/89 ^ VIBRATION - CENTER SUPPORT BRACKET CONTACTS DRIVESHAFT - VEHICLES BUILT BEFORE 2/01/89 Article No. 89-2-1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A driveline vibration between 5-10 MPH (8-16 Km/h) may be caused by the driveshaft contacting the crossmember center support bracket. The crossmember center support bracket may have been initially installed backwards. ACTION: Inspect the position of the crossmember center support bracket to determine if service is required. Refer to the following procedure for service details. FIGURE 1 1. Remove the four (4) bolts holding the body reinforcement, Figure 1. 2. Remove the two (2) bolts and one (1) nut retaining the heat shield. 3. Position the heat shield aside. 4. Make sure the arrow on the center support bracket is pointing toward the rear of the vehicle, Figure 1. If not proceed to Step 5. If okay proceed to Step 8. 5. Remove the two (2) bolts that hold the center support bracket to the body reinforcement, Figure 1. 6. Rotate the center support bracket 180 degrees so the arrow on the bracket points toward the rear of the vehicle. 7. Install the two (2) bolts that hold the center support bracket to the body reinforcement. 8. Reposition the heat shield. 9. Reinstall the two (2) bolts and one (1) nut that retains the heat shield. 10. Reinstall the four (4) bolts that retain the body reinforcement, Figure 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION : 890201A - Inspect TIME: 0.4 Hr. OPERATION: 890201B - Inspect and Correct TIME: 0.5 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Customer Interest for Propeller Shaft: > 8921 > Jan > 89 > Driveshaft - Vibration > Page 5051 DLR. CODING: Basic Part No. 5A041 Condition Code: 79 OASIS CODES: 5950, 7210, 7211, 7212, 7213 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Propeller Shaft: > 8921 > Jan > 89 > Driveshaft - Vibration Propeller Shaft: All Technical Service Bulletins Driveshaft - Vibration ^ CROSSMEMBER - CENTER SUPPORT BRACKET INSTALLATION - VEHICLES BUILT BEFORE 2/01/89 ^ VIBRATION - CENTER SUPPORT BRACKET CONTACTS DRIVESHAFT - VEHICLES BUILT BEFORE 2/01/89 Article No. 89-2-1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A driveline vibration between 5-10 MPH (8-16 Km/h) may be caused by the driveshaft contacting the crossmember center support bracket. The crossmember center support bracket may have been initially installed backwards. ACTION: Inspect the position of the crossmember center support bracket to determine if service is required. Refer to the following procedure for service details. FIGURE 1 1. Remove the four (4) bolts holding the body reinforcement, Figure 1. 2. Remove the two (2) bolts and one (1) nut retaining the heat shield. 3. Position the heat shield aside. 4. Make sure the arrow on the center support bracket is pointing toward the rear of the vehicle, Figure 1. If not proceed to Step 5. If okay proceed to Step 8. 5. Remove the two (2) bolts that hold the center support bracket to the body reinforcement, Figure 1. 6. Rotate the center support bracket 180 degrees so the arrow on the bracket points toward the rear of the vehicle. 7. Install the two (2) bolts that hold the center support bracket to the body reinforcement. 8. Reposition the heat shield. 9. Reinstall the two (2) bolts and one (1) nut that retains the heat shield. 10. Reinstall the four (4) bolts that retain the body reinforcement, Figure 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION : 890201A - Inspect TIME: 0.4 Hr. OPERATION: 890201B - Inspect and Correct TIME: 0.5 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Propeller Shaft: > 8921 > Jan > 89 > Driveshaft - Vibration > Page 5057 DLR. CODING: Basic Part No. 5A041 Condition Code: 79 OASIS CODES: 5950, 7210, 7211, 7212, 7213 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Page 5058 Propeller Shaft: Testing and Inspection The first check to be performed when driveshaft imbalance is suspected is re-indexing the driveshaft. See: Service and Repair/Indexing Driveshaft Balance Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Technical Service Bulletins > Page 5059 Driveshaft Balance Diagnosis Continued A vibration free driveline can result from the driveshaft indexing procedure when minor driveshaft imbalance is cancelled by minor pinion flange runout. If driveshaft indexing is not successful, attempt rebalancing with Whittek clamps as shown in the Driveshaft Balance Diagnosis charts. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Service and Repair > Removal Propeller Shaft: Service and Repair Removal 1. Drain fuel tank. 2. Raise vehicle on a frame contact hoist. Crossmember 3. Remove crossmember on forward side of fuel tank. Exhaust Pipe Hanger On LH Rocker Panel 4. Remove exhaust hanger at LH rocker panel. Exhaust Pipe 5. Remove exhaust pipe at muffler. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Service and Repair > Removal > Page 5062 Exhaust Pipe Supported By Wire 6. Lower exhaust pipe and support with wire. Driveshaft Hoop 7. Remove driveshaft hoop on rear side of tank. Fuel Tank Filler Tube 8. Remove fuel tank filler tube retaining bolt from RH frame rail. Fuel Tank Supported By Transmission Jack 9. Place a transmission jack under fuel tank. CAUTION: Use care not to damage tank. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Service and Repair > Removal > Page 5063 Fuel Tank Support 10. Remove support on forward side of fuel tank. Fuel Tank Support Straps 11. Remove fuel tank support straps. Lower fuel tank approximately 15 centimeters (6 inches). Marking Driveshaft Flange 12. Locate original paint mark on axle companion flange and mark driveshaft flange in same location. NOTE: If original mark is not visible on companion flange, mark both the companion flange and driveshaft flange. Driveshaft Retaining Bolts 13. Remove driveshaft retaining bolts. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Service and Repair > Removal > Page 5064 Pull Driveshaft Rearward To Remove 14. Separate the driveshaft from the axle companion flange and pull driveshaft rearward to remove. Install a plug in extension housing to prevent fluid loss. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Service and Repair > Removal > Page 5065 Propeller Shaft: Service and Repair Installation 1. Lubricate the slip yoke splines with Long Life Lubricant C1AZ-19590-BA or equivalent. Remove the plug from the transmission extension. Inspect the housing seal for damage; replace if required. Install the driveshaft assembly. Do not allow the slip yoke assembly to bottom on the output shaft with excessive force. Marking Driveshaft Flange 2. Align marks on driveshaft with axle companion flange. Install and tighten retaining bolts to 95-130 Nm (71-95 lb-ft). NOTE: When installing a new driveshaft assembly, align (factory made) yellow paint mark at rear of driveshaft tube with (factory made) yellow paint mark on outside diameter of axle companion flange. If paint marks are not visible, refer to Driveshaft Indexing. 3. Raise fuel tank and install support straps. Tighten retaining bolts to 28-40 Nm (21-29 lb-ft). Fuel Tank Filler Tube 4. Install fuel tank filler tube retaining bolt. Tighten retaining bolt to 4-5.5 Nm (36-48 lb-in). 5. Install driveshaft hoop. Tighten retaining bolts to 40-61 Nm (30-45 lb-ft). Fuel Tank Support 6. Install support on forward side of fuel tank. Tighten bolts to 40-61 Nm (30-45 lb-ft). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Service and Repair > Removal > Page 5066 Exhaust Pipe Hanger On LH Rocker Panel 7. Install exhaust pipe hanger at LH rocker panel. Tighten bolts to 16-24 Nm (12-17 lb-ft). Exhaust Pipe 8. Install exhaust pipe to muffler. Tighten bolts to 28-40 Nm (21-29 lb-ft). Crossmember 9. Install crossmember on forward side of fuel tank. Tighten bolts to 16-24 Nm (12-17 lb-ft). 10. Lower vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Drive/Propeller Shafts, Bearings and Joints > Propeller Shaft <--> [Drive/Propeller Shaft] > Component Information > Service and Repair > Removal > Page 5067 Propeller Shaft: Service and Repair Indexing Marking Position On Driveshaft Yoke 1. Mark one hole position on driveshaft yoke at rear of driveshaft with the letter A and the eight circular flange holes (starting with the mating hole with driveshaft position A) from one through eight. Position A-1 is considered the original index position. NOTE: Check U-joints for binding during first re-indexing. 2. Index driveshaft-to-axle 180 degrees to position A-5. Test drive vehicle; it unsatisfactory, evaluate position A-3 and position A-7. 3. If further improvement is desired, evaluate remaining positions that are located between the best of the two previous positions, A-3 and A-7. If vehicle tests satisfactorily at any point during this procedure, do not proceed with any further steps. If indexing is not successful, refer to Driveshaft Balance Diagnosis. See: Testing and Inspection NOTE: Original equipment driveshaft-to-axle companion flange attaching bolts (N-800594-S100) are Loctite coated and do not require a lockwasher. If these bolts are removed, they may be installed, if additional Loctite is applied. New and used bolts must be tightened to 95-129 Nm (70-95 lb-ft). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Technical Service Bulletins > Customer Interest for Shift Indicator: > 89139 > Jun > 89 > A/T - PRNDL Bulb Socket Melted Shift Indicator: Customer Interest A/T - PRNDL Bulb Socket Melted LAMP-TRANSMISSION PRNDL BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 TRANSMISSION-PRNDL LIGHT BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 Article No. 89-13-9 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Heat from the transmission "PRNDL" light bulb may soften and melt the plastic bulb socket. This is caused by the two (2) candlepower bulb. ACTION: Install a new bulb and socket assembly. The new assembly has a one (1) candlepower bulb which will operate cooler. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 17-02 for service details. NOTE: THE NEW BULB AND SOCKET ASSEMBLY ALSO HAS A LIGHTER GREEN FILTER SO THE LESS BRIGHT BULB WILL STILL SUPPLY THE CORRECT GREEN COLOR AND INTENSITY. PART NUMBER PART NAME CLASS E9SZ-15A808-C Bulb and Socket Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891309A Install Bulb & Socket 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 15A808 46 OASIS CODES: 2100, 2150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Lamps and Indicators - Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Indicator: > 89139 > Jun > 89 > A/T - PRNDL Bulb Socket Melted Shift Indicator: All Technical Service Bulletins A/T - PRNDL Bulb Socket Melted LAMP-TRANSMISSION PRNDL BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 TRANSMISSION-PRNDL LIGHT BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 Article No. 89-13-9 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Heat from the transmission "PRNDL" light bulb may soften and melt the plastic bulb socket. This is caused by the two (2) candlepower bulb. ACTION: Install a new bulb and socket assembly. The new assembly has a one (1) candlepower bulb which will operate cooler. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 17-02 for service details. NOTE: THE NEW BULB AND SOCKET ASSEMBLY ALSO HAS A LIGHTER GREEN FILTER SO THE LESS BRIGHT BULB WILL STILL SUPPLY THE CORRECT GREEN COLOR AND INTENSITY. PART NUMBER PART NAME CLASS E9SZ-15A808-C Bulb and Socket Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891309A Install Bulb & Socket 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 15A808 46 OASIS CODES: 2100, 2150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Case, M/T > Component Information > Service and Repair Case: Service and Repair DISASSEMBLY 1. Remove three M6 Torx head screws from the shift control housing assembly. 2. Lift shift lever assembly off shift control housing. Offset side of shift lever, flat side of lower boot assembly, shift lever plate and gasket assembly are located on the passenger side of the vehicle. 3. Remove lower boot assembly, shift lever plate, gasket assembly, spring shim and busing from lever, then replace as necessary. ASSEMBLY NOTE: Apply a light coating of grease to the shift lever ball and shift control housing socket prior to assembly. 1. Install shift lever in shift control housing. Ensure that offset side of lever is located on righthand side of vehicle. 2. Place bushing, shim and spring assembly in shift control housing, ensuring to seat bottom slots of bushing into tabs of control housing. 3. Clean mating surface of the shift lever plate, then retain new gasket to plate using grease. 4. Align flat side of lower boot assembly and shift lever plate to righthand side of vehicle, then place over lever onto shift control housing. 5. Install three M6 Torx head screws through lower boot assembly and shift lever plate, then torque screws to 69-95 inch lbs. 6. Clean all old sealant from shift control housing, then apply a 1/16 inch bead of silicone sealant No. D6AZ-19562-B or equivalent. 7. Install shift control housing assembly onto extension housing. Torque bolts to 69-95 inch lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Countershaft, M/T > Component Information > Service and Repair Countershaft: Service and Repair DISASSEMBLY 1. Using a press and bearing cone remover T71P-4621-B or equivalent, remove the countershaft center bearing inner race. 2. Using a press and bearing splitter tool No. T84L-1123-A or equivalent, remove the countershaft front bearing inner race. INSPECTION 1. Check countershaft gear teeth and splines for wear or damage. Replace countershaft if worn, bent or scored. ASSEMBLY 1. Using a press, suitable spacer, bearing replacer tool No. T53T-4621-B and bearing plate tool No. T75L-1165-B or equivalent, install center bearing inner race. 2. Using a press, suitable spacer, bearing replacer tool No. T53T-4621-B, bearing plate tool No. T75L-1165-B, and countershaft front bearing replacer tool No. T77J-7025-L or equivalent, install countershaft front bearing inner race. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information Fluid - M/T: Technical Service Bulletins M/T - Mercon(R) V ATF Usage Information TSB 06-26-1 01/08/07 MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS FORD: 1981-2003 Escort 1984-1995 Thunderbird 1985-2007 Mustang 1985-1996 Bronco 1985-2007 Ranger 1986-1997 Aerostar 1991-2004 Explorer 1995-2007 F-150 1996-2007 F-Super Duty 2001-2003 Explorer Sport Trac, Explorer Sport LINCOLN: 2001-2002 Lincoln LS MERCURY: 1984-1995 Cougar 1987-1999 Tracer ISSUE MERCON(R) Automatic Transmission Fluid is being replaced by MERCON(R) V as the service fluid for manual transmissions originally requiring MERCON(R). ACTION Beginning immediately all manual transmission applications requiring MERCON(R) can now be serviced using MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON(R) / MERCON(R) V. After July 1, 2007, MERCON(R) Automatic Transmission Fluid will no longer be manufactured, therefore, availability of this fluid will continue until remaining inventory has been depleted. SERVICE PROCEDURE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 5094 Service manual transmissions requiring MERCON(R) with MERCON(R) V or MERCON(R) Automatic Transmission Fluid or dual usage fluids labeled MERCON/MERCON(R) V. For proper fluid application on current and past model manual transmissions refer to the fluid usage chart. (Figure 1) WARNING FULL SYNTHETIC MANUAL TRANSMISSION FLUID (XT-M5-QS), SAE 75W-90 API GL-4 GEAR OIL (XY-75W90-QGL) AND SAE 75W-90 PREMIUM SYNTHETIC TRANSAXLE LUBRICANT (XT-75W90-QGT) ARE UNIQUE FLUIDS AND MUST BE USED IN APPLICATIONS RECOMMENDING THAT PARTICULAR FLUID. USE OF ANY OTHER FLUID MAY CAUSE REDUCED FUNCTIONALITY OR DAMAGE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > M/T - Mercon(R) V ATF Usage Information > Page 5095 Parts Block WARRANTY STATUS: Information Only Disclaimer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Fluid - M/T > Component Information > Technical Service Bulletins > Page 5096 Fluid - M/T: Specifications Type MA(MERCON (R) V Automatic Transmission Fluid) CAPACITY, Refill: Mustang 5.5 pt (US) Thunderbird, Cougar 6.4 pt (US) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Testing and Inspection Synchronizer Hub: Testing and Inspection FORD M5R2 (5-SPEED) INSPECTION 1. Check operation of clutch hub sleeve on hub. 2. Position clutch hub and sleeve horizontally. Lift the hub approximately three-quarters of the way off the sleeve. Release the hub and observe downward motion. Hub should slide downward into sleeve. It should not be necessary to push hub into sleeve. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear, M/T > Synchronizer Hub, M/T > Component Information > Testing and Inspection > Page 5101 Synchronizer Hub: Service and Repair DISASSEMBLY 1. Place synchronizer assembly face down, then using a suitable tool, remove synchronizer spring. 2. Holding sleeve and hub assembly in place, turn assembly over to the opposite face, then remove second spring and three insert keys and slide sleeve from hub. Replace parts as necessary. INSPECTION 1. Inspect gear teeth on synchronizer ring for chipping or excessively worn teeth, then replace as necessary. 2. Inspect synchronizer ring for wear by fitting synchronizer ring evenly to gear cone. Measure clearance between side faces of synchronizer ring and gear using feeler gauge. If clearance is less than 0.031 inch, replace synchronizer ring or gear. 3. Inspect contact between inner surface of reverse synchronizer ring and cone surface of reverse gear by applying a thin coat of Prussian blue or equivalent to surface of cone, then fit cone into ring. If pattern is poor, correct by applying compound and lapping surfaces together. 4. Inspect fiber lined blocker ring for evidence of wear, flaking, glazing and burned or missing lining material. 5. Ensure clutch sleeve sides freely on clutch hub. 6. Check synchronizer inserts (keys), inner surface of clutch sleeve and insert groove on clutch hub for wear. 7. Check synchronizer insert spring for tension. ASSEMBLY Synchronizer Clutch Hub To Sleeve Direction 1. Locate indented dot reference mark on the shoulder of one face side of sleeve. Insert hub into sleeve with one of the three insert slots of hub aligned with reference mark. Ensure hub moves freely on sleeve. 2. Place hub and sleeve assembly face down, then install three insert keys into hub slots. 3. Insert one synchronizer spring into clip hole located in inner shoulder of sleeve, and place spring under protruding edge of each insert key. 4. While holding hub and sleeve together, turn assembly over and insert other spring in opposite direction of the first spring. 5. Excessive movement between hub and sleeve during sliding onto shaft will cause insert keys to pop out of hub slots. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Gear Sensor/Switch, M/T > Component Information > Locations Gear Sensor/Switch: Locations LH Side Of Manual Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Input Shaft, M/T > Component Information > Service and Repair Input Shaft: Service and Repair DISASSEMBLY 1. Remove and discard plastic scoop ring. Removing Tapered Roller Bearing 2. Press tapered roller bearing from input shaft using bearing cone remover tool No. T71P-4621-B or equivalent and a suitable press. Discard bearing after removal. ASSEMBLY 1. Install input shaft tapered roller bearing onto input shaft using a press bearing plate tool No. T75L-1165-B, and bearing cone replacer tool No. T88T-7025-B or equivalent. 2. Install plastic scoop ring onto shaft. Manually rotate ring clockwise to ensure input shaft oil holes properly engage scoop ring. A click should be heard as scoop ring notches align with input shaft oil holes. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair > Disassembly Output Shaft: Service and Repair Disassembly 1. Remove pilot bearing, retaining ring, spacer and needle bearing from front of output shaft. 2. Position front of output shaft so that it faces upward, then remove third/fourth clutch hub and sleeve. 3. Remove third gear synchronizer blocker ring. 4. Remove third gear. 5. Remove needle bearing. 6. Position output shaft with rear end (long side of flange) facing upward. Place output shaft into press with press cradle contacting lower part of second gear. Ensure that output shaft flange does not contact or ride up onto press cradle, as improper positioning of output shaft can cause component damage. Disassembly Of Output Shaft 7. Press off center bearing, first gear sleeve, first gear needle bearing, first gear, first gear synchronizer blocker ring first/second clutch hub and sleeve assembly, second gear synchronizer blocker ring, second gear and second gear needle bearing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair > Disassembly > Page 5112 Output Shaft: Service and Repair Inspection Measuring Output Shaft Runout 1. Check output shaft for run-out by mounting the shaft between V blocks and applying a dial indicator to several places along shaft. If run-out exceeds 0.002 inch, replace mainshaft. 2. Replace input shaft if splines are damaged, needle bearing surface in bore of bearing is worn or rough or cone surface is damaged. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Output Shaft, M/T > Component Information > Service and Repair > Disassembly > Page 5113 Output Shaft: Service and Repair Assembly NOTE: Lubricate all rotating and sliding components with Dexron-II or equivalent during assembly. Output Shaft Assembly 1. Position output shaft so rear end faces upward. Lubricate all bearing journals. Install the following parts in the order listed, using bearing replacer tool No. T53T-4621-B and bearing plate tool No. T75L-1165-B or equivalent. a. Second gear needle bearing. b. Second gear. c. Second gear synchronizer blocker ring, aligning ring with synchronizer insert keys. d. First/second clutch hub and sleeve assembly. Ensure smaller width of sleeve faces second gear side and reference mark for installation faces rear of transmission. e. First gear synchronizer blocker ring, aligning ring with synchronizer insert keys. f. First gear needle bearing to first gear sleeve. g. First gear. h. First gear sleeve and needle bearing assembly. i. Center bearing. Ensure bearing is installed completely onto output shaft. 2. Position output shaft so front of output shaft flange faces upward, then install the following components: a. Third gear needle bearing. b. Third gear. c. Third gear synchronizer blocker ring. 3. Install third/fourth clutch hub and sleeve as follows: a. Mate clutch hub synchronizer key groove with reference mark on the clutch hub sleeve. Reference mark should face rearward. b. Install longer flange on clutch hub sleeve, toward third gear (rear) side. The front and rear sides of the clutch sleeve are the same except for the reference mark on one side. 4. Install spacer, needle bearing rollers upward, retaining ring. 5. Install original retaining ring. Check clutch hub endplay using a feeler gauge. Retaining Ring Selection Chart 6. If necessary, adjust third/fourth clutch hub endplay to 0.0000-0.0019 inch by selecting required required retaining ring. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Reverse Gear Shaft > Component Information > Service and Repair Reverse Gear Shaft: Service and Repair DISASSEMBLY 1. Remove retaining ring and spacer. 2. Remove idler gear. 3. Remove needle bearings and thrust washer. ASSEMBLY 1. Install reverse idler shaft in transmission case. Apply sealant to reverse idler shaft fixing bolt threads. Torque fixing bolt to 58-86 ft lbs. 2. Install thrust washer (brass side facing gear) onto reverse idler gear shaft. Ensure tab on thrust washer mates with groove on reverse idler shaft to prevent rotation of thrust washer. 3. Install needle bearings onto reverse idler gear shaft. 4. Install reverse idler gear. 5. Install spacer (brass side to gear) and original retaining ring onto reverse idler gear shaft. Insert a feeler gauge between retaining ring and spacer to measure reverse idler gear endplay. Reverse Idler Gear Retaining Ring Chart 6. Using the reverse idler gear retaining rings selection chart, adjust reverse idler gear endplay to 0.0039-0.0078 inch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Sensors and Switches - M/T > Gear Sensor/Switch, M/T > Component Information > Locations Gear Sensor/Switch: Locations LH Side Of Manual Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Fork, M/T > Component Information > Testing and Inspection Shift Fork: Testing and Inspection INSPECTION 1. Check the contact surfaces of the shift fork and clutch hub sleeve for evidence of wear or damage. 2. Verify that clearance exists between shift fork and slot in the hub sleeve. Measure clearance from shift fork to clutch hub sleeve. Clearance should not exceed 0.031 inch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Manual Transmission/Transaxle > Shift Linkage, M/T > Shift Rail, M/T > Component Information > Service and Repair Shift Rail: Service and Repair SHIFT CONTROL FRAME ASSEMBLY 1. If necessary, remove four shift control frame assembly attaching bolts from top cover. 2. Remove shift control frame assembly from top cover. Shift rails must be in neutral position for proper disassembly and assembly. Cover lock ball bores, friction device and spring seats with a clean cloth to prevent loss of parts. 3. Remove fifth/reverse shift rod, then shift rod detent balls and spring from shift control frame assembly. 4. Remove roll pin from third/fourth gear fork and shift rod using a 5/32 inch punch and hammer. 5. Remove third/fourth gear fork from shift rod. 6. Remove roll pin from first/second gear fork and shift rod using a 5/32 inch punch and hammer. 7. Rotate first/second shift rod and gate slightly to clear third/fourth shift gate, then tap lightly to remove third/fourth shift rod and gate assembly. 8. If necessary, place third/fourth shift rod and gate assembly in a vise, then using a 5/32 inch punch and hammer remove roll pin from shift rod and gate. Slide gate off shift rod. 9. Remove third/fourth shift rod detent ball and spring, then first/second shift detent ball and spring using a pencil magnet. 10. Remove the interlock pins for fifth/reverse and first/second shift rods through the service bore. 11. Remove first/second shift rod and gate by rotating approximately 45° while pulling outward. 12. Remove shift rod seat and damper spring assemblies by tilting shift control frame and tapping loose. 13. Reverse procedure to assemble. Torque downshift control frame assembly to top cover bolts to 7.0-9.7 inch lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors and Switches - M/T > Gear Sensor/Switch, M/T > Component Information > Locations Gear Sensor/Switch: Locations LH Side Of Manual Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Technical Service Bulletins > Customer Interest for Shift Indicator: > 89139 > Jun > 89 > A/T - PRNDL Bulb Socket Melted Shift Indicator: Customer Interest A/T - PRNDL Bulb Socket Melted LAMP-TRANSMISSION PRNDL BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 TRANSMISSION-PRNDL LIGHT BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 Article No. 89-13-9 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Heat from the transmission "PRNDL" light bulb may soften and melt the plastic bulb socket. This is caused by the two (2) candlepower bulb. ACTION: Install a new bulb and socket assembly. The new assembly has a one (1) candlepower bulb which will operate cooler. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 17-02 for service details. NOTE: THE NEW BULB AND SOCKET ASSEMBLY ALSO HAS A LIGHTER GREEN FILTER SO THE LESS BRIGHT BULB WILL STILL SUPPLY THE CORRECT GREEN COLOR AND INTENSITY. PART NUMBER PART NAME CLASS E9SZ-15A808-C Bulb and Socket Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891309A Install Bulb & Socket 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 15A808 46 OASIS CODES: 2100, 2150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Lamps and Indicators Transmission and Drivetrain > Lamps and Indicators - A/T > Shift Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Indicator: > 89139 > Jun > 89 > A/T - PRNDL Bulb Socket Melted Shift Indicator: All Technical Service Bulletins A/T - PRNDL Bulb Socket Melted LAMP-TRANSMISSION PRNDL BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 TRANSMISSION-PRNDL LIGHT BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 Article No. 89-13-9 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Heat from the transmission "PRNDL" light bulb may soften and melt the plastic bulb socket. This is caused by the two (2) candlepower bulb. ACTION: Install a new bulb and socket assembly. The new assembly has a one (1) candlepower bulb which will operate cooler. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 17-02 for service details. NOTE: THE NEW BULB AND SOCKET ASSEMBLY ALSO HAS A LIGHTER GREEN FILTER SO THE LESS BRIGHT BULB WILL STILL SUPPLY THE CORRECT GREEN COLOR AND INTENSITY. PART NUMBER PART NAME CLASS E9SZ-15A808-C Bulb and Socket Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891309A Install Bulb & Socket 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 15A808 46 OASIS CODES: 2100, 2150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - M/T > Gear Sensor/Switch, M/T > Component Information > Locations Gear Sensor/Switch: Locations LH Side Of Manual Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Diode > Component Information > Locations ABS Diode: Locations Engine Compartment Component Locations In Headlamp To Dash Panel Harness, Near C103 Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation This lamp will be illuminated when the ignition switch is placed in the On position. The lamp maybe illuminated for as long as 30 seconds as a bulb and system check. For 89-90 Probe, the light will flash when self-test is activated. If lamp remains illuminated or comes on while operating the vehicle, a problem in the anti-lock brake system is indicated. When lamp is illuminated, place ignition switch in Off position, then restart engine. If lamp still remains illuminated, the anti-lock brake system should be serviced. The brake system will remain functional, but without the anti-lock function. After servicing the anti-lock brake system, the lamp will automatically be reset when vehicle is operated at a speed over 25 MPH. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Antilock Power Relay <--> [ABS Main Relay] > Component Information > Locations Antilock Power Relay: Locations Engine Compartment Component Locations RH Front Of Dash, On Relay Bracket Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Accumulator > Component Information > Specifications Brake Fluid Accumulator: Specifications Accumulator-to-Pump Housing Adapter 30-34 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Accumulator > Component Information > Specifications > Page 5168 Brake Fluid Accumulator: Service and Repair Fig. 9 Hydraulic accumulator replacement Relieve system hydraulic pressure by turning ignition off and pumping brake pedal at least 20 times until an increase in pedal force is felt. 1. Disconnect battery ground cable and electrical connector from hydraulic pump motor. 2. Remove accumulator, Fig. 9, ensuring no debris falls into open port. 3. Remove accumulator adapter block, if necessary. 4. Reverse procedure to install. Torque adapter block bolt to 25---34 ft. lbs. and accumulator to 30---34 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Specifications Brake Fluid Pump: Specifications Pump Mounting Bolt 5-7 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Specifications > Page 5172 Brake Fluid Pump: Locations Part Of Control Unit, On LH Side Of Dash Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Specifications > Page 5173 Brake Fluid Pump: Description and Operation Fig. 4 Electric Pump Assembly This system uses high pressure brake fluid stored in a hydraulic accumulator, for power assist as well as for rear wheel braking. The accumulator is a gas filled pressure chamber that stores brake fluid up to 2600 psi. The fluid is pressurized by an electric motor driven pump. The pump is switched on and off automatically by a pressure sensing switch through a relay circuit. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump > Component Information > Specifications > Page 5174 Brake Fluid Pump: Service and Repair Fig. 10 Hydraulic pump motor replacement Relieve system hydraulic pressure by turning ignition off and pumping brake pedal at least 20 times until an increase in pedal force is felt. 1. Disconnect battery ground cable. 2. Disconnect electrical connectors from hydraulic pump motor and warning switch. 3. Remove accumulator, ensuring no debris falls into open port. 4. Position a large vacuum nipple over reservoir opening to prevent fluid loss, then disconnect suction line between reservoir and pump at pump end by twisting and pulling. 5. Remove banjo bolt securing pump high pressure line, Fig. 10. 6. Remove allen head bolt securing pump and motor assembly to extension housing, located directly under the accumulator. Retain thick spacer between extension housing and shock mount for use during installation. 7. Move pump toward engine, the remove assembly from retainer pin on inboard side of extension housing. 8. Reverse procedure to install. Torque allen head bolt to 5---7 ft. lbs., banjo bolt to 12---15 ft. lbs. and the accumulator to 30---34 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump Relay > Component Information > Locations Brake Fluid Pump Relay: Locations Engine Compartment Component Locations RH Side Of Dash, On Relay Bracket Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Body & Chassis Components Below Center Of Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5181 Electronic Brake Control Module: Description and Operation The electronic controller is located on a package tray in the upper portion of the luggage compartment of the vehicle, behind the righthand side of the rear seat. It is an on-board self test non-repairable unit, consisting of two microprocessors and the necessary circuitry for their operation. These microprocessors are programmed identically and operate on the principle of two channel redundant data processing and plausibility criteria monitoring. Most failures which occur to the system will be stored as a code in the controllers constant memory. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake Control Module > Component Information > Locations > Page 5182 Electronic Brake Control Module: Service and Repair Fig. 11 Electronic controller replacement Located, Lower RH panel in luggage compartment. 1. Disconnect battery ground cable. 2. Disconnect electrical connector from electronic controller, Fig. 11. 3. Remove electronic controller attaching screws and the controller. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Hydraulic Unit-to-Dash Panel Nuts 13-25 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5186 Hydraulic Control Assembly - Antilock Brakes: Locations Engine Compartment Component Locations Part Of Brake Control Unit Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5187 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Solenoid valve block assembly The solenoid valve block assembly contains three pairs of solenoid valves, one pair for each front wheel and the third pair for both rear wheels. The paired solenoid valves are inlet and outlet valves, with the inlet valve normally open and the outlet valve normally closed. During anti-lock operation, the inlet and outlet valves are alternately opened and closed approximately 10 times per second to provide pressure modulation to wheel of impending lockup. The solenoid valve block is bolted to the hydraulic actuation unit, behind the lefthand shock tower. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Assembly Fig. 2 Hydraulic Actuation Unit. Cougar, Thunderbird & 1989 Continental Fig. 3 Hydraulic Actuation Unit. Mark VII 1. With hydraulic system discharged, disconnect battery ground cable. 2. Remove air cleaner housing and duct assembly. 3. Label, then disconnect electrical connectors from fluid level indicator, main valve, solenoid valve block, pressure warning switch, hydraulic pump motor and ground connector from master cylinder portion of actuation assembly. 4. Disconnect and cap three brake tube fittings. Do not allow brake fluid to come in contact with any of the electrical connectors. 5. Remove trim panel under steering column. Disconnect actuation assembly push rod from brake pedal. Slide switch, push rod and plastic bushings off pedal pin. 6. Remove four retaining nuts, securing actuation assembly to brake pedal support bracket. 7. Remove actuation assembly from engine compartment. 8. Reverse procedure to install. Torque the four hydraulic unit to pedal support and brake tube lock nuts to 13-25 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 5190 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Solenoid Valve Body Relieve system hydraulic pressure by turning ignition off and pumping brake pedal at least 20 times until an increase in pedal force is felt. Removal 1. Discharge system. 2. Disconnect negative battery cable. 3. Remove LH cowl vent screen. 4. Disconnect electrical connector from valve block. 5. Disconnect brake lines at solenoid valve block. 6. Remove solenoid valve block. 7. Reverse procedure to install. Tighten solenoid valve block to 15-21 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front/Rear Sensor Tightening Torque Front/Rear Sensor Tightening Torque Front Sensor Bracket Bolts 10-15 ft.lb Rear Sensor Bolts 14-20 ft.lb Sensor Bracket Post Bolts 40-60 in.lb Sensor Set Screws 21-26 in.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 5194 Wheel Speed Sensor: Locations Body & Chassis Components In Respective Wheelhouse Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 5195 Wheel Speed Sensor: Description and Operation Fig. 7 Wheel Sensor Assembly (righthand Side Shown, Lefthand Side Similar). 1989 Continental Fig. 8 Wheel Sensor Assembly. Cougar & Thunderbird Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Specifications > Page 5196 Fig. 9 Wheel Sensor Assembly. Mark VII This system, Figs. 7 thru 9, uses four sets of variable reluctance sensors and toothed speed indicator rings to determine the rotational speed of each wheel. The sensors operate on magnetic induction principle. For example, as the teeth on the speed indicator ring rotate past the stationary sensor, a signal proportional to the speed of the rotation is generated and transmitted to the electronic control unit (ECU) through a coaxial cable. The front sensors are attached to the suspension knuckles and the speed indicator rings are pressed onto the hubs. The rear sensors are attached to the axle housing and the speed indicator rings are pressed onto the inner CV joints. The sensors and the speed indicator rings are serviced individually. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Front Fig. 16 Front toothed sensor ring removal REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake caliper and rotor assemblies. 3. Position rotor assembly on an arbor press with studs facing up, then carefully press each stud individually until they contact sensor ring surface. 4. Press studs and sensor ring out of rotor simultaneously, Fig. 16. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5199 Fig. 17 Front toothed sensor ring installation INSTALLATION 1. Install studs into rotor one at a time. 2. Position sensor ring onto rotor, then press ring until fully seated, Fig. 17. 3. Install rotor and caliper assemblies, then the wheel and tire. Rear Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5200 Fig. 18 Rear toothed sensor ring removal Removal 1. Remove rear axle shaft, refer to Rear Axle Replacement Procedures. 2. Install pinion bearing cone remover tool, Fig. 18, between axle shaft flange and sensor ring. Ensure recessed portion of inner surface of tool is toward axle flange. 3. Position axle in an arbor press and press axle out of sensor ring. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5201 Fig. 19 Rear toothed sensor ring installation Installation 1. To install, position sensor on axle shaft with recessed side facing inboard. 2. Install pinion bearing cone remover tool, Fig. 19, on axle shaft. 3. Position a piece of bar stock on top of axle flange, then press sensor ring onto axle shaft until a 1.8 inch gap between face of sensor ring and flange is obtained. 4. Install axle shaft. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5202 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Front 1. Disconnect sensor electrical connector for RH or LH front sensor from underside of the vehicle (up near radiator support). 2. Remove routing clips along wiring harness. 3. Remove Torx head screw securing sensor to spindle. 4. Reverse procedure to install. Torque Torx head screw to 40-60 inch lbs. Rear 1. Disconnect battery ground cable. 2. Disconnect wheel sensor electrical connector, located behind wheelwell, under carpeting, inside luggage compartment. 3. Push sensor wire grommet through hole in luggage compartment floor. 4. Raise and support vehicle, then remove sensor wire from routing clips. 5. On Cougar and Thunderbird models, remove sensor retaining bolt with a 1/2 inch socket. 6. On Mark VII models, proceed as follows: a. Remove wheel and tire assembly, then caliper and rotor assemblies. b. Remove Torx head retaining bolt, then slip grommet out of rear brake splash shield and pull sensor out through the hole. 7. Reverse procedure to install, noting the following: a. On Cougar and Thunderbird models, align sensor location tab and bolt hole to axle, then push into position. b. Torque retaining bolt to 14-20 ft. lbs. c. On Mark VII models, loosen 5mm setscrew on sensor and ensure sensor slides freely on sensor bracket post. d. If sensor is to be reused or adjusted, ensure sensor face is clean and free of foreign material. Carefully scrape pole face with a dull knife. Glue a new front paper spacer on pole face (spacer is marked with a "R" and is .043 inch thick). Steel sleeve around post bolt must be rotated to provide a new surface for setscrew to indent and lock into. e. Torque Torx head screw to 40-60 inch lbs. f. Push sensor toward toothed ring, until new paper sensor contacts sensor ring. Hold sensor, then torque 5mm setscrew to 21-26 inch lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding Pressure bleeding is recommended for all hydraulic brake systems. The bleeding operation itself is fairly well standardized. First step in all cases is cleaning the dirt from the filler cap before removing it from the master cylinder. This should be done thoroughly. Pressure bleeding is fastest because the master cylinder doesn't have to be refilled several times, and the job can be done by one man. To prevent air from the pressure tank getting into the lines, do not shake the tank while air is being added to the tank or after it has been pressurized. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full. On vehicles equipped with disc brakes and master cylinders without proportioners or pressure control valves located in the master cylinder outlet port, the brake metering valve or combination valve must be held in position using a suitable tool. If air does get into the fluid, releasing the pressure will cause the bubbles to increase in size, rise to the top of the fluid, and escape. Pressure should not be greater than about 35 psi. On vehicles equipped with plastic reservoirs, do not exceed 25 psi bleeding pressure. When bleeding without pressure, open the bleed valve three-quarters of a turn, depress the pedal a full stroke, then allow the pedal to return slowly to its released position. It is suggested that after the pedal has been depressed to the end of its stroke, the bleeder valve should be closed before the start of the return stroke. On models with power brakes, first reduce the vacuum in the power unit to zero by pumping the brake pedal several times with the engine off before starting to bleed the system. Pressure bleeding, of course, eliminates the need for pedal pumping. Discard drained or bled brake fluid. Care should be taken not to spill brake fluid, since this can damage the finish of the car. Flushing is essential if there is water, mineral oil or other contaminants in the lines, and whenever new parts are installed in the hydraulic system. Fluid contamination is usually indicated by swollen and deteriorated cups and other rubber parts. Wheel cylinders on disc brakes are equipped with bleeder valves, and are bled in the same manner as wheel cylinders for drum brakes. Bleeding is necessary on all four wheels if air has entered the system because of low fluid level, or the line or lines have been disconnected. If a line is disconnected at any one wheel cylinder, that cylinder only need be bled. Of course, on brake reline jobs, bleeding is advisable to remove any air or contaminants. Master cylinders equipped with bleeder valves should be bled first before the wheel cylinders are bled. In all cases where a master cylinder has been overhauled, it must be bled. Where there is no bleeder valve, this can be done by leaving the lines loose, actuating the brake pedal to expel the air and then tightening the lines. After overhauling a dual master cylinder used in conjunction with disc brakes, it is advisable to bleed the cylinder before installing it on the car. The reason for this recommendation is that air may be trapped between the master cylinder pistons because there is only one residual pressure valve (check valve) used in these units. WHEEL BLEEDING SEQUENCE Rear Wheel Drive................................................................................................................................. .............................................................RR-LR-RF-LF Front Wheel Drive............................................ .................................................................................................................................................RR-LFLR-RF Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5207 Brake Bleeding: Service and Repair Priming Brake System When a new master cylinder has been installed or the brake system emptied or partially emptied, fluid may not flow from the bleeder screws during normal bleeding. It may be necessary to prime the system using the following procedure: 1. Using a tubing wrench, remove the brake lines from the master cylinder. 2. Install short brake lines in the master cylinder and position them back into the reservoir, ensure that the short brake line ends are submerged in the reservoir brake fluid. 3. Fill the reservoir with recommended brake fluid, then cover master cylinder fluid reservoir with shop towel. 4. Pump the brakes until clear, bubble free fluid comes out of both brake lines. If any brake fluid spills on paint, wash it off immediately with water. 5. Remove the short brake lines, then reinstall original brake lines. 6. Bleed each brake line at the master cylinder using the following procedure: a. Have assistant pump brake pedal 10 times, then hold firm pressure on the pedal. b. Open the rear-most brake line fittings with a tubing wrench until a stream of brake fluid comes out. Have assistant maintain pressure on the brake pedal until the brake line fitting is tightened again. c. Repeat this operation until clear, bubble free fluid comes out from around tube fitting. d. Repeat this bleeding operation at the front brake line fitting. 7. If any of the brake lines or calipers have been removed, it may be helpful to prime the system by gravity bleeding. This should be done after the master cylinder is primed and bled. To prime the system using the gravity method, proceed as follows: a. Fill the master cylinder with manufacturer recommended brake fluid or equivalent. b. Loosen both rear bleeder screws and leave them open until clear brake fluid flows out. Check reservoir fluid level frequently, do not allow fluid level to drop below half full. c. Tighten rear bleeder screws. d. Loosen bleeder screw on front caliper, leave open until clear fluid flows out. Bleed front calipers one side at a time. 8. After the master cylinder has been primed, the lines bled at the master cylinder and the brake system primed, normal brake system bleeding can be resumed at each wheel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5208 Brake Bleeding: Service and Repair With ABS FRONT BRAKES The front brakes can be bled in the same manner as conventional brakes, with or without the accumulator being charged. REAR BRAKES If the pump motor is allowed to operate continuously for approximately 20 minutes, a thermal safety switch (inside the motor) will automatically shut off the motor. A 2 to 10 minute cool down period is typical before normal operation can resume. Exercise care when opening the rear caliper bleeder screws, due to the high pressure available from a completely charged accumulator at the bleeder screws. Serious injury may result if care is not taken. Bleeding w/Accumulator Charged 1. With accumulator pressure applied to the system, bleed rear brakes by opening rear brake caliper bleed screws for 10 seconds at a time while applying brake pedal with ignition switch in Run position. 2. Repeat step 1 until air-free flow of brake fluid is observed at each caliper. 3. Close bleed screws, then pump brake pedal several times. 4. Adjust brake fluid quantity in reservoir to MAX level with accumulator fully charged. Bleeding w/Pressure Bleeder 1. Attach Rotunda bleeder No. 104-00064, or equivalent, to reservoir cap opening and apply a minimum pressure of 35 psi to system. 2. With brake pedal at rest and ignition switch in Off position, open rear caliper bleed screws for 10 seconds at a time. 3. When an air-free flow of brake fluid is observed at each caliper, close bleed screws and turn ignition switch to Run position. 4. Pump brake pedal several times, then adjust brake fluid quantity in reservoir to MAX level with accumulator fully charged. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Adjustments Brake Pedal Assy: Adjustments Proper adjustment of the master cylinder pushrod is necessary to ensure proper operation of the power brake system. A pushrod that is too long will prevent the master cylinder piston from completely releasing hydraulic pressure, eventually, causing the brakes to drag. A pushrod that is too short will cause excessive brake pedal travel and cause groaning noises to come from the booster when the brakes are applied. A properly adjusted pushrod that remains assembled to the booster with which is was matched during production should not require service adjustment. However, if the booster, master cylinder or pushrod are serviced, the pushrod may require adjustment. If the power unit pushrod requires an adjustment the Power Unit Repair Kit for the unit being serviced includes a gauge. The gauge measures from the end of the pushrod to the power unit shell. On Capri models, push rod length is not adjustable. To ensure the master cylinder is free to return to its rest position with no residual pressure, verify stoplamp switch adjustment. Fig. 1 Master Cylinder Pushrod Adjustment. Bendix Type Vacuum Booster BENDIX TYPE 1. Disconnect master cylinder from booster leaving brake lines connected, and secure cylinder to prevent lines from being damaged. 2. Start engine and operate engine at idle speed. 3. With engine running, position gauge over pushrod. Gauge should bottom against booster housing with a force of approximately 5 lbs. applied to pushrod, Fig. 1. 4. If force required to seat gauge exceeds 5 lb., shorten length of pushrod. If force required to seat gauge is less than 5 lbs., lengthen pushrod. Ensure that pushrod is properly seated in booster when performing gauge check. 5. Install master cylinder, then remove reservoir cover. 6. With engine running, observe fluid surface in reservoir when brakes are applied and released rapidly. If no movement is observed on fluid surface, pushrod is adjusted too long. SINGLE DIAPHRAGM BOOSTER 1. Remove master cylinder as previously outlined. 2. Position master cylinder gauge T87C-2500-A or equivalent on end of master cylinder. 3. Loosen set screw and push gauge plunger against bottom of primary piston. 4. While holding gauge in position, tighten set screw. 5. Invert gauge and place over brake booster push rod, reading should be 0. 6. If clearance is not 0, loosen push rod locknut and adjust push rod. 7. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Brake Pad Wear Sensor > Component Information > Locations Brake Pad Wear Sensor: Locations At Respective Wheels, On Brake Housing Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Recalls: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification Technical Service Bulletin # 89S63 Date: 890601 Recall - Front Suspension Hardware Modification RECALL NUMBER 89S63 Date: June, 1989 TO: All Ford and Lincoln Mercury Dealers SUBJECT: Safety Recall 89S63 - 1989 Thunderbird and Cougar - Extended Brake Pedal Travel AFFECTED VEHICLES 1989 Thunderbird and Cougar - Built from Job # 1 through March 27, 1989 REASONS FOR RECALL EXCESSIVE BRAKE PEDAL TRAVEL During full-lock, low speed turns (less than 5 MPH) the inboard front brake caliper may contact the stabilizer bar or stabilizer link. This can push the front disc caliper piston back and force brake fluid back into the master cylinder reservoir. This results in increased brake pedal travel during the next brake application. After one brake application, the piston is repositioned and proper pedal travel and brake performance is restored. The sequence could repeat, however, following the next low speed full-lock turn. ATTACHMENTS Attachment I - Administrative Information Attachment II - Labor Allowances - Parts Ordering Information Attachment III - Technical Information Attachment I Administrative Information CARES/OASIS YOU MUST USE CARES OR OASIS TO DETERMINE IF A VEHICLEIS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT CONTACT Advise district office if: - an owner cannot be contacted. - an owner does not make a service date FPSD CONTACT Talk with your FPSD Service Zone Manager about recallconcerns. REIMBURSEMENT FORM 1864 Submit 1864 claims for all completed vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Recalls: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5225 WARRANTY AND POLICY MANUAL See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation. Attachment II Parts & Time Information SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) LABOR ALLOWANCES Inspect for Tension Strut Hex Cap Nut 0.1 Hrs. - Insert in Box "A" on Form 1864 Install two Tension Strut Hex Cap Nuts (Includes inspection) 0.3 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS N806301-S150 HEX CAP NUTS SG (pack of 2) ( tension strut) Attachment III Technical Instructions SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Recalls: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5226 TECHNICAL INSTRUCTIONS The front tension strut-to-lower control arm nuts are to be replaced with special acorn type nuts that serve as steering stops and eliminate the potential for caliper contact. INSPECTION/REPLACEMENT PROCEDURE ^ Put car on hoist. ^ Inspect for acorn type nuts on tension strut-to-lower control arm. If acorn type nuts are in place, claim inspection time on Form 1864 and release car from Recall 89S63. ^ If acorn type are not found follow steps listed below for installation. PASSENGER SIDE ^ Turn front wheels to full left and remove tension strut nut from lower control arm on passenger side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). DRIVERS SIDE ^ Turn front wheels to full right and remove tension strut nut from lower control arm on drivers side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). ^ Lower and remove car from hoist. ^ Complete Form 1864 and release car from recall 89S63. Owner Letter Dear Owner: June, 1989 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Thunderbirds and Cougars. Safety Defect During slow speed extreme turns (less than 5 MPH)the right or left front brake caliper may contact a part of the front suspension. If this happens, extended brake pedal travel could occur during the next brake application. This may result in reduced braking capability and increased stopping distance. A vehicle crash may result. Subsequent brake applications will result in normal braking, until another slow speed extreme turn is made. Repairs At no cost to you, your dealer will modify thefront suspension of your car by installing special nuts to eliminate the contact condition. How long will it take? The time needed to repair your car is less than one hour. Call your dealer Call your dealer without delay and ask for a service date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Recalls: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5227 Changed address or sold the car? If you have changed your address or sold the car, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your Owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application Brake Caliper: Customer Interest Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 5233 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 9562 > Mar > 95 > Brakes - Roughness During Application Brake Caliper: All Technical Service Bulletins Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 5239 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification Technical Service Bulletin # 89S63 Date: 890601 Recall - Front Suspension Hardware Modification RECALL NUMBER 89S63 Date: June, 1989 TO: All Ford and Lincoln Mercury Dealers SUBJECT: Safety Recall 89S63 - 1989 Thunderbird and Cougar - Extended Brake Pedal Travel AFFECTED VEHICLES 1989 Thunderbird and Cougar - Built from Job # 1 through March 27, 1989 REASONS FOR RECALL EXCESSIVE BRAKE PEDAL TRAVEL During full-lock, low speed turns (less than 5 MPH) the inboard front brake caliper may contact the stabilizer bar or stabilizer link. This can push the front disc caliper piston back and force brake fluid back into the master cylinder reservoir. This results in increased brake pedal travel during the next brake application. After one brake application, the piston is repositioned and proper pedal travel and brake performance is restored. The sequence could repeat, however, following the next low speed full-lock turn. ATTACHMENTS Attachment I - Administrative Information Attachment II - Labor Allowances - Parts Ordering Information Attachment III - Technical Information Attachment I Administrative Information CARES/OASIS YOU MUST USE CARES OR OASIS TO DETERMINE IF A VEHICLEIS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT CONTACT Advise district office if: - an owner cannot be contacted. - an owner does not make a service date FPSD CONTACT Talk with your FPSD Service Zone Manager about recallconcerns. REIMBURSEMENT FORM 1864 Submit 1864 claims for all completed vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5244 WARRANTY AND POLICY MANUAL See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation. Attachment II Parts & Time Information SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) LABOR ALLOWANCES Inspect for Tension Strut Hex Cap Nut 0.1 Hrs. - Insert in Box "A" on Form 1864 Install two Tension Strut Hex Cap Nuts (Includes inspection) 0.3 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS N806301-S150 HEX CAP NUTS SG (pack of 2) ( tension strut) Attachment III Technical Instructions SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5245 TECHNICAL INSTRUCTIONS The front tension strut-to-lower control arm nuts are to be replaced with special acorn type nuts that serve as steering stops and eliminate the potential for caliper contact. INSPECTION/REPLACEMENT PROCEDURE ^ Put car on hoist. ^ Inspect for acorn type nuts on tension strut-to-lower control arm. If acorn type nuts are in place, claim inspection time on Form 1864 and release car from Recall 89S63. ^ If acorn type are not found follow steps listed below for installation. PASSENGER SIDE ^ Turn front wheels to full left and remove tension strut nut from lower control arm on passenger side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). DRIVERS SIDE ^ Turn front wheels to full right and remove tension strut nut from lower control arm on drivers side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). ^ Lower and remove car from hoist. ^ Complete Form 1864 and release car from recall 89S63. Owner Letter Dear Owner: June, 1989 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Thunderbirds and Cougars. Safety Defect During slow speed extreme turns (less than 5 MPH)the right or left front brake caliper may contact a part of the front suspension. If this happens, extended brake pedal travel could occur during the next brake application. This may result in reduced braking capability and increased stopping distance. A vehicle crash may result. Subsequent brake applications will result in normal braking, until another slow speed extreme turn is made. Repairs At no cost to you, your dealer will modify thefront suspension of your car by installing special nuts to eliminate the contact condition. How long will it take? The time needed to repair your car is less than one hour. Call your dealer Call your dealer without delay and ask for a service date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5246 Changed address or sold the car? If you have changed your address or sold the car, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your Owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 9562 > Mar > 95 > Brakes - Roughness During Application Brake Caliper: All Technical Service Bulletins Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 5252 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification Technical Service Bulletin # 89S63 Date: 890601 Recall - Front Suspension Hardware Modification RECALL NUMBER 89S63 Date: June, 1989 TO: All Ford and Lincoln Mercury Dealers SUBJECT: Safety Recall 89S63 - 1989 Thunderbird and Cougar - Extended Brake Pedal Travel AFFECTED VEHICLES 1989 Thunderbird and Cougar - Built from Job # 1 through March 27, 1989 REASONS FOR RECALL EXCESSIVE BRAKE PEDAL TRAVEL During full-lock, low speed turns (less than 5 MPH) the inboard front brake caliper may contact the stabilizer bar or stabilizer link. This can push the front disc caliper piston back and force brake fluid back into the master cylinder reservoir. This results in increased brake pedal travel during the next brake application. After one brake application, the piston is repositioned and proper pedal travel and brake performance is restored. The sequence could repeat, however, following the next low speed full-lock turn. ATTACHMENTS Attachment I - Administrative Information Attachment II - Labor Allowances - Parts Ordering Information Attachment III - Technical Information Attachment I Administrative Information CARES/OASIS YOU MUST USE CARES OR OASIS TO DETERMINE IF A VEHICLEIS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT CONTACT Advise district office if: - an owner cannot be contacted. - an owner does not make a service date FPSD CONTACT Talk with your FPSD Service Zone Manager about recallconcerns. REIMBURSEMENT FORM 1864 Submit 1864 claims for all completed vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5258 WARRANTY AND POLICY MANUAL See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation. Attachment II Parts & Time Information SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) LABOR ALLOWANCES Inspect for Tension Strut Hex Cap Nut 0.1 Hrs. - Insert in Box "A" on Form 1864 Install two Tension Strut Hex Cap Nuts (Includes inspection) 0.3 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS N806301-S150 HEX CAP NUTS SG (pack of 2) ( tension strut) Attachment III Technical Instructions SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5259 TECHNICAL INSTRUCTIONS The front tension strut-to-lower control arm nuts are to be replaced with special acorn type nuts that serve as steering stops and eliminate the potential for caliper contact. INSPECTION/REPLACEMENT PROCEDURE ^ Put car on hoist. ^ Inspect for acorn type nuts on tension strut-to-lower control arm. If acorn type nuts are in place, claim inspection time on Form 1864 and release car from Recall 89S63. ^ If acorn type are not found follow steps listed below for installation. PASSENGER SIDE ^ Turn front wheels to full left and remove tension strut nut from lower control arm on passenger side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). DRIVERS SIDE ^ Turn front wheels to full right and remove tension strut nut from lower control arm on drivers side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). ^ Lower and remove car from hoist. ^ Complete Form 1864 and release car from recall 89S63. Owner Letter Dear Owner: June, 1989 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Thunderbirds and Cougars. Safety Defect During slow speed extreme turns (less than 5 MPH)the right or left front brake caliper may contact a part of the front suspension. If this happens, extended brake pedal travel could occur during the next brake application. This may result in reduced braking capability and increased stopping distance. A vehicle crash may result. Subsequent brake applications will result in normal braking, until another slow speed extreme turn is made. Repairs At no cost to you, your dealer will modify thefront suspension of your car by installing special nuts to eliminate the contact condition. How long will it take? The time needed to repair your car is less than one hour. Call your dealer Call your dealer without delay and ask for a service date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5260 Changed address or sold the car? If you have changed your address or sold the car, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your Owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Bore Diameter Brake Caliper: Specifications Front 2.87 in Rear 1.789 in Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Specifications > Bore Diameter > Page 5263 Brake Caliper: Specifications Caliper Bolt 80-100 ft.lb Caliper To Knuckle Bolts 44-60 ft.lb Brake Caliper Torx Bolts 25 ft.lb Locating Pins 45-65 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Front Brake Caliper: Description and Operation Front Fig. 1 Front Pin Sliding Disc Brake Caliper Fig. 2 Front Pin Sliding Disc Brake Caliper The caliper assembly consists of a pin slider caliper housing, inner and outer shoe and lining assemblies and a single piston, Figs. 1 and 2. The caliper slides on two pins which also act as attaching bolts between caliper and the combination anchor plate and spindle. The outer brake shoe and lining assembly is longer than the inner brake shoe and lining assembly. Inner and outer shoe and lining assemblies are attached to the caliper by spring clips riveted to the shoe surfaces. The inner shoe is attached to the caliper by installing the spring clip to the inside of the caliper piston. The outer shoe clips directly to the caliper housing. A wear indicator is incorporated which emits a noise when the lining is worn to a point when replacement is necessary. Inner and outer shoes are of left and right hand and are not interchangeable. The inner shoe and lining on Mustang with V8-302 engine has a replaceable single finger anti-rattle clip and an insulator held in position by the clip. The shoe is slotted to accept the snap on clip which loads the assembly against the caliper bridge. The inner shoe on the Mustang with 2300cc engine has a single finger anti-rattle clip, holding the shoe down against the spindle ledge. The clip does not lock into the piston. The insulator is also riveted to the shoe and is not replaceable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Front > Page 5266 Brake Caliper: Description and Operation Rear Fig. 1 Rear Disc Brake Caliper Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Description and Operation > Front > Page 5267 Fig. 2 Rear Disc Brake Caliper Assembly Sliding caliper rear disc brakes are used on Continental, Mark VII & Thunderbird, Figs. 1 and 2. The caliper is basically the same as the larger front wheel caliper, however, a parking brake mechanism and a larger inner brake shoe anti-rattle spring have been added. The parking brake lever, located at the rear of the caliper, is actuated by a cable system similar to rear drum brake applications. When the parking brake is applied, the cable rotates the lever and operating shaft, driving the caliper piston and brake shoe assembly against the rotor. An automatic adjuster in the assembly compensates for lining wear and maintains proper clearance in the parking brake mechanism. The cast iron rotors are ventilated by curved fins located between the braking surfaces and are designed to cause the rotor to act as an air pump when the vehicle is traveling forward. The rotors are not interchangeable and are identified by a Right or Left marking cast inside the hat section of the rotor. The rotor is secured to the axle flange in the same manner as a rear brake drum. A splash shield is bolted to a forged axle adapter to protect the inboard rotor surface. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Disassembly and Assembly Fig. 1 Front Pin Sliding Disc Brake Caliper Fig. 2 Front Pin Sliding Disc Brake Caliper DISASSEMBLY 1. Remove caliper assembly from vehicle as described under Removal/Installation. 2. Position fiber block and shop towels between caliper piston and caliper housing, then apply compressed air to caliper brake line fitting bore to force piston from caliper. 3. Remove dust boot from caliper assembly, Figs. 1 and 2. 4. Remove piston seal from cylinder and discard. INSPECTION 1. Check piston for scratches, scoring or damage. Replace, if necessary. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5270 2. Check caliper bore for scratches, scoring or corrosion. Light scratches or slight corrosion can be polished out using crocus cloth. 3. Check that bleeder screw and bleeder screw bore hole in caliper are fully open. 4. Check caliper bushings for corrosion and dust boot retaining ring for damage or tension loss. Replace parts as necessary. ASSEMBLY 1. Lubricate piston seal with clean brake fluid, then install seal in caliper bore. Ensure seal is firmly seated in groove. 2. Install dust boot in outer groove of caliper bore, Figs. 1 and 2. 3. Coat piston with clean brake fluid and install piston in caliper bore. Spread dust boot over piston as it is installed. Seat dust boot in piston groove. 4. Install caliper assembly as described under Removal/Installation. Removal and Installation REMOVAL Before removing calipers, mark left and right hand calipers so they can be installed in the same position. 1. Raise and support front of vehicle, then remove wheel and tire assembly. 2. Loosen brake tube fitting which connects brake tube to fitting on frame and plug brake tube. Remove retaining clip from brake hose and bracket, then disconnect brake hose from caliper. 3. Remove caliper locating pins. 4. Lift caliper from rotor and spindle anchor plate assembly. On models equipped with phenolic caliper piston, do not pry directly against the piston or damage may result. INSTALLATION 1. Install caliper assembly over rotor with outer shoe against rotor braking surface during installation on spindle and anchor plate to prevent pinching of piston boot between inner brake shoe and piston. Ensure calipers are installed in the correct position. 2. Install locating pins. Torque locating pins to specification. 3. Connect brake hose to caliper and tighten hose fitting. 4. Position upper end of brake hose in bracket and install retaining clip. Remove plug from brake line, then connect brake hose fitting to brake line. 5. Perform system brake bleeding procedures. 6. Install wheel and tire assembly, then lower vehicle. 7. Pump brake pedal several times to position brake shoes before moving vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5271 Brake Caliper: Service and Repair Rear Disassembly and Assembly Fig. 2 Rear Disc Brake Caliper Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5272 Fig. 13 Seating Caliper Piston Fig. 14 Positioning Caliper Piston To Brake Pad Nib Disassembly 1. Remove caliper assembly from vehicle. 2. Position caliper assembly in a soft jawed vise. 3. Using tool No. T75P-2588-B or equivalent, rotate caliper piston counterclockwise to remove from caliper bore, Fig. 13. 4. Remove piston dust boot and seal from caliper piston bore, Fig. 2. 5. Remove snap ring retaining pushrod to caliper. Use care when removing, as the snap ring and spring cover are under spring load. 6. Remove spring cover, spring, washer, key plate and pushrod and strut pin from caliper. 7. Remove O-ring from pushrod. 8. Remove parking brake lever return spring, then remove brake lever stop bolt and pull lever from caliper. Cleaning & Inspection 1. Clean all metal components with isopropyl alcohol. 2. Use compressed air to clean out passages and grooves. 3. Inspect caliper bore for damage and excessive wear. 4. Inspect caliper piston for pitting, scoring or worn plating and replace as necessary. Assembly 1. Apply a light coating of silicone dielectric compound to parking brake lever bore and parking brake lever seal, then position seal into caliper bore, Fig. 2. 2. Apply silicone dielectric compound to parking brake lever shaft, then insert shaft into caliper housing bore. 3. Install O-ring into groove on pushrod, then apply silicone dielectric compound to recesses in pushrod. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5273 4. Place strut pin into caliper housing and into recess of parking brake lever shaft. 5. Position pushrod into caliper housing bore, ensuring strut pin is properly located between shaft recesses and recess at end of pushrod. 6. Position key plate over pushrod, so that washer nib is located in hole in caliper housing. 7. Install flat washer, spring and spring cage into caliper bore. 8. Install snap ring using tool No. T87P-2588-P or equivalent. Ensure snap ring is properly seated in recess. 9. Lubricate replacement piston seal with clean brake fluid, then install seal into caliper bore groove. 10. Lubricate piston and dust boot with clean brake fluid, then install dust boot into caliper bore. 11. Position piston into dust boot, seating dust boot in piston groove. 12. Using tool No. T75P-2588-B or equivalent, turn piston in clockwise direction until piston is fully seated in caliper bore, Fig. 13. 13. Position one of the two slots on the piston so that it will engage the nib on the rear of the disc pad when the caliper is installed, Fig. 14. 14. Install caliper assembly. Removal and Installation REMOVAL 1. Raise and support rear of vehicle, then remove wheel and tire assembly. 2. Disconnect brake hose from caliper assembly. 3. Remove retaining clip, then disconnect parking brake cable from lever arm. 4. Using an open end wrench to hold slider pin in position, remove pinch bolts, Fig. 11. 5. Lift caliper assembly from anchor plate, then remove slider pins and boots. Fig. 12 Positioning Anti-rattle Clips INSTALLATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information > Service and Repair > Front > Page 5274 1. Apply a suitable silicone dielectric compound to slider pins and inside of boots. 2. Place slider pins and boots on anchor plate, then position caliper assembly on anchor plate. Check to be sure that brake pads and anti-rattle springs are properly positioned, Fig. 12. 3. Apply suitable sealer and thread locking compound to pinch bolt threads, then install pinch bolts. While using an open end wrench to hold slider pin in position, torque pinch bolts to specification. 4. Attach parking brake cable to lever arm, then install retaining clip. 5. Using replacement washers, connect brake hose to caliper. Torque retaining bolt to 30-45 ft lbs. 6. Perform system brake bleeding procedures, then install wheel and tire assembly. 7. Cycle brake pedal several times to position brake pads and caliper piston. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Brake Pad Wear Sensor > Component Information > Locations Brake Pad Wear Sensor: Locations At Respective Wheels, On Brake Housing Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Recalls: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement Technical Service Bulletin # 92B11 Date: 921001 Campaign - Front Disc Rotor and Pad Replacement TO: All Ford and Lincoln-Mercury Dealers October, 1992 SUBJECT: Owner Notification Program - 92B11 - Front Disc Brake Roughness on Certain 1989, 1990 and 1991 Thunderbird and Cougar Cars Equipped With 4-Wheel Disc Brakes OASIS - YES OWNER LIST - YES PARTS RETURN - NO PROGRAM COVERAGE- FOR 1 YEAR FROM DATE OF OWNER LETTER AFFECTED VEHICLES: Certain 1989, 1990 and 1991 Thunderbird and Cougar cars equipped with 4-wheel disc brakes. REASONS FOR THIS PROGRAM: We have found that the semi-metallic brake linings installed on some of these cars may be too abrasive. The abrasive linings can cause the rotors to wear unevenly. Cars with this condition may exhibit brake shudder (roughness) during braking causing the car to vibrate and the steering wheel to shake. SERVICE ACTION: Cars returned for this service will have both front brake rotors and linings replaced with new rotors and new non-abrasive linings. REFUNDS: Only for owner-paid repairs made before date of this owner letter. ATTACHMENTS Attachment I Administrative Information Attachment II Labor Allowances - Parts Ordering Information Attachment III Technical Information Administrative Information - Attachment I ATTACHMENT I 92B11 Program OASIS: YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS PROGRAM. PLEASE NOTE: CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT: ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT: Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. FPSD CONTACT: Talk with your FPSD Service Zone Manager about program concerns. FORM 1863: Enter 1863 claims using DWE (or mail direct) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Recalls: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5287 See Warranty and Policy Manual: ^ Section 5.5-1/Section 6.1 - 24 (Owner Notification Programs) OWNER REFUNDS: See Warranty and Policy Manual: Section 6.1 - pages 25 through 26 (Owner Refund) For owner-paid repairs made before date of this Owner Letter. - submit on separate Form 1863 using the codes shown below: Program Code Box - 92B11 Causal Basic Part Number - 2001 Condition Code - 79 Labor Operation (1st line) - REFUND Labor Operation (2nd line) - ALLOW Administrative Allowance - 0.2 Hrs. Customer Concern Code - N99 Labor and Parts Information - Attachment II ATTACHMENT II 92B11 Program OWNER NOTIFICATION PROGRAM 92B11 4-WHEEL DISC BRAKE ROUGHNESS LABOR ALLOWANCES Replace Both Front Brake Rotors, Shoe and Lining Assemblies and Check Rotor Runout...1.5hrs. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Parts prices current until next issue of Master Price Book. For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book. CLAIMS PREPARATIONS ^ Use Form 1863. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Recalls: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5288 ^ Enter using DWE. ^ Use code information shown below: Program Code - 92B11 Causal Basic Part Number - 2001 Condition Code - 79 Labor Operation - B11B Customer Concern Code - N99 Technical Information - Attachment III ATTACHMENT III 92B11 Program OWNER NOTIFICATION PROGRAM 92B11 4-WHEEL DISC BRAKE ROUGHNESS TECHNICAL INSTRUCTIONS Replace the front brake rotors and linings and check the assembly for hub/rotor stacked runout. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on the hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT 1. Clean the hub area that will contact the new rotor. Remove all rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/1990 vehicles and FISZ-1125-A for 1991 vehicles) on the hub. Tighten the lug nuts to 10 lb.ft. (13 N-m) for testing. 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system. See Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeded .002" (.051 mm), rust/contamination could still be trapped between the hub and rotor mounting surface or the rotor and hub (high and low spots) are not properly positioned together. Proceed as follows: a. Remove the rotor and reclean the hub and rotor mounting surfaces. Rotate the rotor on the hub clockwise until the next hole lines up with the stud. b. Secure the rotor in the new position, as described in Step 2 and recheck the runout as described in Step 3. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.051 mm) or less total runout. FRONT BRAKE SHOE AND LINING ASSEMBLY REPLACEMENT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Recalls: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5289 1. Install a new set of non-abrasive front brake shoe and lining assemblies. Only Use front brake shoe and lining kit F1SZ-2001-A. 2. Refer to the appropriate Thunderbird/Cougar Service Manual for service details. MUTILATE AND SCRAP THE REMOVED PARTS. Owner Letter Serial Number: 1FMCA11S6XYZ12345 Date Here Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a no-charge Service Program, Number 92B11, to owners of certain 1989 and 1990 Thunderbird and Cougar cars equipped with 4-wheel disc brakes. REASON FOR THIS PROGRAM: Some cars equipped with 4-wheel disc brakes may exhibit a brake shudder (roughness) during braking causing the car to vibrate and the steering wheel to shake. This problem has returned on some cars that were repaired under a previous Owner Notification Program. We apologize for the inconvenience this second brake program may cause, but we have found that the front brake linings installed on your car may be too abrasive. The abrasive linings can cause the rotors to wear unevenly. We have new improved brake linings for your car and we want to be sure your car has the latest level of parts. NO COST SERVICE: At no cost to you, your dealer will replace both front brake rotors and linings with new rotors and new non-abrasive linings. This no charge service is available for 1 year from the date of this letter. HOW LONG WILL IT TAKE? The time reeded for this service is about two hours. However, due to service scheduling times, your dealer may need your car for one full working day. CALL YOUR DEALER: Ask for a service date and if parts are in stock. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Recalls: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5290 If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS: If you paid to have this service done before the date of this letter, Ford is offering a full refund. For the refund, please show your paid work-order to your Ford or Lincoln-Mercury dealer. FUTURE SERVICE: If the brake linings installed by this service program ever require replacement, use Ford part number F1SZ-2001-A or equivalent to maintain proper performance. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Recalls: > M71901001 > Oct > 90 > Campaign - Brake Rotor/Pad Replacement Technical Service Bulletin # M71901001 Date: 901001 Campaign - Brake Rotor/Pad Replacement TO: All Ford and Lincoln-Mercury Dealers October, 1990 SUBJECT: Owner Notification M71 - Front Disc Brakes Additional Coverage IN CARES/OASIS - NO LISTINGS - NO PROGRAM COVERAGE - 24 MONTHS/24,000 MILES OR THROUGH MAY 31, 1991, WHICHEVER PROVIDES GREATER COVERAGE. REFUND PROVISIONS - YES AFFECTED VEHICLES All 1989 and 1990 Thunderbird and Cougar cars are involved in this program. REASONS FOR The front brake rotors on some of these cars THIS PROGRAM may not be wearing evenly. This condition may cause the car to vibrate and the steering wheel to shake during brake applications. PROGRAM Owners of affected cars will be notified that a PROVISIONS no-charge service program is available if their AND LIMITATIONS cars should experience the described condition. This service will be available for 24 months/ 24,000 miles or through May 31, 1991, whichever provides greater coverage. REFUNDS When all or a portion of the repair covered by the program is paid by the owner and/or the dealer prior to the release of the program, both the owner and/or dealer are eligible for a refund. SERVICE Cars returned for service under this program ACTION will have front brake rotors and shoe and lining assemblies replaced. ATTACHMENTS Attachment I - Administrative Information - Refund Codes Attachment II Labor Allowances - Parts Ordering Information Attachment III Teclinical Information Administration Instructions ATTACHMENT I M Program CARES/OASIS NEITHER CARES NOR OASIS WILL BE IN EFFECT FOR THIS OWNER NOTIFICATION PROGRAM. FPSD CONTACT Talk with your FPSD Service Zone Manager about program concerns. FORM 1863 Enter 1863 claims using DWE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Recalls: > M71901001 > Oct > 90 > Campaign - Brake Rotor/Pad Replacement > Page 5295 See Warranty and Policy Manual: Section 5.5 - 1/Section 6.1 - 19 (Owner Notification Programs) REFUNDS See Warranty and Policy Manual: Section 6.1 - 20 (Owner Refund) For owner or dealer paid repairs made before date of Owner Letter: - submit on separate Form 1863 using the codes shown below: Program Code Box - M71 Causal Basic Part Number - 1125 Condition Code - 67 Labor Operation (1st line) - REFUND Labor Operation (2nd line) - ALLOW Administrative Allowance - 0.2 Hrs. Labor Allowances ATTACHMENT II OWNER NOTIFICATION PROGRAM M71 LABOR ALLOWANCES Scheduled Labor Time(Hours) Operation Verify Brake Roughness Concern ........................ 0.3 Hrs. M71A Replace Front Brake Rotors and Shoe and Lining Assemblies (Includes Verification of Brake Roughness) ...................... 1.5 Hrs. M71B Parts Requirements Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. PART DEALER NUMBER DESCRIPTION CLASS PRICE FOSZ-1L104-A Kit, Front Brake BG $ 61.33 Rotor (Contains (2) Full Cast Rotors and (20) Lug Nuts) FOSZ-2001-A Kit, Front Brake BG $ 64.19 Shoe and Lining (For Cars Equipped With Rear Disc Brakes) F1SZ-2001-A Kit, Front Brake BG $ 64.19 Shoe and Lining (For Cars Equipped With Rear Drum Brakes) Parts prices current until next issue of Master Price Book. For latest prices, check or call your: * Order Processing Center * DOES II * Updated Price Book. CLAIMS PREPARATIONS Use Form 1863. Enter using DWE. Use code information shown below: Program Code - M71 Causal Basic Part Number - 1125 Condition Code - 67 Labor Operations - M71A - M71B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Recalls: > M71901001 > Oct > 90 > Campaign - Brake Rotor/Pad Replacement > Page 5296 Technical Instructions ATTACHMENT III OWNER NOTIFICATION PROGRAM M71 FRONT DISC BRAKES TECHNICAL INSTRUCTIONS Before starting, verify the condition. If the car exhibits brake shudder (roughness) during braking, causing the car to vibrate and the steering wheel to shake, replace the front brake rotors and shoe and lining assemblies as described below. If the car does not exhibit the condition, complete Form 1863 and release the car. 1. Remove both front rotors and front shoe and lining assemblies. Refer to the 1989 or 1990 Thunderbird/Cougar Shop Manual, Section 12-20 for service details. 2. Install the two (2) new design full cast front brake rotor assemblies included in the Front Brake Service Kit, FOSZ-1L104-A. 3. Install a new set of front disc brake shoe and lining assemlies. ^ If the car is equipped with rear disc brakes, use front shoe and lining kit FOSZ-2001-A. ^ If the car is equipped with rear drum brakes, use front shoe and lining kit F1SZ-2001-A. CAUTION: THE NEW FULL CAST FRONT BRAKE ROTOR MOUNTING SURFACE IS 4.4 MM THICKER THAN THE CURRENT DESIGN ROTOR. THEREFORE, IT IS REQUIRED THAT ALL TWENTY (20) WHEEL LUG NUTS BE REPLACED WITH THE TWENTY (20) NEW WHEEL LUG NUTS. IF THE CAR IS EQUIPPED WITH ALUMINUM WHEELS AND LOCKING WHEEL LUG NUTS (ONE PER WHEEL), THESE LOCKING NUTS CAN BE REUSED. 4. Rotate the wheel and tire assemblies. Refer to the rotation instructions in the 1989 or 1990 Thunderbird/Cougar Shop Manual, Section 11-01. NOTE: DO NOT CROSS ROTATE UNI-DIRECTIONAL TIRES. Owner Letter Serial Number IFMCA11S6XYZ12345 October 1990 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a no-charge Service Program, number "M71", to owners of certain 1989-90 model Thunderbird and Cougar cars. REASON FOR The front brake rotors on some of these cars THIS PROGRAM may not be wearing evenly. This condition may cause the car to vibrate and the steering wheel to shake during brake applications. WHAT WE If your car should have this condition, any WILL DO Ford or Lincoln-Mercury dealer will replace the front brake rotors and shoe and lining assemblies. This no-charge service is available for 24 months/24,000 miles or through May 31, 1991, whichever provides greater coverage. WHAT YOU PLEASE KEEP THIS LETTER. If your car should SHOULD DO exhibit the above described condition within the indicated time/mileage limitations, contact your Ford or Lincoln-Mercury dealer. Give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS If you paid to have this service done before the date of this letter, Ford is offering a full refund, including deductible costs. For a refund, please show your paid work-order or parts receipt to your Ford dealer. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford built car. Export Sales Dealer Letter November, 1990 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Recalls: > M71901001 > Oct > 90 > Campaign - Brake Rotor/Pad Replacement > Page 5297 To: All NAAO Export Sales North American Ford Product Dealers in U.S. Federalized Markets and Involved Dealers in non-Federalized Locations All NAAO Export Sales District Offices Service Managers, All Affiliated Ford Motor Companies Subject: Owner Notification Program M71 - Front Disc Brakes Additional Coverage - 1989 and 1990 Thunderbird and Cougar Cars Enclosed are copies of FPSD's Owner Notification Program M71 bulletin applicable to the subject North American Ford built vehicles. If your dealership/location is involved, the applicable VIN listing is included. If not, use the bulletins as information only. Please note that some details in the enclosed bulletins such as parts ordering and claim submission procedures are applicable to U.S. dealers only. A copy of NAAO Export Sales' owner notification letter is attached to this letter. Please observe the following administrative procedures: 1. Parts Orders Order the parts directly from FPSD-IDO, Windsor, Canada using conventional parts ordering procedures. Parts will be reimbursed by submission of warranty claim Form 1863. 2. Reimbursement Only the Form 1863 will be accepted for reimbursement under this campaign. Upon completion of the required service, the Form 1863 must be completely filled out and signed by authorized dealer personnel. Dealers having Direct Warranty Entry (DWE) are to use that method of claims submission. PLEASE ENSURE THAT COPIES OF THIS PROGRAM ANNOUNCEMENT ARE ROUTED TO YOUR PARTS AND SERVICE PERSONNEL. Export Sales Owner Letter Serial Number Ford Motor Company is providing a no-charge Service Program, number "M71", to owners of certain 1989-90 model Thunderbird and Cougar cars. REASON FOR The front brake rotors on some of these cars THIS PROGRAM may not be wearing evenly. This condition may cause the car to vibrate and the steering wheel to shake during brake applications. WHAT WE If your car should have this condition, any WILL DO Ford or Lincoln-Mercury dealer will replace the front brake rotors and shoe and lining assemblies. This no-charge service is available for 24 months/24,000 miles or through May 31, 1991, whichever provides greater coverage. WHAT YOU PLEASE KEEP THIS LETTER. If your car should SHOULD DO exhibit the above described condition within the indicated time/mileage limitations, contact your Ford or Lincoln-Mercury dealer. Give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS If you paid to have this service done before the date of this letter, Ford is offering a full refund, including deductible costs. For a refund, please show your paid work-order or parts receipt to your Ford or Lincoln-Mercury dealer. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction with your Ford built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Recalls: > M71901001 > Oct > 90 > Campaign - Brake Rotor/Pad Replacement > Page 5298 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application Brake Rotor/Disc: Customer Interest Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 5304 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Brake Rotor/Disc: Customer Interest Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 5309 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 5310 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 9562 > Mar > 95 > Brakes Roughness During Application Brake Rotor/Disc: All Technical Service Bulletins Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 9562 > Mar > 95 > Brakes Roughness During Application > Page 5316 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 94252 > Dec > 94 > Brake Rotor Machining Equipment/Warranty Information Brake Rotor/Disc: All Technical Service Bulletins Brake Rotor - Machining Equipment/Warranty Information Article No. 94-25-2 12/12/94 ^ BRAKES - AVAILABILITY OF ON-VEHICLE CALIPER - MOUNTED BRAKE ROTOR MACHINING EQUIPMENT AND WARRANTY COVERAGE INFORMATION ^ BRAKE ROTOR MACHINING - AVAILABILITY OF ON-VEHICLE CALIPER - MOUNTED BRAKE ROTOR MACHINING EQUIPMENT AND WARRANTY COVERAGE INFORMATION FORD: 1979-95 MUSTANG 1981-95 ESCORT 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE, THUNDERBIRD 1991-95 CROWN VICTORIA 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1979-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1988-89 TRACER 1988-95 CONTINENTAL 1989-95 COUGAR 1991-94 CAPRI 1991-95 GRAND MARQUIS, TOWN CAR, TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-90 BRONCO II 1984-95 RANGER 1986-95 AEROSTAR 1990-95 BRONCO, E-150, E-250, F-150, F-250 1991-95 EXPLORER 1993-95 VILLAGER 1995 WINDSTAR This TSB is being republished in its entirety to include the 1994 and 1995 model years. ISSUE: On-vehicle caliper-mounted brake rotor machining equipment from Rotunda is now approved for warranty and service use. Brake roughness, pulsation and steering wheel nibble will occur when rotors wear unevenly (thickness variation). This article specifically addresses brake roughness, pulsation and steering wheel nibble resulting from disc brake rotor thickness variation induced by rotor runout. ACTION: Use Rotunda On-Vehicle Brake Lathes 104-00129, 104-00130, 168-00004, or 168-00005 to service vehicles with brake roughness. This method is more effective because it allows machining of the rotor while it is still mounted on the vehicle. This improves the overall run-out of the assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 94252 > Dec > 94 > Brake Rotor Machining Equipment/Warranty Information > Page 5321 Rotunda on-vehicle caliper-mounted brake rotor machining equipment may correct runout if used according to the equipment manufacturer's instructions. Refer to Figures 1 and 2. Machining the rotor with the use of a caliper-mounted brake lathe will be an eligible repair under warranty for the vehicles listed. NOTE: THERE MAY BE ADDITIONAL MANUFACTURERS OF SIMILAR EQUIPMENT. FORD DOES NOT ENDORSE, INDICATE ANY PREFERENCE FOR, OR ASSUME ANY RESPONSIBILITY FOR EQUIPMENT FROM THESE FIRMS, OR FOR ANY SUCH ITEMS WHICH MAY BE AVAILABLE FROM OTHER SOURCES. NOTE: DEALERS THAT HAVE APPROVED ON-VEHICLE BRAKE ROTOR MACHINING EQUIPMENT ARE REQUIRED TO RESURFACE BRAKE ROTORS UNDER THE BUMPER TO BUMPER COVERAGE PERIOD. IF A DEALER HAS THE ON-VEHICLE BRAKE ROTOR MACHINING EQUIPMENT, ROTOR REPLACEMENT WILL ONLY BE ALLOWED WHEN THE ROTOR IS BROKEN OR DOES NOT HAVE ENOUGH MATERIAL TO ALLOW TURNING. SUCH REPLACEMENTS MUST BE AUTHORIZED BY SERVICE MANAGEMENT. NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 94252 > Dec > 94 > Brake Rotor Machining Equipment/Warranty Information > Page 5322 EXCEPTIONS TO THE LAST STATEMENT ARE REAR ROTORS ON THE TOWN CAR, GRAND MARQUIS, CROWN VICTORIA, MUSTANG AND FRONT ROTORS ON F-350, F-47 AND F-53 HEAVY DUTY LIGHT TRUCKS. ON THESE VEHICLES, ROTORS CANNOT BE MACHINED. SERVICE MANAGEMENT AUTHORIZATION IS NOT REQUIRED FOR THESE EXCEPTIONS. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-13-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement Technical Service Bulletin # 92B11 Date: 921001 Campaign - Front Disc Rotor and Pad Replacement TO: All Ford and Lincoln-Mercury Dealers October, 1992 SUBJECT: Owner Notification Program - 92B11 - Front Disc Brake Roughness on Certain 1989, 1990 and 1991 Thunderbird and Cougar Cars Equipped With 4-Wheel Disc Brakes OASIS - YES OWNER LIST - YES PARTS RETURN - NO PROGRAM COVERAGE- FOR 1 YEAR FROM DATE OF OWNER LETTER AFFECTED VEHICLES: Certain 1989, 1990 and 1991 Thunderbird and Cougar cars equipped with 4-wheel disc brakes. REASONS FOR THIS PROGRAM: We have found that the semi-metallic brake linings installed on some of these cars may be too abrasive. The abrasive linings can cause the rotors to wear unevenly. Cars with this condition may exhibit brake shudder (roughness) during braking causing the car to vibrate and the steering wheel to shake. SERVICE ACTION: Cars returned for this service will have both front brake rotors and linings replaced with new rotors and new non-abrasive linings. REFUNDS: Only for owner-paid repairs made before date of this owner letter. ATTACHMENTS Attachment I Administrative Information Attachment II Labor Allowances - Parts Ordering Information Attachment III Technical Information Administrative Information - Attachment I ATTACHMENT I 92B11 Program OASIS: YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS PROGRAM. PLEASE NOTE: CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT: ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT: Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. FPSD CONTACT: Talk with your FPSD Service Zone Manager about program concerns. FORM 1863: Enter 1863 claims using DWE (or mail direct) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5327 See Warranty and Policy Manual: ^ Section 5.5-1/Section 6.1 - 24 (Owner Notification Programs) OWNER REFUNDS: See Warranty and Policy Manual: Section 6.1 - pages 25 through 26 (Owner Refund) For owner-paid repairs made before date of this Owner Letter. - submit on separate Form 1863 using the codes shown below: Program Code Box - 92B11 Causal Basic Part Number - 2001 Condition Code - 79 Labor Operation (1st line) - REFUND Labor Operation (2nd line) - ALLOW Administrative Allowance - 0.2 Hrs. Customer Concern Code - N99 Labor and Parts Information - Attachment II ATTACHMENT II 92B11 Program OWNER NOTIFICATION PROGRAM 92B11 4-WHEEL DISC BRAKE ROUGHNESS LABOR ALLOWANCES Replace Both Front Brake Rotors, Shoe and Lining Assemblies and Check Rotor Runout...1.5hrs. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Parts prices current until next issue of Master Price Book. For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book. CLAIMS PREPARATIONS ^ Use Form 1863. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5328 ^ Enter using DWE. ^ Use code information shown below: Program Code - 92B11 Causal Basic Part Number - 2001 Condition Code - 79 Labor Operation - B11B Customer Concern Code - N99 Technical Information - Attachment III ATTACHMENT III 92B11 Program OWNER NOTIFICATION PROGRAM 92B11 4-WHEEL DISC BRAKE ROUGHNESS TECHNICAL INSTRUCTIONS Replace the front brake rotors and linings and check the assembly for hub/rotor stacked runout. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on the hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT 1. Clean the hub area that will contact the new rotor. Remove all rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/1990 vehicles and FISZ-1125-A for 1991 vehicles) on the hub. Tighten the lug nuts to 10 lb.ft. (13 N-m) for testing. 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system. See Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeded .002" (.051 mm), rust/contamination could still be trapped between the hub and rotor mounting surface or the rotor and hub (high and low spots) are not properly positioned together. Proceed as follows: a. Remove the rotor and reclean the hub and rotor mounting surfaces. Rotate the rotor on the hub clockwise until the next hole lines up with the stud. b. Secure the rotor in the new position, as described in Step 2 and recheck the runout as described in Step 3. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.051 mm) or less total runout. FRONT BRAKE SHOE AND LINING ASSEMBLY REPLACEMENT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5329 1. Install a new set of non-abrasive front brake shoe and lining assemblies. Only Use front brake shoe and lining kit F1SZ-2001-A. 2. Refer to the appropriate Thunderbird/Cougar Service Manual for service details. MUTILATE AND SCRAP THE REMOVED PARTS. Owner Letter Serial Number: 1FMCA11S6XYZ12345 Date Here Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a no-charge Service Program, Number 92B11, to owners of certain 1989 and 1990 Thunderbird and Cougar cars equipped with 4-wheel disc brakes. REASON FOR THIS PROGRAM: Some cars equipped with 4-wheel disc brakes may exhibit a brake shudder (roughness) during braking causing the car to vibrate and the steering wheel to shake. This problem has returned on some cars that were repaired under a previous Owner Notification Program. We apologize for the inconvenience this second brake program may cause, but we have found that the front brake linings installed on your car may be too abrasive. The abrasive linings can cause the rotors to wear unevenly. We have new improved brake linings for your car and we want to be sure your car has the latest level of parts. NO COST SERVICE: At no cost to you, your dealer will replace both front brake rotors and linings with new rotors and new non-abrasive linings. This no charge service is available for 1 year from the date of this letter. HOW LONG WILL IT TAKE? The time reeded for this service is about two hours. However, due to service scheduling times, your dealer may need your car for one full working day. CALL YOUR DEALER: Ask for a service date and if parts are in stock. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5330 If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS: If you paid to have this service done before the date of this letter, Ford is offering a full refund. For the refund, please show your paid work-order to your Ford or Lincoln-Mercury dealer. FUTURE SERVICE: If the brake linings installed by this service program ever require replacement, use Ford part number F1SZ-2001-A or equivalent to maintain proper performance. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 92124 > Jun > 92 > Brakes Roughness/Runout Check Brake Rotor/Disc: All Technical Service Bulletins Brakes - Roughness/Runout Check Article No. 92-12-4 DATE: 06-03-92 ^ BRAKES-ROTOR-REPLACEMENT SERVICE TIPS ^ BRAKES-ROUGHNESS DEVELOPED FROM INCREASE IN ROTOR RUNOUT ^ WHEELS-LUG NUT TIGHTENING PROCEDURE FORD: 1986-92 TAURUS 1989-92 THUNDERBIRD 1992 CROWN VICTORIA LINCOLN-MERCURY: 1986-92 SABLE 1988-92 CONTINENTAL 1989-92 COUGAR 1991-92 TOWN CAR 1992 GRAND MARQUIS ISSUE: Brake roughness may occur after the lug nuts are installed and tightened with an impact wrench. The resulting torque difference from stud to stud can be as high as 60 lb.ft (81 N-m). This torque difference stud to stud may cause an increase in rotor runout by as much as .003"-.005"(.076mm-.127mm). The increase in rotor runout may speed up the development of brake roughness. ACTION: Tighten the wheel lug nuts in the "final' torque in the sequence described in the Service Manual. Use a torque wrench set to 95 +/- 10 lb.ft (129 +/- l4N-m). When performing brake service work that involves replacing or removing the rotor, refer to the following service procedure which minimizes hub/rotor "stacked" runout, a cause of brake roughness and uneven rotor wear. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new/turned rotor installed on the hub) indicates more then .002" (.05mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. HIGH SYSTEM RUNOUT High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT SERVICE TIPS 1. Completely clean the hub area that will contact the new/turned rotor. Remove rust build up. 2. Install the new/turned rotor on the hub and secure it with at least three (3) lug nuts. Tighten the lug nuts to 20 lb.ft (27 N-m) for testing. 3. Using a dial indicator 4201-C or equivalent, determine the total runout of the system. The total system (rotor and hub) runout must not exceed .002" (.05mm). 4. If the runout exceeds .002" (.05mm), proceed as follows: a. Remove the rotor and rotate it clockwise until the next hole lines up with a stud. b. Secure the rotor in the new position, reindexed as described in Step 2. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.05mm) or less total runout. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 92124 > Jun > 92 > Brakes Roughness/Runout Check > Page 5335 5. If .002" (.05mm) or less runout cannot be reached, the hub should be replaced and Steps 2 through 4 repeated when the new hub/rotor is installed. NOTE: IT IS RECOMMENDED THAT NEW BRAKE ROTORS NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUNOUT AND THICKNESS VARIATION SPECIFICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake Brake Rotor/Disc: All Technical Service Bulletins Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake > Page 5340 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake > Page 5341 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > M71901001 > Oct > 90 > Campaign Brake Rotor/Pad Replacement Technical Service Bulletin # M71901001 Date: 901001 Campaign - Brake Rotor/Pad Replacement TO: All Ford and Lincoln-Mercury Dealers October, 1990 SUBJECT: Owner Notification M71 - Front Disc Brakes Additional Coverage IN CARES/OASIS - NO LISTINGS - NO PROGRAM COVERAGE - 24 MONTHS/24,000 MILES OR THROUGH MAY 31, 1991, WHICHEVER PROVIDES GREATER COVERAGE. REFUND PROVISIONS - YES AFFECTED VEHICLES All 1989 and 1990 Thunderbird and Cougar cars are involved in this program. REASONS FOR The front brake rotors on some of these cars THIS PROGRAM may not be wearing evenly. This condition may cause the car to vibrate and the steering wheel to shake during brake applications. PROGRAM Owners of affected cars will be notified that a PROVISIONS no-charge service program is available if their AND LIMITATIONS cars should experience the described condition. This service will be available for 24 months/ 24,000 miles or through May 31, 1991, whichever provides greater coverage. REFUNDS When all or a portion of the repair covered by the program is paid by the owner and/or the dealer prior to the release of the program, both the owner and/or dealer are eligible for a refund. SERVICE Cars returned for service under this program ACTION will have front brake rotors and shoe and lining assemblies replaced. ATTACHMENTS Attachment I - Administrative Information - Refund Codes Attachment II Labor Allowances - Parts Ordering Information Attachment III Teclinical Information Administration Instructions ATTACHMENT I M Program CARES/OASIS NEITHER CARES NOR OASIS WILL BE IN EFFECT FOR THIS OWNER NOTIFICATION PROGRAM. FPSD CONTACT Talk with your FPSD Service Zone Manager about program concerns. FORM 1863 Enter 1863 claims using DWE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > M71901001 > Oct > 90 > Campaign Brake Rotor/Pad Replacement > Page 5346 See Warranty and Policy Manual: Section 5.5 - 1/Section 6.1 - 19 (Owner Notification Programs) REFUNDS See Warranty and Policy Manual: Section 6.1 - 20 (Owner Refund) For owner or dealer paid repairs made before date of Owner Letter: - submit on separate Form 1863 using the codes shown below: Program Code Box - M71 Causal Basic Part Number - 1125 Condition Code - 67 Labor Operation (1st line) - REFUND Labor Operation (2nd line) - ALLOW Administrative Allowance - 0.2 Hrs. Labor Allowances ATTACHMENT II OWNER NOTIFICATION PROGRAM M71 LABOR ALLOWANCES Scheduled Labor Time(Hours) Operation Verify Brake Roughness Concern ........................ 0.3 Hrs. M71A Replace Front Brake Rotors and Shoe and Lining Assemblies (Includes Verification of Brake Roughness) ...................... 1.5 Hrs. M71B Parts Requirements Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. PART DEALER NUMBER DESCRIPTION CLASS PRICE FOSZ-1L104-A Kit, Front Brake BG $ 61.33 Rotor (Contains (2) Full Cast Rotors and (20) Lug Nuts) FOSZ-2001-A Kit, Front Brake BG $ 64.19 Shoe and Lining (For Cars Equipped With Rear Disc Brakes) F1SZ-2001-A Kit, Front Brake BG $ 64.19 Shoe and Lining (For Cars Equipped With Rear Drum Brakes) Parts prices current until next issue of Master Price Book. For latest prices, check or call your: * Order Processing Center * DOES II * Updated Price Book. CLAIMS PREPARATIONS Use Form 1863. Enter using DWE. Use code information shown below: Program Code - M71 Causal Basic Part Number - 1125 Condition Code - 67 Labor Operations - M71A - M71B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > M71901001 > Oct > 90 > Campaign Brake Rotor/Pad Replacement > Page 5347 Technical Instructions ATTACHMENT III OWNER NOTIFICATION PROGRAM M71 FRONT DISC BRAKES TECHNICAL INSTRUCTIONS Before starting, verify the condition. If the car exhibits brake shudder (roughness) during braking, causing the car to vibrate and the steering wheel to shake, replace the front brake rotors and shoe and lining assemblies as described below. If the car does not exhibit the condition, complete Form 1863 and release the car. 1. Remove both front rotors and front shoe and lining assemblies. Refer to the 1989 or 1990 Thunderbird/Cougar Shop Manual, Section 12-20 for service details. 2. Install the two (2) new design full cast front brake rotor assemblies included in the Front Brake Service Kit, FOSZ-1L104-A. 3. Install a new set of front disc brake shoe and lining assemlies. ^ If the car is equipped with rear disc brakes, use front shoe and lining kit FOSZ-2001-A. ^ If the car is equipped with rear drum brakes, use front shoe and lining kit F1SZ-2001-A. CAUTION: THE NEW FULL CAST FRONT BRAKE ROTOR MOUNTING SURFACE IS 4.4 MM THICKER THAN THE CURRENT DESIGN ROTOR. THEREFORE, IT IS REQUIRED THAT ALL TWENTY (20) WHEEL LUG NUTS BE REPLACED WITH THE TWENTY (20) NEW WHEEL LUG NUTS. IF THE CAR IS EQUIPPED WITH ALUMINUM WHEELS AND LOCKING WHEEL LUG NUTS (ONE PER WHEEL), THESE LOCKING NUTS CAN BE REUSED. 4. Rotate the wheel and tire assemblies. Refer to the rotation instructions in the 1989 or 1990 Thunderbird/Cougar Shop Manual, Section 11-01. NOTE: DO NOT CROSS ROTATE UNI-DIRECTIONAL TIRES. Owner Letter Serial Number IFMCA11S6XYZ12345 October 1990 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a no-charge Service Program, number "M71", to owners of certain 1989-90 model Thunderbird and Cougar cars. REASON FOR The front brake rotors on some of these cars THIS PROGRAM may not be wearing evenly. This condition may cause the car to vibrate and the steering wheel to shake during brake applications. WHAT WE If your car should have this condition, any WILL DO Ford or Lincoln-Mercury dealer will replace the front brake rotors and shoe and lining assemblies. This no-charge service is available for 24 months/24,000 miles or through May 31, 1991, whichever provides greater coverage. WHAT YOU PLEASE KEEP THIS LETTER. If your car should SHOULD DO exhibit the above described condition within the indicated time/mileage limitations, contact your Ford or Lincoln-Mercury dealer. Give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS If you paid to have this service done before the date of this letter, Ford is offering a full refund, including deductible costs. For a refund, please show your paid work-order or parts receipt to your Ford dealer. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford built car. Export Sales Dealer Letter November, 1990 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > M71901001 > Oct > 90 > Campaign Brake Rotor/Pad Replacement > Page 5348 To: All NAAO Export Sales North American Ford Product Dealers in U.S. Federalized Markets and Involved Dealers in non-Federalized Locations All NAAO Export Sales District Offices Service Managers, All Affiliated Ford Motor Companies Subject: Owner Notification Program M71 - Front Disc Brakes Additional Coverage - 1989 and 1990 Thunderbird and Cougar Cars Enclosed are copies of FPSD's Owner Notification Program M71 bulletin applicable to the subject North American Ford built vehicles. If your dealership/location is involved, the applicable VIN listing is included. If not, use the bulletins as information only. Please note that some details in the enclosed bulletins such as parts ordering and claim submission procedures are applicable to U.S. dealers only. A copy of NAAO Export Sales' owner notification letter is attached to this letter. Please observe the following administrative procedures: 1. Parts Orders Order the parts directly from FPSD-IDO, Windsor, Canada using conventional parts ordering procedures. Parts will be reimbursed by submission of warranty claim Form 1863. 2. Reimbursement Only the Form 1863 will be accepted for reimbursement under this campaign. Upon completion of the required service, the Form 1863 must be completely filled out and signed by authorized dealer personnel. Dealers having Direct Warranty Entry (DWE) are to use that method of claims submission. PLEASE ENSURE THAT COPIES OF THIS PROGRAM ANNOUNCEMENT ARE ROUTED TO YOUR PARTS AND SERVICE PERSONNEL. Export Sales Owner Letter Serial Number Ford Motor Company is providing a no-charge Service Program, number "M71", to owners of certain 1989-90 model Thunderbird and Cougar cars. REASON FOR The front brake rotors on some of these cars THIS PROGRAM may not be wearing evenly. This condition may cause the car to vibrate and the steering wheel to shake during brake applications. WHAT WE If your car should have this condition, any WILL DO Ford or Lincoln-Mercury dealer will replace the front brake rotors and shoe and lining assemblies. This no-charge service is available for 24 months/24,000 miles or through May 31, 1991, whichever provides greater coverage. WHAT YOU PLEASE KEEP THIS LETTER. If your car should SHOULD DO exhibit the above described condition within the indicated time/mileage limitations, contact your Ford or Lincoln-Mercury dealer. Give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS If you paid to have this service done before the date of this letter, Ford is offering a full refund, including deductible costs. For a refund, please show your paid work-order or parts receipt to your Ford or Lincoln-Mercury dealer. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction with your Ford built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > M71901001 > Oct > 90 > Campaign Brake Rotor/Pad Replacement > Page 5349 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Rotor/Disc: > 90199 > Sep > 90 > Lug Nuts Proper Torqueing Procedure Brake Rotor/Disc: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 9562 > Mar > 95 > Brakes - Roughness During Application Brake Rotor/Disc: All Technical Service Bulletins Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 5359 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 94252 > Dec > 94 > Brake Rotor Machining Equipment/Warranty Information Brake Rotor/Disc: All Technical Service Bulletins Brake Rotor - Machining Equipment/Warranty Information Article No. 94-25-2 12/12/94 ^ BRAKES - AVAILABILITY OF ON-VEHICLE CALIPER - MOUNTED BRAKE ROTOR MACHINING EQUIPMENT AND WARRANTY COVERAGE INFORMATION ^ BRAKE ROTOR MACHINING - AVAILABILITY OF ON-VEHICLE CALIPER - MOUNTED BRAKE ROTOR MACHINING EQUIPMENT AND WARRANTY COVERAGE INFORMATION FORD: 1979-95 MUSTANG 1981-95 ESCORT 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE, THUNDERBIRD 1991-95 CROWN VICTORIA 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1979-86 CAPRI 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1988-89 TRACER 1988-95 CONTINENTAL 1989-95 COUGAR 1991-94 CAPRI 1991-95 GRAND MARQUIS, TOWN CAR, TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1984-90 BRONCO II 1984-95 RANGER 1986-95 AEROSTAR 1990-95 BRONCO, E-150, E-250, F-150, F-250 1991-95 EXPLORER 1993-95 VILLAGER 1995 WINDSTAR This TSB is being republished in its entirety to include the 1994 and 1995 model years. ISSUE: On-vehicle caliper-mounted brake rotor machining equipment from Rotunda is now approved for warranty and service use. Brake roughness, pulsation and steering wheel nibble will occur when rotors wear unevenly (thickness variation). This article specifically addresses brake roughness, pulsation and steering wheel nibble resulting from disc brake rotor thickness variation induced by rotor runout. ACTION: Use Rotunda On-Vehicle Brake Lathes 104-00129, 104-00130, 168-00004, or 168-00005 to service vehicles with brake roughness. This method is more effective because it allows machining of the rotor while it is still mounted on the vehicle. This improves the overall run-out of the assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 94252 > Dec > 94 > Brake Rotor Machining Equipment/Warranty Information > Page 5364 Rotunda on-vehicle caliper-mounted brake rotor machining equipment may correct runout if used according to the equipment manufacturer's instructions. Refer to Figures 1 and 2. Machining the rotor with the use of a caliper-mounted brake lathe will be an eligible repair under warranty for the vehicles listed. NOTE: THERE MAY BE ADDITIONAL MANUFACTURERS OF SIMILAR EQUIPMENT. FORD DOES NOT ENDORSE, INDICATE ANY PREFERENCE FOR, OR ASSUME ANY RESPONSIBILITY FOR EQUIPMENT FROM THESE FIRMS, OR FOR ANY SUCH ITEMS WHICH MAY BE AVAILABLE FROM OTHER SOURCES. NOTE: DEALERS THAT HAVE APPROVED ON-VEHICLE BRAKE ROTOR MACHINING EQUIPMENT ARE REQUIRED TO RESURFACE BRAKE ROTORS UNDER THE BUMPER TO BUMPER COVERAGE PERIOD. IF A DEALER HAS THE ON-VEHICLE BRAKE ROTOR MACHINING EQUIPMENT, ROTOR REPLACEMENT WILL ONLY BE ALLOWED WHEN THE ROTOR IS BROKEN OR DOES NOT HAVE ENOUGH MATERIAL TO ALLOW TURNING. SUCH REPLACEMENTS MUST BE AUTHORIZED BY SERVICE MANAGEMENT. NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 94252 > Dec > 94 > Brake Rotor Machining Equipment/Warranty Information > Page 5365 EXCEPTIONS TO THE LAST STATEMENT ARE REAR ROTORS ON THE TOWN CAR, GRAND MARQUIS, CROWN VICTORIA, MUSTANG AND FRONT ROTORS ON F-350, F-47 AND F-53 HEAVY DUTY LIGHT TRUCKS. ON THESE VEHICLES, ROTORS CANNOT BE MACHINED. SERVICE MANAGEMENT AUTHORIZATION IS NOT REQUIRED FOR THESE EXCEPTIONS. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-13-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 92124 > Jun > 92 > Brakes Roughness/Runout Check Brake Rotor/Disc: All Technical Service Bulletins Brakes - Roughness/Runout Check Article No. 92-12-4 DATE: 06-03-92 ^ BRAKES-ROTOR-REPLACEMENT SERVICE TIPS ^ BRAKES-ROUGHNESS DEVELOPED FROM INCREASE IN ROTOR RUNOUT ^ WHEELS-LUG NUT TIGHTENING PROCEDURE FORD: 1986-92 TAURUS 1989-92 THUNDERBIRD 1992 CROWN VICTORIA LINCOLN-MERCURY: 1986-92 SABLE 1988-92 CONTINENTAL 1989-92 COUGAR 1991-92 TOWN CAR 1992 GRAND MARQUIS ISSUE: Brake roughness may occur after the lug nuts are installed and tightened with an impact wrench. The resulting torque difference from stud to stud can be as high as 60 lb.ft (81 N-m). This torque difference stud to stud may cause an increase in rotor runout by as much as .003"-.005"(.076mm-.127mm). The increase in rotor runout may speed up the development of brake roughness. ACTION: Tighten the wheel lug nuts in the "final' torque in the sequence described in the Service Manual. Use a torque wrench set to 95 +/- 10 lb.ft (129 +/- l4N-m). When performing brake service work that involves replacing or removing the rotor, refer to the following service procedure which minimizes hub/rotor "stacked" runout, a cause of brake roughness and uneven rotor wear. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new/turned rotor installed on the hub) indicates more then .002" (.05mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. HIGH SYSTEM RUNOUT High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT SERVICE TIPS 1. Completely clean the hub area that will contact the new/turned rotor. Remove rust build up. 2. Install the new/turned rotor on the hub and secure it with at least three (3) lug nuts. Tighten the lug nuts to 20 lb.ft (27 N-m) for testing. 3. Using a dial indicator 4201-C or equivalent, determine the total runout of the system. The total system (rotor and hub) runout must not exceed .002" (.05mm). 4. If the runout exceeds .002" (.05mm), proceed as follows: a. Remove the rotor and rotate it clockwise until the next hole lines up with a stud. b. Secure the rotor in the new position, reindexed as described in Step 2. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.05mm) or less total runout. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 92124 > Jun > 92 > Brakes Roughness/Runout Check > Page 5370 5. If .002" (.05mm) or less runout cannot be reached, the hub should be replaced and Steps 2 through 4 repeated when the new hub/rotor is installed. NOTE: IT IS RECOMMENDED THAT NEW BRAKE ROTORS NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUNOUT AND THICKNESS VARIATION SPECIFICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake Brake Rotor/Disc: All Technical Service Bulletins Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake > Page 5375 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake > Page 5376 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Brake Rotor/Disc: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 94252 > Dec > 94 > Brake Rotor Machining Equipment/Warranty Information > Page 5386 Rotunda on-vehicle caliper-mounted brake rotor machining equipment may correct runout if used according to the equipment manufacturer's instructions. Refer to Figures 1 and 2. Machining the rotor with the use of a caliper-mounted brake lathe will be an eligible repair under warranty for the vehicles listed. NOTE: THERE MAY BE ADDITIONAL MANUFACTURERS OF SIMILAR EQUIPMENT. FORD DOES NOT ENDORSE, INDICATE ANY PREFERENCE FOR, OR ASSUME ANY RESPONSIBILITY FOR EQUIPMENT FROM THESE FIRMS, OR FOR ANY SUCH ITEMS WHICH MAY BE AVAILABLE FROM OTHER SOURCES. NOTE: DEALERS THAT HAVE APPROVED ON-VEHICLE BRAKE ROTOR MACHINING EQUIPMENT ARE REQUIRED TO RESURFACE BRAKE ROTORS UNDER THE BUMPER TO BUMPER COVERAGE PERIOD. IF A DEALER HAS THE ON-VEHICLE BRAKE ROTOR MACHINING EQUIPMENT, ROTOR REPLACEMENT WILL ONLY BE ALLOWED WHEN THE ROTOR IS BROKEN OR DOES NOT HAVE ENOUGH MATERIAL TO ALLOW TURNING. SUCH REPLACEMENTS MUST BE AUTHORIZED BY SERVICE MANAGEMENT. NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 94252 > Dec > 94 > Brake Rotor Machining Equipment/Warranty Information > Page 5387 EXCEPTIONS TO THE LAST STATEMENT ARE REAR ROTORS ON THE TOWN CAR, GRAND MARQUIS, CROWN VICTORIA, MUSTANG AND FRONT ROTORS ON F-350, F-47 AND F-53 HEAVY DUTY LIGHT TRUCKS. ON THESE VEHICLES, ROTORS CANNOT BE MACHINED. SERVICE MANAGEMENT AUTHORIZATION IS NOT REQUIRED FOR THESE EXCEPTIONS. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-13-3 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement Technical Service Bulletin # 92B11 Date: 921001 Campaign - Front Disc Rotor and Pad Replacement TO: All Ford and Lincoln-Mercury Dealers October, 1992 SUBJECT: Owner Notification Program - 92B11 - Front Disc Brake Roughness on Certain 1989, 1990 and 1991 Thunderbird and Cougar Cars Equipped With 4-Wheel Disc Brakes OASIS - YES OWNER LIST - YES PARTS RETURN - NO PROGRAM COVERAGE- FOR 1 YEAR FROM DATE OF OWNER LETTER AFFECTED VEHICLES: Certain 1989, 1990 and 1991 Thunderbird and Cougar cars equipped with 4-wheel disc brakes. REASONS FOR THIS PROGRAM: We have found that the semi-metallic brake linings installed on some of these cars may be too abrasive. The abrasive linings can cause the rotors to wear unevenly. Cars with this condition may exhibit brake shudder (roughness) during braking causing the car to vibrate and the steering wheel to shake. SERVICE ACTION: Cars returned for this service will have both front brake rotors and linings replaced with new rotors and new non-abrasive linings. REFUNDS: Only for owner-paid repairs made before date of this owner letter. ATTACHMENTS Attachment I Administrative Information Attachment II Labor Allowances - Parts Ordering Information Attachment III Technical Information Administrative Information - Attachment I ATTACHMENT I 92B11 Program OASIS: YOU MUST USE OASIS TO DETERMINE IF A VEHICLE IS ELIGIBLE FOR THIS PROGRAM. PLEASE NOTE: CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT: ^ Affected vehicles on the enclosed list. ^ Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT: Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. Arrange with the owner for a service date. FPSD CONTACT: Talk with your FPSD Service Zone Manager about program concerns. FORM 1863: Enter 1863 claims using DWE (or mail direct) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5392 See Warranty and Policy Manual: ^ Section 5.5-1/Section 6.1 - 24 (Owner Notification Programs) OWNER REFUNDS: See Warranty and Policy Manual: Section 6.1 - pages 25 through 26 (Owner Refund) For owner-paid repairs made before date of this Owner Letter. - submit on separate Form 1863 using the codes shown below: Program Code Box - 92B11 Causal Basic Part Number - 2001 Condition Code - 79 Labor Operation (1st line) - REFUND Labor Operation (2nd line) - ALLOW Administrative Allowance - 0.2 Hrs. Customer Concern Code - N99 Labor and Parts Information - Attachment II ATTACHMENT II 92B11 Program OWNER NOTIFICATION PROGRAM 92B11 4-WHEEL DISC BRAKE ROUGHNESS LABOR ALLOWANCES Replace Both Front Brake Rotors, Shoe and Lining Assemblies and Check Rotor Runout...1.5hrs. PARTS REQUIREMENTS Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. Parts prices current until next issue of Master Price Book. For latest prices, check or call your: ^ Order Processing Center ^ DOES II ^ Updated Price Book. CLAIMS PREPARATIONS ^ Use Form 1863. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5393 ^ Enter using DWE. ^ Use code information shown below: Program Code - 92B11 Causal Basic Part Number - 2001 Condition Code - 79 Labor Operation - B11B Customer Concern Code - N99 Technical Information - Attachment III ATTACHMENT III 92B11 Program OWNER NOTIFICATION PROGRAM 92B11 4-WHEEL DISC BRAKE ROUGHNESS TECHNICAL INSTRUCTIONS Replace the front brake rotors and linings and check the assembly for hub/rotor stacked runout. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on the hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT 1. Clean the hub area that will contact the new rotor. Remove all rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/1990 vehicles and FISZ-1125-A for 1991 vehicles) on the hub. Tighten the lug nuts to 10 lb.ft. (13 N-m) for testing. 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system. See Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeded .002" (.051 mm), rust/contamination could still be trapped between the hub and rotor mounting surface or the rotor and hub (high and low spots) are not properly positioned together. Proceed as follows: a. Remove the rotor and reclean the hub and rotor mounting surfaces. Rotate the rotor on the hub clockwise until the next hole lines up with the stud. b. Secure the rotor in the new position, as described in Step 2 and recheck the runout as described in Step 3. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.051 mm) or less total runout. FRONT BRAKE SHOE AND LINING ASSEMBLY REPLACEMENT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5394 1. Install a new set of non-abrasive front brake shoe and lining assemblies. Only Use front brake shoe and lining kit F1SZ-2001-A. 2. Refer to the appropriate Thunderbird/Cougar Service Manual for service details. MUTILATE AND SCRAP THE REMOVED PARTS. Owner Letter Serial Number: 1FMCA11S6XYZ12345 Date Here Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a no-charge Service Program, Number 92B11, to owners of certain 1989 and 1990 Thunderbird and Cougar cars equipped with 4-wheel disc brakes. REASON FOR THIS PROGRAM: Some cars equipped with 4-wheel disc brakes may exhibit a brake shudder (roughness) during braking causing the car to vibrate and the steering wheel to shake. This problem has returned on some cars that were repaired under a previous Owner Notification Program. We apologize for the inconvenience this second brake program may cause, but we have found that the front brake linings installed on your car may be too abrasive. The abrasive linings can cause the rotors to wear unevenly. We have new improved brake linings for your car and we want to be sure your car has the latest level of parts. NO COST SERVICE: At no cost to you, your dealer will replace both front brake rotors and linings with new rotors and new non-abrasive linings. This no charge service is available for 1 year from the date of this letter. HOW LONG WILL IT TAKE? The time reeded for this service is about two hours. However, due to service scheduling times, your dealer may need your car for one full working day. CALL YOUR DEALER: Ask for a service date and if parts are in stock. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 92B11 > Oct > 92 > Campaign - Front Disc Rotor and Pad Replacement > Page 5395 If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS: If you paid to have this service done before the date of this letter, Ford is offering a full refund. For the refund, please show your paid work-order to your Ford or Lincoln-Mercury dealer. FUTURE SERVICE: If the brake linings installed by this service program ever require replacement, use Ford part number F1SZ-2001-A or equivalent to maintain proper performance. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > 92124 > Jun > 92 > Brakes Roughness/Runout Check > Page 5400 5. If .002" (.05mm) or less runout cannot be reached, the hub should be replaced and Steps 2 through 4 repeated when the new hub/rotor is installed. NOTE: IT IS RECOMMENDED THAT NEW BRAKE ROTORS NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUNOUT AND THICKNESS VARIATION SPECIFICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > M71901001 > Oct > 90 > Campaign Brake Rotor/Pad Replacement Technical Service Bulletin # M71901001 Date: 901001 Campaign - Brake Rotor/Pad Replacement TO: All Ford and Lincoln-Mercury Dealers October, 1990 SUBJECT: Owner Notification M71 - Front Disc Brakes Additional Coverage IN CARES/OASIS - NO LISTINGS - NO PROGRAM COVERAGE - 24 MONTHS/24,000 MILES OR THROUGH MAY 31, 1991, WHICHEVER PROVIDES GREATER COVERAGE. REFUND PROVISIONS - YES AFFECTED VEHICLES All 1989 and 1990 Thunderbird and Cougar cars are involved in this program. REASONS FOR The front brake rotors on some of these cars THIS PROGRAM may not be wearing evenly. This condition may cause the car to vibrate and the steering wheel to shake during brake applications. PROGRAM Owners of affected cars will be notified that a PROVISIONS no-charge service program is available if their AND LIMITATIONS cars should experience the described condition. This service will be available for 24 months/ 24,000 miles or through May 31, 1991, whichever provides greater coverage. REFUNDS When all or a portion of the repair covered by the program is paid by the owner and/or the dealer prior to the release of the program, both the owner and/or dealer are eligible for a refund. SERVICE Cars returned for service under this program ACTION will have front brake rotors and shoe and lining assemblies replaced. ATTACHMENTS Attachment I - Administrative Information - Refund Codes Attachment II Labor Allowances - Parts Ordering Information Attachment III Teclinical Information Administration Instructions ATTACHMENT I M Program CARES/OASIS NEITHER CARES NOR OASIS WILL BE IN EFFECT FOR THIS OWNER NOTIFICATION PROGRAM. FPSD CONTACT Talk with your FPSD Service Zone Manager about program concerns. FORM 1863 Enter 1863 claims using DWE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > M71901001 > Oct > 90 > Campaign Brake Rotor/Pad Replacement > Page 5405 See Warranty and Policy Manual: Section 5.5 - 1/Section 6.1 - 19 (Owner Notification Programs) REFUNDS See Warranty and Policy Manual: Section 6.1 - 20 (Owner Refund) For owner or dealer paid repairs made before date of Owner Letter: - submit on separate Form 1863 using the codes shown below: Program Code Box - M71 Causal Basic Part Number - 1125 Condition Code - 67 Labor Operation (1st line) - REFUND Labor Operation (2nd line) - ALLOW Administrative Allowance - 0.2 Hrs. Labor Allowances ATTACHMENT II OWNER NOTIFICATION PROGRAM M71 LABOR ALLOWANCES Scheduled Labor Time(Hours) Operation Verify Brake Roughness Concern ........................ 0.3 Hrs. M71A Replace Front Brake Rotors and Shoe and Lining Assemblies (Includes Verification of Brake Roughness) ...................... 1.5 Hrs. M71B Parts Requirements Parts will not be direct shipped for this program. Order your parts requirements through normal order processing channels. PART DEALER NUMBER DESCRIPTION CLASS PRICE FOSZ-1L104-A Kit, Front Brake BG $ 61.33 Rotor (Contains (2) Full Cast Rotors and (20) Lug Nuts) FOSZ-2001-A Kit, Front Brake BG $ 64.19 Shoe and Lining (For Cars Equipped With Rear Disc Brakes) F1SZ-2001-A Kit, Front Brake BG $ 64.19 Shoe and Lining (For Cars Equipped With Rear Drum Brakes) Parts prices current until next issue of Master Price Book. For latest prices, check or call your: * Order Processing Center * DOES II * Updated Price Book. CLAIMS PREPARATIONS Use Form 1863. Enter using DWE. Use code information shown below: Program Code - M71 Causal Basic Part Number - 1125 Condition Code - 67 Labor Operations - M71A - M71B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > M71901001 > Oct > 90 > Campaign Brake Rotor/Pad Replacement > Page 5406 Technical Instructions ATTACHMENT III OWNER NOTIFICATION PROGRAM M71 FRONT DISC BRAKES TECHNICAL INSTRUCTIONS Before starting, verify the condition. If the car exhibits brake shudder (roughness) during braking, causing the car to vibrate and the steering wheel to shake, replace the front brake rotors and shoe and lining assemblies as described below. If the car does not exhibit the condition, complete Form 1863 and release the car. 1. Remove both front rotors and front shoe and lining assemblies. Refer to the 1989 or 1990 Thunderbird/Cougar Shop Manual, Section 12-20 for service details. 2. Install the two (2) new design full cast front brake rotor assemblies included in the Front Brake Service Kit, FOSZ-1L104-A. 3. Install a new set of front disc brake shoe and lining assemlies. ^ If the car is equipped with rear disc brakes, use front shoe and lining kit FOSZ-2001-A. ^ If the car is equipped with rear drum brakes, use front shoe and lining kit F1SZ-2001-A. CAUTION: THE NEW FULL CAST FRONT BRAKE ROTOR MOUNTING SURFACE IS 4.4 MM THICKER THAN THE CURRENT DESIGN ROTOR. THEREFORE, IT IS REQUIRED THAT ALL TWENTY (20) WHEEL LUG NUTS BE REPLACED WITH THE TWENTY (20) NEW WHEEL LUG NUTS. IF THE CAR IS EQUIPPED WITH ALUMINUM WHEELS AND LOCKING WHEEL LUG NUTS (ONE PER WHEEL), THESE LOCKING NUTS CAN BE REUSED. 4. Rotate the wheel and tire assemblies. Refer to the rotation instructions in the 1989 or 1990 Thunderbird/Cougar Shop Manual, Section 11-01. NOTE: DO NOT CROSS ROTATE UNI-DIRECTIONAL TIRES. Owner Letter Serial Number IFMCA11S6XYZ12345 October 1990 Mr. John Sample 123 Main Street Anywhere, USA 12345 Ford Motor Company is providing a no-charge Service Program, number "M71", to owners of certain 1989-90 model Thunderbird and Cougar cars. REASON FOR The front brake rotors on some of these cars THIS PROGRAM may not be wearing evenly. This condition may cause the car to vibrate and the steering wheel to shake during brake applications. WHAT WE If your car should have this condition, any WILL DO Ford or Lincoln-Mercury dealer will replace the front brake rotors and shoe and lining assemblies. This no-charge service is available for 24 months/24,000 miles or through May 31, 1991, whichever provides greater coverage. WHAT YOU PLEASE KEEP THIS LETTER. If your car should SHOULD DO exhibit the above described condition within the indicated time/mileage limitations, contact your Ford or Lincoln-Mercury dealer. Give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS If you paid to have this service done before the date of this letter, Ford is offering a full refund, including deductible costs. For a refund, please show your paid work-order or parts receipt to your Ford dealer. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction in your Ford built car. Export Sales Dealer Letter November, 1990 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > M71901001 > Oct > 90 > Campaign Brake Rotor/Pad Replacement > Page 5407 To: All NAAO Export Sales North American Ford Product Dealers in U.S. Federalized Markets and Involved Dealers in non-Federalized Locations All NAAO Export Sales District Offices Service Managers, All Affiliated Ford Motor Companies Subject: Owner Notification Program M71 - Front Disc Brakes Additional Coverage - 1989 and 1990 Thunderbird and Cougar Cars Enclosed are copies of FPSD's Owner Notification Program M71 bulletin applicable to the subject North American Ford built vehicles. If your dealership/location is involved, the applicable VIN listing is included. If not, use the bulletins as information only. Please note that some details in the enclosed bulletins such as parts ordering and claim submission procedures are applicable to U.S. dealers only. A copy of NAAO Export Sales' owner notification letter is attached to this letter. Please observe the following administrative procedures: 1. Parts Orders Order the parts directly from FPSD-IDO, Windsor, Canada using conventional parts ordering procedures. Parts will be reimbursed by submission of warranty claim Form 1863. 2. Reimbursement Only the Form 1863 will be accepted for reimbursement under this campaign. Upon completion of the required service, the Form 1863 must be completely filled out and signed by authorized dealer personnel. Dealers having Direct Warranty Entry (DWE) are to use that method of claims submission. PLEASE ENSURE THAT COPIES OF THIS PROGRAM ANNOUNCEMENT ARE ROUTED TO YOUR PARTS AND SERVICE PERSONNEL. Export Sales Owner Letter Serial Number Ford Motor Company is providing a no-charge Service Program, number "M71", to owners of certain 1989-90 model Thunderbird and Cougar cars. REASON FOR The front brake rotors on some of these cars THIS PROGRAM may not be wearing evenly. This condition may cause the car to vibrate and the steering wheel to shake during brake applications. WHAT WE If your car should have this condition, any WILL DO Ford or Lincoln-Mercury dealer will replace the front brake rotors and shoe and lining assemblies. This no-charge service is available for 24 months/24,000 miles or through May 31, 1991, whichever provides greater coverage. WHAT YOU PLEASE KEEP THIS LETTER. If your car should SHOULD DO exhibit the above described condition within the indicated time/mileage limitations, contact your Ford or Lincoln-Mercury dealer. Give the dealer this letter. If you misplace this letter, your dealer will still do the work, free of charge. REFUNDS If you paid to have this service done before the date of this letter, Ford is offering a full refund, including deductible costs. For a refund, please show your paid work-order or parts receipt to your Ford or Lincoln-Mercury dealer. We are taking this action as part of our ongoing efforts to maintain owner confidence in our products. We hope this program will confirm your continued satisfaction with your Ford built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Rotor/Disc: > M71901001 > Oct > 90 > Campaign Brake Rotor/Pad Replacement > Page 5408 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc Brake Rotor/Disc: Specifications Brake Rotor/Disc Nominal Thickness 1.03 in Minimum Refinish Thickness 0.972 in Thickness Variation (Parallelism) 0.0005 in Lateral Run-out (T.I.R.) 0.003 in Finish 15-125 micro-in Splash Shield To Knuckle Bolts 45-59 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component Information > Specifications > Brake Rotor/Disc > Page 5415 Brake Rotor/Disc: Specifications Splash Shield Attaching Bolts 10-15 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > Customer Interest for Brake Drum: > 9363 > Mar > 93 > Rear Brakes - Pedal Pulsation Brake Drum: Customer Interest Rear Brakes - Pedal Pulsation Article No. 93-6-3 03/17/93 BRAKES - REAR - BRAKE PEDAL PULSATION FROM DRUM ROUGHNESS FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR ISSUE: Rear brake drum roughness may occur because of the rear drum's manufacturing tolerances. ACTION: Install new rear brake drums in axle sets which are manufactured to revised tolerances to minimize rear brake roughness. Refer to the 1989-91 Thunderbird/Cougar Service Manual, Section 12-02, or the 1992-93 Thunderbird/Cougar Service Manual, Section 06-02, for service details. PART NUMBER PART NAME CLASS F3SZ-1126-A Brake Drums C OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper For 1992/93 Vehicles, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 930603A Replace Both Drums 0.6 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 1126 11 OASIS CODES: 203000, 301000, 703400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Drum: > 9363 > Mar > 93 > Rear Brakes - Pedal Pulsation Brake Drum: All Technical Service Bulletins Rear Brakes - Pedal Pulsation Article No. 93-6-3 03/17/93 BRAKES - REAR - BRAKE PEDAL PULSATION FROM DRUM ROUGHNESS FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR ISSUE: Rear brake drum roughness may occur because of the rear drum's manufacturing tolerances. ACTION: Install new rear brake drums in axle sets which are manufactured to revised tolerances to minimize rear brake roughness. Refer to the 1989-91 Thunderbird/Cougar Service Manual, Section 12-02, or the 1992-93 Thunderbird/Cougar Service Manual, Section 06-02, for service details. PART NUMBER PART NAME CLASS F3SZ-1126-A Brake Drums C OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper For 1992/93 Vehicles, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 930603A Replace Both Drums 0.6 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 1126 11 OASIS CODES: 203000, 301000, 703400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Drum Deminsions Brake Drum: Specifications Except Heavy Duty Inside Diameter 9 in Bore Limit (Maximum) 9.06 in Maximum Run-out 0.007 in Heavy Duty Inside Diameter 10 in Bore Limit (Maximum) 10.06 in Maximum Run-out 0.007 in Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Drum Deminsions > Page 5432 Brake Drum: Specifications Except Station Wagon, Brake Drum Dimensions Except Station Wagon, Brake Drum Dimensions Inside Diameter 10 in Bore Limit (Maximum) 10.03 in Maximum Run-out 0.007 in Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 5433 Brake Drum: Testing and Inspection BRAKE DRUMS Any time the brake drums are removed for brake service, the braking surface diameter should be checked with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Minor scores should be removed with sandpaper. Grooves and large scores can only be removed by machining with special equipment, as long as the braking surface is within specifications stamped on brake drum outer surface. Any brake drum sufficiently out of round to cause vehicle vibration or noise while braking or showing taper should also be machined, removing only enough stock to true up the brake drum. After a brake drum is machined, wipe the braking surface diameter with a denatured alcohol soaked cloth. If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. BRAKE LININGS & SPRINGS Inspect brake linings for excessive wear, damage, oil, grease or brake fluid contamination. If any of the above conditions exists, brake linings should be replaced. Do not attempt to replace only one set of brake shoes. They should be replaced as an axle set only to maintain equal braking forces. Examine brake shoe webbing, hold-down and return springs for signs of overheating indicated by a slight blue color. If any component exhibits overheating signs, replace hold-down and return springs with new ones. Overheated springs lose their pull and could cause brake linings to wear out prematurely. Inspect all springs for sags, bends and external damage and replace as necessary. Inspect hold-down retainers and pins for bends, rust and corrosion. If any of the above is found, replace as required. BACKING PLATE Inspect backing plate shoe contact surface for grooves that may restrict shoe movement and cannot be removed by lightly sanding with emery cloth or other suitable abrasive. If backing plate exhibits above condition, it should be replaced. Also inspect for signs of cracks, warpage and excessive rust, indicating need for replacement. ADJUSTER MECHANISM Inspect all components for rust, corrosion, bends and fatigue. Replace as necessary. On adjuster mechanism equipped with adjuster cable, inspect cable for kinks, fraying or elongation of eyelet and replace as necessary. PARKING BRAKE CABLE Inspect parking brake cable end for kinks, fraying and elongation and replace as necessary. Use a small hose clamp to compress clamp where it enters backing plate to remove. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 5434 Brake Drum: Service and Repair Fig. 1 Drum Brake Assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 5435 Fig. 2 Drum Brake Assembly. REMOVAL 1. Raise and support rear of vehicle, then remove tire and wheel assembly. 2. Remove brake drum. If brake lining is dragging on brake drum, back off brake adjustment by rotating adjustment screw. Refer to individual car chapter for procedure. If brake drum is rusted or corroded to axle flange and cannot be removed, lightly tap axle flange to drum mounting surface with a suitable hammer. 3. Install suitable wheel cylinder clamp over ends of wheel cylinder to retain pistons in bore. 4. On type 1 brakes, Fig 1, remove parking brake lever retaining clip. 5. On both types, Figs. 1 and 2, remove adjuster lever spring, primary and secondary shoe return springs using a suitable pair of brake spring pliers. 6. Remove shoe guide plate, if equipped and adjuster cable and guide plate. 7. Using suitable tool, compress hold-down springs, then remove spring retainers, hold-down springs and pins. 8. Separate springs and remove from backing plate. 9. On type 2 brake, disengage parking brake lever from secondary shoe. 10. On all types, remove parking brake lever from cable. 11. Separate all components from brake shoes. 12. Clean dirt from brake drum, backing plate and all other components. Do not use compressed air or dry brush to clean brake parts. Many brake parts contain asbestos fibers which, if inhaled, can cause serious injury. Clean brake parts with a water soaked rag or a suitable vacuum cleaner to minimize airborne dust. Brake Adjustment Gauge INSTALLATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information > Specifications > Page 5436 1. Lightly lubricate backing plate shoe contact surfaces with suitable brake lube. 2. On type 1 brakes, assemble parking brake lever to secondary shoe and secure with spring washer and retaining clip. Crimp ends of clip with suitable pliers. On type 2 brakes, engage parking brake lever tang with secondary shoe. 3. Position brake shoes on backing plate, primary (short lining) shoe facing front of vehicle and secondary (long lining) facing rear. Secure brake shoes with hold-down springs, pins and retainers. 4. Install parking brake link and spring between shoes. 5. Loosen parking brake adjustment nut, then install parking brake cable on parking brake lever. 6. Install shoe guide plate and adjuster cable eyelet on anchor. Ensure adjuster cable crimp faces out. 7. Ensure parking brake link is properly positioned between brake shoes and wheel cylinder links are engaged in shoe web. 8. Using suitable brake spring pliers, install primary return spring from brake shoe to anchor, then secondary return spring from brake shoe to anchor. 9. On all types, remove wheel cylinder clamp installed during removal of brake shoes. 10. Tighten adjuster screw assembly to thread limit and back off 1/2 turn. 11. Install adjuster screw assembly between shoes. Ensure toothed wheel is on secondary shoe side. Adjuster screw assemblies are stamped R (right) and L (left). To ensure proper adjuster operation, they must be installed on their respective sides. 12. Hook adjuster cable hook into adjuster lever hole, then position adjuster spring hook in large hole in primary shoe web. Using suitable brake spring pliers, install adjuster spring in adjuster lever hole. 13. Ensure adjuster cable is properly seated in cable guide, then pull adjuster lever, cable and adjuster spring down and towards the rear, engaging lever pivot hook in the large hole of secondary shoe web. 14. After installation, check adjuster operation by pulling adjuster cable between cable guide and adjuster lever towards secondary shoe sufficiently to lift adjuster lever past one tooth on adjuster screw assembly. The adjuster lever should snap into position behind the next tooth, then upon release of adjuster cable, rotate toothed wheel one notch. If operation is not satisfactory, recheck installation. 15. Ensure brake shoe upper ends are seated against anchor pin and shoe assemblies are centered on backing plate. If not, back off parking brake adjustment. 16. Using suitable brake drum to shoe gauge, Fig. 3, measure brake drum inside diameter. Adjust brake shoes to dimension obtained on outside portion of gauge using adjuster screw. 17. Install brake drum, wheel and tire assembly. 18. If any hydraulic brake connections have been opened, perform system brake bleeding procedures. 19. Adjust parking brake. Refer to individual car chapter for procedures. 20. Inspect all hydraulic lines and connections for leakage and repair as necessary. 21. Check master cylinder fluid level and replenish as necessary. 22. Check brake pedal for proper feel and return. 23. Lower vehicle and road test. Do not severely apply brakes immediately after installation of new brake linings or permanent damage may occur to linings, and/or brake drums may become scored. Brakes must be used moderately during first several hundred miles of operation to ensure proper burnishing of linings. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Brakes - Intermittent Brake Squeal Brake Shoe: Technical Service Bulletins Brakes - Intermittent Brake Squeal Article No. 90-22-6 ^ BRAKES - OCCASIONAL OR INTERMITTENT "SQUEAL" ^ NOISE - BRAKES - OCCASIONAL OR INTERMITTENT SQUEAL" FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER This TSB article is being republished in its entirety to expand the model and model year coverage. ISSUE: Occasional or intermittent brake squeal may be cause by the brake friction material generating noise and heat in order to dissipate energy. This occasional or intermittent squeal may be a normal condition and requires no corrective action. ACTION: If a customer is concerned about occasional or intermittent brake squeal, it should be explained that brake friction materials inherently generate noise and heat in order to dissipate energy. As a result, an occasional squeal condition may be normal, and could be affected by cold, heat, wetness, snow, salt, mud etc. NOTE: THIS OCCASIONAL OR INTERMITTENT SQUEAL IS NOT A FUNCTIONAL PROBLEM AND DOES NOT INDICATE ANY LOSS OF BRAKE EFFECTIVENESS. OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-16-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5441 Brake Shoe: Testing and Inspection BRAKE DRUMS Any time the brake drums are removed for brake service, the braking surface diameter should be checked with a suitable brake drum micrometer at several points to determine if they are within the safe oversize limit stamped on the brake drum outer surface. If the braking surface diameter exceeds specifications, the drum must be replaced. If the braking surface diameter is within specifications, drums should be cleaned and inspected for cracks, scores, deep grooves, taper, out of round and heat spotting. If drums are cracked or heat spotted, they must be replaced. Minor scores should be removed with sandpaper. Grooves and large scores can only be removed by machining with special equipment, as long as the braking surface is within specifications stamped on brake drum outer surface. Any brake drum sufficiently out of round to cause vehicle vibration or noise while braking or showing taper should also be machined, removing only enough stock to true up the brake drum. After a brake drum is machined, wipe the braking surface diameter with a denatured alcohol soaked cloth. If one brake drum is machined, the other should also be machined to the same diameter to maintain equal braking forces. BRAKE LININGS & SPRINGS Inspect brake linings for excessive wear, damage, oil, grease or brake fluid contamination. If any of the above conditions exists, brake linings should be replaced. Do not attempt to replace only one set of brake shoes. They should be replaced as an axle set only to maintain equal braking forces. Examine brake shoe webbing, hold-down and return springs for signs of overheating indicated by a slight blue color. If any component exhibits overheating signs, replace hold-down and return springs with new ones. Overheated springs lose their pull and could cause brake linings to wear out prematurely. Inspect all springs for sags, bends and external damage and replace as necessary. Inspect hold-down retainers and pins for bends, rust and corrosion. If any of the above is found, replace as required. BACKING PLATE Inspect backing plate shoe contact surface for grooves that may restrict shoe movement and cannot be removed by lightly sanding with emery cloth or other suitable abrasive. If backing plate exhibits above condition, it should be replaced. Also inspect for signs of cracks, warpage and excessive rust, indicating need for replacement. ADJUSTER MECHANISM Inspect all components for rust, corrosion, bends and fatigue. Replace as necessary. On adjuster mechanism equipped with adjuster cable, inspect cable for kinks, fraying or elongation of eyelet and replace as necessary. PARKING BRAKE CABLE Inspect parking brake cable end for kinks, fraying and elongation and replace as necessary. Use a small hose clamp to compress clamp where it enters backing plate to remove. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5442 Brake Shoe: Adjustments Fig. 5 Rear Drum Type Brakes Self-adjusting shoe mechanisms assure correct lining-to-drum clearances at all times. Fig. 5, The automatic adjusters operate only when the brakes are applied as the vehicle is moving rearward. Although the brakes are self-adjusting, an initial adjustment is necessary after the brake shoes have been relined or replaced, or when the length of the star wheel adjuster has been changed during some other service operation. Frequent usage of an automatic transmission forward range to halt vehicle motion may prevent the automatic adjusters from functioning, thereby inducing low pedal heights. Should low pedal heights be encountered, it is recommended that numerous forward and reverse stops be performed with a firm pedal effort until satisfactory pedal height is obtained. If a low pedal height condition cannot be corrected by making numerous reverse stops (provided the hydraulic system is free of air), it indicates that the self-adjusting mechanism is not functioning. It will be necessary to remove brake drums, clean, free up and lubricate the adjusting mechanism. Then adjust the brakes, being sure the parking brake is fully released. Fig. 6 Backing Off Brake Adjustment By Disengaging Adjusting Lever Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5443 INITIAL ADJUSTMENT 1. Remove adjusting hole cover from brake backing plate and from the backing plate side, turn the adjusting screw upward with a screwdriver or other suitable tool to expand the shoes until a slight drag is felt when the drums are rotated. 2. Remove the drum. 3. While holding the adjuster lever out of engagement with the adjusting screw, fig. 6, back off the adjusting screw about one full turn with the fingers. If finger movement will not turn the screw, free it up. If this is not done, the adjusting lever will not turn the screw during vehicle operation. Lubricate the screw during with oil and coat with wheel bearing grease. Any other adjustment procedure may cause damage to the adjusting screw with consequent self-adjuster problems. 4. Install brake drum and wheel, and adjusting hole cover. Adjust brakes on remaining wheels in the same manner. 5. If pedal height is not satisfactory, drive the vehicle and make sufficient reverse stops with a firm pedal effort until proper pedal height is obtained. BRAKE SHOE ADJUSTMENT GAUGE Fig. 5 Brake adjustment with gauge 1. Use the brake shoe adjustment gauge shown in Fig 4 to obtain the drum inside diameter as shown. Tighten the adjusting knob on the gauge to hold this setting. 2. Place the opposite side of the gauge over the brake shoes and adjust the shoes by turning the adjuster screw until the gauge just slides over the linings. Rotate the gauge around the lining surface to assure proper lining diameter adjustment and clearance. 3. Install brake drum and wheel, final adjustment is accomplished by making several firm reverse stops, using the brake pedal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5444 Brake Shoe: Service and Repair Fig. 1 Drum Brake Assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5445 Fig. 2 Drum Brake Assembly. REMOVAL 1. Raise and support rear of vehicle, then remove tire and wheel assembly. 2. Remove brake drum. If brake lining is dragging on brake drum, back off brake adjustment by rotating adjustment screw. Refer to individual car chapter for procedure. If brake drum is rusted or corroded to axle flange and cannot be removed, lightly tap axle flange to drum mounting surface with a suitable hammer. 3. Install suitable wheel cylinder clamp over ends of wheel cylinder to retain pistons in bore. 4. On type 1 brakes, Fig 1, remove parking brake lever retaining clip. 5. On both types, Figs. 1 and 2, remove adjuster lever spring, primary and secondary shoe return springs using a suitable pair of brake spring pliers. 6. Remove shoe guide plate, if equipped and adjuster cable and guide plate. 7. Using suitable tool, compress hold-down springs, then remove spring retainers, hold-down springs and pins. 8. Separate springs and remove from backing plate. 9. On type 2 brake, disengage parking brake lever from secondary shoe. 10. On all types, remove parking brake lever from cable. 11. Separate all components from brake shoes. 12. Clean dirt from brake drum, backing plate and all other components. Do not use compressed air or dry brush to clean brake parts. Many brake parts contain asbestos fibers which, if inhaled, can cause serious injury. Clean brake parts with a water soaked rag or a suitable vacuum cleaner to minimize airborne dust. Brake Adjustment Gauge INSTALLATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information > Technical Service Bulletins > Page 5446 1. Lightly lubricate backing plate shoe contact surfaces with suitable brake lube. 2. On type 1 brakes, assemble parking brake lever to secondary shoe and secure with spring washer and retaining clip. Crimp ends of clip with suitable pliers. On type 2 brakes, engage parking brake lever tang with secondary shoe. 3. Position brake shoes on backing plate, primary (short lining) shoe facing front of vehicle and secondary (long lining) facing rear. Secure brake shoes with hold-down springs, pins and retainers. 4. Install parking brake link and spring between shoes. 5. Loosen parking brake adjustment nut, then install parking brake cable on parking brake lever. 6. Install shoe guide plate and adjuster cable eyelet on anchor. Ensure adjuster cable crimp faces out. 7. Ensure parking brake link is properly positioned between brake shoes and wheel cylinder links are engaged in shoe web. 8. Using suitable brake spring pliers, install primary return spring from brake shoe to anchor, then secondary return spring from brake shoe to anchor. 9. On all types, remove wheel cylinder clamp installed during removal of brake shoes. 10. Tighten adjuster screw assembly to thread limit and back off 1/2 turn. 11. Install adjuster screw assembly between shoes. Ensure toothed wheel is on secondary shoe side. Adjuster screw assemblies are stamped R (right) and L (left). To ensure proper adjuster operation, they must be installed on their respective sides. 12. Hook adjuster cable hook into adjuster lever hole, then position adjuster spring hook in large hole in primary shoe web. Using suitable brake spring pliers, install adjuster spring in adjuster lever hole. 13. Ensure adjuster cable is properly seated in cable guide, then pull adjuster lever, cable and adjuster spring down and towards the rear, engaging lever pivot hook in the large hole of secondary shoe web. 14. After installation, check adjuster operation by pulling adjuster cable between cable guide and adjuster lever towards secondary shoe sufficiently to lift adjuster lever past one tooth on adjuster screw assembly. The adjuster lever should snap into position behind the next tooth, then upon release of adjuster cable, rotate toothed wheel one notch. If operation is not satisfactory, recheck installation. 15. Ensure brake shoe upper ends are seated against anchor pin and shoe assemblies are centered on backing plate. If not, back off parking brake adjustment. 16. Using suitable brake drum to shoe gauge, Fig. 3, measure brake drum inside diameter. Adjust brake shoes to dimension obtained on outside portion of gauge using adjuster screw. 17. Install brake drum, wheel and tire assembly. 18. If any hydraulic brake connections have been opened, bleed brake system. 19. Adjust parking brake. Refer to individual car chapter for procedures. 20. Inspect all hydraulic lines and connections for leakage and repair as necessary. 21. Check master cylinder fluid level and replenish as necessary. 22. Check brake pedal for proper feel and return. 23. Lower vehicle and road test. Do not severely apply brakes immediately after installation of new brake linings or permanent damage may occur to linings, and/or brake drums may become scored. Brakes must be used moderately during first several hundred miles of operation to ensure proper burnishing of linings. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Attaching Bolts 5-7 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 5450 Wheel Cylinder: Testing and Inspection 1. Inspect components for damage and unusual wear. Replace as necessary. 2. Inspect wheel cylinders. Boots which are torn, cut, or heat damaged indicate need for wheel cylinder replacement. Fluid spilling from boot center hole, or wetness around wheel cylinder ends indicates cup leakage and need for wheel cylinder replacement. A small amount of fluid is always present and is considered normal, acting as a lubricant for the cylinder pistons. 3. Inspect backing plate for evidence of seal leakage. If leakage exists, refer to individual car chapters for axle seal replacement procedure. 4. Inspect backing plate attaching bolts and ensure they are tight. 5. Check adjuster screw operation. If satisfactory, lightly lubricate adjusting screw and washer with suitable brake lube. If operation is unsatisfactory, replace. 6. Using fine emery cloth or other suitable abrasive, clean rust and dirt from shoe contact surfaces on backing plate. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component Information > Specifications > Page 5451 Wheel Cylinder: Service and Repair REMOVAL 1. Remove wheel, drum and brake shoes. 2. Disconnect hydraulic line at wheel cylinder. Do not pull metal line away from cylinder as the cylinder connection will bend metal line and make installation difficult. Line will separate from cylinder when cylinder is moved away from brake backing plate. 3. Remove screws holding cylinder to brake plate and remove cylinder. Fig. 23 Wheel Cylinder Disassembled OVERHAUL 1. Referring to Fig. 23 as a guide, remove boots, pistons, springs and cups from cylinder. 2. Place all parts, except cylinder casting in clean brake fluid. Wipe cylinder walls with clean brake fluid. 3. Examine cylinder bore. A scored bore may be honed providing the diameter is not increased more than .005 inch. Replace worn or damaged parts from the repair kit. 4. Before assembling, wash hands with soap and water only, as oil, kerosene or gasoline will contaminate rubber parts. 5. Lubricate cylinder wall and rubber cups with brake fluid. 6. Install springs, cups, pistons and boots in housing. 7. Wipe end of hydraulic line to remove any foreign matter. 8. Place hydraulic cylinder in position. Enter tubing into cylinder and start connecting fitting. 9. Secure cylinder to backing plate and then complete tightening of tubing fitting. 10. Install brake shoes, drum and wheel. 11. Perform system brake bleeding procedure as outlined previously, and adjust brakes. INSTALLATION 1. Wipe end of hydraulic line to remove any foreign matter. 2. Place hydraulic cylinder in position. Enter tubing into cylinder and start connecting fitting. 3. Secure cylinder to backing plate and then complete tightening of tubing fitting. 4. Install brake shoes, drum and wheel. 5. Perform system brake bleeding procedure as outlined previously, and adjust brakes. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding Brake Bleeding: Service and Repair Manual Bleeding Pressure bleeding is recommended for all hydraulic brake systems. The bleeding operation itself is fairly well standardized. First step in all cases is cleaning the dirt from the filler cap before removing it from the master cylinder. This should be done thoroughly. Pressure bleeding is fastest because the master cylinder doesn't have to be refilled several times, and the job can be done by one man. To prevent air from the pressure tank getting into the lines, do not shake the tank while air is being added to the tank or after it has been pressurized. Set the tank in the required location, bring the air hose to the tank, and do not move it during the bleeding operation. The tank should be kept at least one-third full. On vehicles equipped with disc brakes and master cylinders without proportioners or pressure control valves located in the master cylinder outlet port, the brake metering valve or combination valve must be held in position using a suitable tool. If air does get into the fluid, releasing the pressure will cause the bubbles to increase in size, rise to the top of the fluid, and escape. Pressure should not be greater than about 35 psi. On vehicles equipped with plastic reservoirs, do not exceed 25 psi bleeding pressure. When bleeding without pressure, open the bleed valve three-quarters of a turn, depress the pedal a full stroke, then allow the pedal to return slowly to its released position. It is suggested that after the pedal has been depressed to the end of its stroke, the bleeder valve should be closed before the start of the return stroke. On models with power brakes, first reduce the vacuum in the power unit to zero by pumping the brake pedal several times with the engine off before starting to bleed the system. Pressure bleeding, of course, eliminates the need for pedal pumping. Discard drained or bled brake fluid. Care should be taken not to spill brake fluid, since this can damage the finish of the car. Flushing is essential if there is water, mineral oil or other contaminants in the lines, and whenever new parts are installed in the hydraulic system. Fluid contamination is usually indicated by swollen and deteriorated cups and other rubber parts. Wheel cylinders on disc brakes are equipped with bleeder valves, and are bled in the same manner as wheel cylinders for drum brakes. Bleeding is necessary on all four wheels if air has entered the system because of low fluid level, or the line or lines have been disconnected. If a line is disconnected at any one wheel cylinder, that cylinder only need be bled. Of course, on brake reline jobs, bleeding is advisable to remove any air or contaminants. Master cylinders equipped with bleeder valves should be bled first before the wheel cylinders are bled. In all cases where a master cylinder has been overhauled, it must be bled. Where there is no bleeder valve, this can be done by leaving the lines loose, actuating the brake pedal to expel the air and then tightening the lines. After overhauling a dual master cylinder used in conjunction with disc brakes, it is advisable to bleed the cylinder before installing it on the car. The reason for this recommendation is that air may be trapped between the master cylinder pistons because there is only one residual pressure valve (check valve) used in these units. WHEEL BLEEDING SEQUENCE Rear Wheel Drive................................................................................................................................. .............................................................RR-LR-RF-LF Front Wheel Drive............................................ .................................................................................................................................................RR-LFLR-RF Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5457 Brake Bleeding: Service and Repair Priming Brake System When a new master cylinder has been installed or the brake system emptied or partially emptied, fluid may not flow from the bleeder screws during normal bleeding. It may be necessary to prime the system using the following procedure: 1. Using a tubing wrench, remove the brake lines from the master cylinder. 2. Install short brake lines in the master cylinder and position them back into the reservoir, ensure that the short brake line ends are submerged in the reservoir brake fluid. 3. Fill the reservoir with recommended brake fluid, then cover master cylinder fluid reservoir with shop towel. 4. Pump the brakes until clear, bubble free fluid comes out of both brake lines. If any brake fluid spills on paint, wash it off immediately with water. 5. Remove the short brake lines, then reinstall original brake lines. 6. Bleed each brake line at the master cylinder using the following procedure: a. Have assistant pump brake pedal 10 times, then hold firm pressure on the pedal. b. Open the rear-most brake line fittings with a tubing wrench until a stream of brake fluid comes out. Have assistant maintain pressure on the brake pedal until the brake line fitting is tightened again. c. Repeat this operation until clear, bubble free fluid comes out from around tube fitting. d. Repeat this bleeding operation at the front brake line fitting. 7. If any of the brake lines or calipers have been removed, it may be helpful to prime the system by gravity bleeding. This should be done after the master cylinder is primed and bled. To prime the system using the gravity method, proceed as follows: a. Fill the master cylinder with manufacturer recommended brake fluid or equivalent. b. Loosen both rear bleeder screws and leave them open until clear brake fluid flows out. Check reservoir fluid level frequently, do not allow fluid level to drop below half full. c. Tighten rear bleeder screws. d. Loosen bleeder screw on front caliper, leave open until clear fluid flows out. Bleed front calipers one side at a time. 8. After the master cylinder has been primed, the lines bled at the master cylinder and the brake system primed, normal brake system bleeding can be resumed at each wheel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System Information > Service and Repair > Manual Bleeding > Page 5458 Brake Bleeding: Service and Repair With ABS FRONT BRAKES The front brakes can be bled in the same manner as conventional brakes, with or without the accumulator being charged. REAR BRAKES If the pump motor is allowed to operate continuously for approximately 20 minutes, a thermal safety switch (inside the motor) will automatically shut off the motor. A 2 to 10 minute cool down period is typical before normal operation can resume. Exercise care when opening the rear caliper bleeder screws, due to the high pressure available from a completely charged accumulator at the bleeder screws. Serious injury may result if care is not taken. Bleeding w/Accumulator Charged 1. With accumulator pressure applied to the system, bleed rear brakes by opening rear brake caliper bleed screws for 10 seconds at a time while applying brake pedal with ignition switch in Run position. 2. Repeat step 1 until air-free flow of brake fluid is observed at each caliper. 3. Close bleed screws, then pump brake pedal several times. 4. Adjust brake fluid quantity in reservoir to MAX level with accumulator fully charged. Bleeding w/Pressure Bleeder 1. Attach Rotunda bleeder No. 104-00064, or equivalent, to reservoir cap opening and apply a minimum pressure of 35 psi to system. 2. With brake pedal at rest and ignition switch in Off position, open rear caliper bleed screws for 10 seconds at a time. 3. When an air-free flow of brake fluid is observed at each caliper, close bleed screws and turn ignition switch to Run position. 4. Pump brake pedal several times, then adjust brake fluid quantity in reservoir to MAX level with accumulator fully charged. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Recalls: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification Technical Service Bulletin # 89S63 Date: 890601 Recall - Front Suspension Hardware Modification RECALL NUMBER 89S63 Date: June, 1989 TO: All Ford and Lincoln Mercury Dealers SUBJECT: Safety Recall 89S63 - 1989 Thunderbird and Cougar - Extended Brake Pedal Travel AFFECTED VEHICLES 1989 Thunderbird and Cougar - Built from Job # 1 through March 27, 1989 REASONS FOR RECALL EXCESSIVE BRAKE PEDAL TRAVEL During full-lock, low speed turns (less than 5 MPH) the inboard front brake caliper may contact the stabilizer bar or stabilizer link. This can push the front disc caliper piston back and force brake fluid back into the master cylinder reservoir. This results in increased brake pedal travel during the next brake application. After one brake application, the piston is repositioned and proper pedal travel and brake performance is restored. The sequence could repeat, however, following the next low speed full-lock turn. ATTACHMENTS Attachment I - Administrative Information Attachment II - Labor Allowances - Parts Ordering Information Attachment III - Technical Information Attachment I Administrative Information CARES/OASIS YOU MUST USE CARES OR OASIS TO DETERMINE IF A VEHICLEIS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT CONTACT Advise district office if: - an owner cannot be contacted. - an owner does not make a service date FPSD CONTACT Talk with your FPSD Service Zone Manager about recallconcerns. REIMBURSEMENT FORM 1864 Submit 1864 claims for all completed vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Recalls: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5467 WARRANTY AND POLICY MANUAL See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation. Attachment II Parts & Time Information SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) LABOR ALLOWANCES Inspect for Tension Strut Hex Cap Nut 0.1 Hrs. - Insert in Box "A" on Form 1864 Install two Tension Strut Hex Cap Nuts (Includes inspection) 0.3 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS N806301-S150 HEX CAP NUTS SG (pack of 2) ( tension strut) Attachment III Technical Instructions SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Recalls: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5468 TECHNICAL INSTRUCTIONS The front tension strut-to-lower control arm nuts are to be replaced with special acorn type nuts that serve as steering stops and eliminate the potential for caliper contact. INSPECTION/REPLACEMENT PROCEDURE ^ Put car on hoist. ^ Inspect for acorn type nuts on tension strut-to-lower control arm. If acorn type nuts are in place, claim inspection time on Form 1864 and release car from Recall 89S63. ^ If acorn type are not found follow steps listed below for installation. PASSENGER SIDE ^ Turn front wheels to full left and remove tension strut nut from lower control arm on passenger side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). DRIVERS SIDE ^ Turn front wheels to full right and remove tension strut nut from lower control arm on drivers side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). ^ Lower and remove car from hoist. ^ Complete Form 1864 and release car from recall 89S63. Owner Letter Dear Owner: June, 1989 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Thunderbirds and Cougars. Safety Defect During slow speed extreme turns (less than 5 MPH)the right or left front brake caliper may contact a part of the front suspension. If this happens, extended brake pedal travel could occur during the next brake application. This may result in reduced braking capability and increased stopping distance. A vehicle crash may result. Subsequent brake applications will result in normal braking, until another slow speed extreme turn is made. Repairs At no cost to you, your dealer will modify thefront suspension of your car by installing special nuts to eliminate the contact condition. How long will it take? The time needed to repair your car is less than one hour. Call your dealer Call your dealer without delay and ask for a service date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Recalls: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 5469 Changed address or sold the car? If you have changed your address or sold the car, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your Owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application Brake Caliper: Customer Interest Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 5475 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 9562 > Mar > 95 > Brakes Roughness During Application Brake Caliper: All Technical Service Bulletins Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 9562 > Mar > 95 > Brakes Roughness During Application > Page 5481 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification Technical Service Bulletin # 89S63 Date: 890601 Recall - Front Suspension Hardware Modification RECALL NUMBER 89S63 Date: June, 1989 TO: All Ford and Lincoln Mercury Dealers SUBJECT: Safety Recall 89S63 - 1989 Thunderbird and Cougar - Extended Brake Pedal Travel AFFECTED VEHICLES 1989 Thunderbird and Cougar - Built from Job # 1 through March 27, 1989 REASONS FOR RECALL EXCESSIVE BRAKE PEDAL TRAVEL During full-lock, low speed turns (less than 5 MPH) the inboard front brake caliper may contact the stabilizer bar or stabilizer link. This can push the front disc caliper piston back and force brake fluid back into the master cylinder reservoir. This results in increased brake pedal travel during the next brake application. After one brake application, the piston is repositioned and proper pedal travel and brake performance is restored. The sequence could repeat, however, following the next low speed full-lock turn. ATTACHMENTS Attachment I - Administrative Information Attachment II - Labor Allowances - Parts Ordering Information Attachment III - Technical Information Attachment I Administrative Information CARES/OASIS YOU MUST USE CARES OR OASIS TO DETERMINE IF A VEHICLEIS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT CONTACT Advise district office if: - an owner cannot be contacted. - an owner does not make a service date FPSD CONTACT Talk with your FPSD Service Zone Manager about recallconcerns. REIMBURSEMENT FORM 1864 Submit 1864 claims for all completed vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification > Page 5486 WARRANTY AND POLICY MANUAL See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation. Attachment II Parts & Time Information SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) LABOR ALLOWANCES Inspect for Tension Strut Hex Cap Nut 0.1 Hrs. - Insert in Box "A" on Form 1864 Install two Tension Strut Hex Cap Nuts (Includes inspection) 0.3 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS N806301-S150 HEX CAP NUTS SG (pack of 2) ( tension strut) Attachment III Technical Instructions SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification > Page 5487 TECHNICAL INSTRUCTIONS The front tension strut-to-lower control arm nuts are to be replaced with special acorn type nuts that serve as steering stops and eliminate the potential for caliper contact. INSPECTION/REPLACEMENT PROCEDURE ^ Put car on hoist. ^ Inspect for acorn type nuts on tension strut-to-lower control arm. If acorn type nuts are in place, claim inspection time on Form 1864 and release car from Recall 89S63. ^ If acorn type are not found follow steps listed below for installation. PASSENGER SIDE ^ Turn front wheels to full left and remove tension strut nut from lower control arm on passenger side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). DRIVERS SIDE ^ Turn front wheels to full right and remove tension strut nut from lower control arm on drivers side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). ^ Lower and remove car from hoist. ^ Complete Form 1864 and release car from recall 89S63. Owner Letter Dear Owner: June, 1989 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Thunderbirds and Cougars. Safety Defect During slow speed extreme turns (less than 5 MPH)the right or left front brake caliper may contact a part of the front suspension. If this happens, extended brake pedal travel could occur during the next brake application. This may result in reduced braking capability and increased stopping distance. A vehicle crash may result. Subsequent brake applications will result in normal braking, until another slow speed extreme turn is made. Repairs At no cost to you, your dealer will modify thefront suspension of your car by installing special nuts to eliminate the contact condition. How long will it take? The time needed to repair your car is less than one hour. Call your dealer Call your dealer without delay and ask for a service date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification > Page 5488 Changed address or sold the car? If you have changed your address or sold the car, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your Owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 9562 > Mar > 95 > Brakes Roughness During Application Brake Caliper: All Technical Service Bulletins Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 9562 > Mar > 95 > Brakes Roughness During Application > Page 5494 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification Technical Service Bulletin # 89S63 Date: 890601 Recall - Front Suspension Hardware Modification RECALL NUMBER 89S63 Date: June, 1989 TO: All Ford and Lincoln Mercury Dealers SUBJECT: Safety Recall 89S63 - 1989 Thunderbird and Cougar - Extended Brake Pedal Travel AFFECTED VEHICLES 1989 Thunderbird and Cougar - Built from Job # 1 through March 27, 1989 REASONS FOR RECALL EXCESSIVE BRAKE PEDAL TRAVEL During full-lock, low speed turns (less than 5 MPH) the inboard front brake caliper may contact the stabilizer bar or stabilizer link. This can push the front disc caliper piston back and force brake fluid back into the master cylinder reservoir. This results in increased brake pedal travel during the next brake application. After one brake application, the piston is repositioned and proper pedal travel and brake performance is restored. The sequence could repeat, however, following the next low speed full-lock turn. ATTACHMENTS Attachment I - Administrative Information Attachment II - Labor Allowances - Parts Ordering Information Attachment III - Technical Information Attachment I Administrative Information CARES/OASIS YOU MUST USE CARES OR OASIS TO DETERMINE IF A VEHICLEIS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT CONTACT Advise district office if: - an owner cannot be contacted. - an owner does not make a service date FPSD CONTACT Talk with your FPSD Service Zone Manager about recallconcerns. REIMBURSEMENT FORM 1864 Submit 1864 claims for all completed vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification > Page 5500 WARRANTY AND POLICY MANUAL See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation. Attachment II Parts & Time Information SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) LABOR ALLOWANCES Inspect for Tension Strut Hex Cap Nut 0.1 Hrs. - Insert in Box "A" on Form 1864 Install two Tension Strut Hex Cap Nuts (Includes inspection) 0.3 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS N806301-S150 HEX CAP NUTS SG (pack of 2) ( tension strut) Attachment III Technical Instructions SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification > Page 5501 TECHNICAL INSTRUCTIONS The front tension strut-to-lower control arm nuts are to be replaced with special acorn type nuts that serve as steering stops and eliminate the potential for caliper contact. INSPECTION/REPLACEMENT PROCEDURE ^ Put car on hoist. ^ Inspect for acorn type nuts on tension strut-to-lower control arm. If acorn type nuts are in place, claim inspection time on Form 1864 and release car from Recall 89S63. ^ If acorn type are not found follow steps listed below for installation. PASSENGER SIDE ^ Turn front wheels to full left and remove tension strut nut from lower control arm on passenger side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). DRIVERS SIDE ^ Turn front wheels to full right and remove tension strut nut from lower control arm on drivers side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). ^ Lower and remove car from hoist. ^ Complete Form 1864 and release car from recall 89S63. Owner Letter Dear Owner: June, 1989 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Thunderbirds and Cougars. Safety Defect During slow speed extreme turns (less than 5 MPH)the right or left front brake caliper may contact a part of the front suspension. If this happens, extended brake pedal travel could occur during the next brake application. This may result in reduced braking capability and increased stopping distance. A vehicle crash may result. Subsequent brake applications will result in normal braking, until another slow speed extreme turn is made. Repairs At no cost to you, your dealer will modify thefront suspension of your car by installing special nuts to eliminate the contact condition. How long will it take? The time needed to repair your car is less than one hour. Call your dealer Call your dealer without delay and ask for a service date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Technical Service Bulletins > All Other Service Bulletins for Brake Caliper: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification > Page 5502 Changed address or sold the car? If you have changed your address or sold the car, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your Owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Bore Diameter Brake Caliper: Specifications Front 2.87 in Rear 1.789 in Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Specifications > Bore Diameter > Page 5505 Brake Caliper: Specifications Caliper Bolt 80-100 ft.lb Caliper To Knuckle Bolts 44-60 ft.lb Brake Caliper Torx Bolts 25 ft.lb Locating Pins 45-65 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Front Brake Caliper: Description and Operation Front Fig. 1 Front Pin Sliding Disc Brake Caliper Fig. 2 Front Pin Sliding Disc Brake Caliper The caliper assembly consists of a pin slider caliper housing, inner and outer shoe and lining assemblies and a single piston, Figs. 1 and 2. The caliper slides on two pins which also act as attaching bolts between caliper and the combination anchor plate and spindle. The outer brake shoe and lining assembly is longer than the inner brake shoe and lining assembly. Inner and outer shoe and lining assemblies are attached to the caliper by spring clips riveted to the shoe surfaces. The inner shoe is attached to the caliper by installing the spring clip to the inside of the caliper piston. The outer shoe clips directly to the caliper housing. A wear indicator is incorporated which emits a noise when the lining is worn to a point when replacement is necessary. Inner and outer shoes are of left and right hand and are not interchangeable. The inner shoe and lining on Mustang with V8-302 engine has a replaceable single finger anti-rattle clip and an insulator held in position by the clip. The shoe is slotted to accept the snap on clip which loads the assembly against the caliper bridge. The inner shoe on the Mustang with 2300cc engine has a single finger anti-rattle clip, holding the shoe down against the spindle ledge. The clip does not lock into the piston. The insulator is also riveted to the shoe and is not replaceable. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Front > Page 5508 Brake Caliper: Description and Operation Rear Fig. 1 Rear Disc Brake Caliper Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Description and Operation > Front > Page 5509 Fig. 2 Rear Disc Brake Caliper Assembly Sliding caliper rear disc brakes are used on Continental, Mark VII & Thunderbird, Figs. 1 and 2. The caliper is basically the same as the larger front wheel caliper, however, a parking brake mechanism and a larger inner brake shoe anti-rattle spring have been added. The parking brake lever, located at the rear of the caliper, is actuated by a cable system similar to rear drum brake applications. When the parking brake is applied, the cable rotates the lever and operating shaft, driving the caliper piston and brake shoe assembly against the rotor. An automatic adjuster in the assembly compensates for lining wear and maintains proper clearance in the parking brake mechanism. The cast iron rotors are ventilated by curved fins located between the braking surfaces and are designed to cause the rotor to act as an air pump when the vehicle is traveling forward. The rotors are not interchangeable and are identified by a Right or Left marking cast inside the hat section of the rotor. The rotor is secured to the axle flange in the same manner as a rear brake drum. A splash shield is bolted to a forged axle adapter to protect the inboard rotor surface. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front Brake Caliper: Service and Repair Front Disassembly and Assembly Fig. 1 Front Pin Sliding Disc Brake Caliper Fig. 2 Front Pin Sliding Disc Brake Caliper DISASSEMBLY 1. Remove caliper assembly from vehicle as described under Removal/Installation. 2. Position fiber block and shop towels between caliper piston and caliper housing, then apply compressed air to caliper brake line fitting bore to force piston from caliper. 3. Remove dust boot from caliper assembly, Figs. 1 and 2. 4. Remove piston seal from cylinder and discard. INSPECTION 1. Check piston for scratches, scoring or damage. Replace, if necessary. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5512 2. Check caliper bore for scratches, scoring or corrosion. Light scratches or slight corrosion can be polished out using crocus cloth. 3. Check that bleeder screw and bleeder screw bore hole in caliper are fully open. 4. Check caliper bushings for corrosion and dust boot retaining ring for damage or tension loss. Replace parts as necessary. ASSEMBLY 1. Lubricate piston seal with clean brake fluid, then install seal in caliper bore. Ensure seal is firmly seated in groove. 2. Install dust boot in outer groove of caliper bore, Figs. 1 and 2. 3. Coat piston with clean brake fluid and install piston in caliper bore. Spread dust boot over piston as it is installed. Seat dust boot in piston groove. 4. Install caliper assembly as described under Removal/Installation. Removal and Installation REMOVAL Before removing calipers, mark left and right hand calipers so they can be installed in the same position. 1. Raise and support front of vehicle, then remove wheel and tire assembly. 2. Loosen brake tube fitting which connects brake tube to fitting on frame and plug brake tube. Remove retaining clip from brake hose and bracket, then disconnect brake hose from caliper. 3. Remove caliper locating pins. 4. Lift caliper from rotor and spindle anchor plate assembly. On models equipped with phenolic caliper piston, do not pry directly against the piston or damage may result. INSTALLATION 1. Install caliper assembly over rotor with outer shoe against rotor braking surface during installation on spindle and anchor plate to prevent pinching of piston boot between inner brake shoe and piston. Ensure calipers are installed in the correct position. 2. Install locating pins. Torque locating pins to specification. 3. Connect brake hose to caliper and tighten hose fitting. 4. Position upper end of brake hose in bracket and install retaining clip. Remove plug from brake line, then connect brake hose fitting to brake line. 5. Perform system brake bleeding procedures. 6. Install wheel and tire assembly, then lower vehicle. 7. Pump brake pedal several times to position brake shoes before moving vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5513 Brake Caliper: Service and Repair Rear Disassembly and Assembly Fig. 2 Rear Disc Brake Caliper Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5514 Fig. 13 Seating Caliper Piston Fig. 14 Positioning Caliper Piston To Brake Pad Nib Disassembly 1. Remove caliper assembly from vehicle. 2. Position caliper assembly in a soft jawed vise. 3. Using tool No. T75P-2588-B or equivalent, rotate caliper piston counterclockwise to remove from caliper bore, Fig. 13. 4. Remove piston dust boot and seal from caliper piston bore, Fig. 2. 5. Remove snap ring retaining pushrod to caliper. Use care when removing, as the snap ring and spring cover are under spring load. 6. Remove spring cover, spring, washer, key plate and pushrod and strut pin from caliper. 7. Remove O-ring from pushrod. 8. Remove parking brake lever return spring, then remove brake lever stop bolt and pull lever from caliper. Cleaning & Inspection 1. Clean all metal components with isopropyl alcohol. 2. Use compressed air to clean out passages and grooves. 3. Inspect caliper bore for damage and excessive wear. 4. Inspect caliper piston for pitting, scoring or worn plating and replace as necessary. Assembly 1. Apply a light coating of silicone dielectric compound to parking brake lever bore and parking brake lever seal, then position seal into caliper bore, Fig. 2. 2. Apply silicone dielectric compound to parking brake lever shaft, then insert shaft into caliper housing bore. 3. Install O-ring into groove on pushrod, then apply silicone dielectric compound to recesses in pushrod. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5515 4. Place strut pin into caliper housing and into recess of parking brake lever shaft. 5. Position pushrod into caliper housing bore, ensuring strut pin is properly located between shaft recesses and recess at end of pushrod. 6. Position key plate over pushrod, so that washer nib is located in hole in caliper housing. 7. Install flat washer, spring and spring cage into caliper bore. 8. Install snap ring using tool No. T87P-2588-P or equivalent. Ensure snap ring is properly seated in recess. 9. Lubricate replacement piston seal with clean brake fluid, then install seal into caliper bore groove. 10. Lubricate piston and dust boot with clean brake fluid, then install dust boot into caliper bore. 11. Position piston into dust boot, seating dust boot in piston groove. 12. Using tool No. T75P-2588-B or equivalent, turn piston in clockwise direction until piston is fully seated in caliper bore, Fig. 13. 13. Position one of the two slots on the piston so that it will engage the nib on the rear of the disc pad when the caliper is installed, Fig. 14. 14. Install caliper assembly. Removal and Installation REMOVAL 1. Raise and support rear of vehicle, then remove wheel and tire assembly. 2. Disconnect brake hose from caliper assembly. 3. Remove retaining clip, then disconnect parking brake cable from lever arm. 4. Using an open end wrench to hold slider pin in position, remove pinch bolts, Fig. 11. 5. Lift caliper assembly from anchor plate, then remove slider pins and boots. Fig. 12 Positioning Anti-rattle Clips INSTALLATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component Information > Service and Repair > Front > Page 5516 1. Apply a suitable silicone dielectric compound to slider pins and inside of boots. 2. Place slider pins and boots on anchor plate, then position caliper assembly on anchor plate. Check to be sure that brake pads and anti-rattle springs are properly positioned, Fig. 12. 3. Apply suitable sealer and thread locking compound to pinch bolt threads, then install pinch bolts. While using an open end wrench to hold slider pin in position, torque pinch bolts to specification. 4. Attach parking brake cable to lever arm, then install retaining clip. 5. Using replacement washers, connect brake hose to caliper. Torque retaining bolt to 30-45 ft lbs. 6. Perform system brake bleeding procedures, then install wheel and tire assembly. 7. Cycle brake pedal several times to position brake pads and caliper piston. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator > Component Information > Specifications Brake Fluid Accumulator: Specifications Accumulator-to-Pump Housing Adapter 30-34 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator > Component Information > Specifications > Page 5520 Brake Fluid Accumulator: Service and Repair Fig. 9 Hydraulic accumulator replacement Relieve system hydraulic pressure by turning ignition off and pumping brake pedal at least 20 times until an increase in pedal force is felt. 1. Disconnect battery ground cable and electrical connector from hydraulic pump motor. 2. Remove accumulator, Fig. 9, ensuring no debris falls into open port. 3. Remove accumulator adapter block, if necessary. 4. Reverse procedure to install. Torque adapter block bolt to 25---34 ft. lbs. and accumulator to 30---34 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Engine Compartment Component Locations In Master Cylinder, Below Reservoir Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications > ABS Pressure Switch Brake Fluid Pressure Sensor/Switch: Specifications Pressure Switch 15-25 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications > ABS Pressure Switch > Page 5528 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > ABS Pressure Switch Brake Fluid Pressure Sensor/Switch: Locations ABS Pressure Switch Engine Compartment Component Locations In Brake Control Unit Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > ABS Pressure Switch > Page 5531 Brake Fluid Pressure Sensor/Switch: Locations Brake Pressure Warning Switch Engine Compartment Component Locations In Brake Line, Below Master Cylinder Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 5532 Brake Fluid Pressure Sensor/Switch: Description and Operation Fig. 4 Pressure Differential Valve & Brake Warning Light Switch Fig. 5 Pressure Differential Valve & Brake Warning Light Switch Fig. 6 Pressure Differential Valve & Brake Warning Light Switch There are four basic types of brake warning light switches as shown in Figs. 4 through 6 and usually form a common electrical circuit with the brake warning light. When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 5533 As shown in Fig. 4, movement of the differential valve forces the switch plunger upward over the tapered shoulder of the valve to close the switch contacts and light the dual brake warning lamp, signaling a brake system failure. In Fig. 5, the valve assembly consists of two valves in a common bore that are spring loaded toward the centered position. The spring-loaded switch contact plunger rests on top of the valves in the centered position (right view). When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. The spring-loaded switch plunger is triggered and the ground circuit for the warning light is completed, lighting the lamp (left view). In Fig. 6, as pressure falls in one system, the other system's normal pressure forces the piston to the inoperative side, contacting the switch terminal, causing the warning light on the instrument panel to glow. On front wheel drive models, a fluid level indicator replaces the pressure differential valve used in previous brake systems. It is contained inside the body of the master cylinder plastic reservoir and activates the brake warning light when fluid level is low. Fig. 7 Typical pressure valve and brake warning light switch Testing Warning Light System If the parking brake light is connected into the service brake warning light system, the brake warning light will flash only when the parking brake is applied with the ignition turned ON. The same light will also glow should one of the two service brake systems fail when the brake pedal is applied. To test the system, turn the ignition on and apply the parking brake. If the lamp fails to light, inspect for a burned out bulb, disconnected socket, a broken or disconnected wire at the switch. Fig. 7 is an exterior view of one of these switches. They are usually mounted on the left frame side rail or on the brake pedal bracket. To test the brake warning system, raise the car and open a wheel bleeder valve while a helper depresses the brake pedal and observes the warning light on the instrument panel. If the bulb fails to light, inspect for a burned out bulb, disconnected socket, or a broken or disconnected wire at the switch. If the bulb is not burned out, and the wire continuity is proven, replace the brake warning switch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 5534 Brake Fluid Pressure Sensor/Switch: Service and Repair Fig. 12 Pressure switch replacement 1. Relieve system hydraulic pressure by turning ignition off and pumping brake pedal at least 20 times until an increase in pedal force is felt. 2. Disconnect battery ground cable. 3. Disconnect 7-pin electrical connector from solenoid valve body and 5-pin pressure warning switch connector if equipped, Fig. 12. It may be necessary to remove the lefthand front tie-rod at the steering knuckle to gain access to the switch. 4. Remove pressure switch using a suitable tool. 5. Reverse procedure to install. Torque pressure switch to 15---25 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > ABS Pressure Hose Brake Hose/Line: Specifications High Pressure Line Bajo Bolts 12-15 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > ABS Pressure Hose > Page 5539 Brake Hose/Line: Specifications Brake Hose Retaining Bolt 9-11 ft.lb Hose Fittings At Gear 20-25 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > ABS Pressure Hose > Page 5540 Brake Hose/Line: Specifications Brake Tubes-to-Solenoid Valve Block 10-18 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Specifications > ABS Pressure Hose > Page 5541 Brake Hose/Line: Specifications Low Pressure Line Banjo Fitting 19-24 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Line Brake Hose/Line: Service and Repair Brake Line Fig. 24 Bleeding Wheel Cylinder Whenever new brake components are installed in the hydraulic system, it is recommended that the entire hydraulic system be thoroughly flushed with clean brake fluid. It may sometime become necessary to flush out the system due to the presence of mineral oil, kerosene, gasoline, etc., which will cause swelling of rubber piston cups and valves so they become inoperative. The procedure is as follows: Flushing is performed at each wheel in the same manner as the brake bleeding operation except that the bleeder valve is opened 1-1/2 turns and the fluid is forced through the lines and bleeder valve until it emerges clear in color, Fig. 24. Approximately one quart of clean brake fluid is required to flush the hydraulic system. After completing the flushing operation at all bleeder valves, check to ensure the master cylinder is filled to the proper level. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component Information > Service and Repair > Brake Line > Page 5544 Brake Hose/Line: Service and Repair High Pressure Line, Brakes Fig. 25 Flaring Hydraulic Brake Tubing Never use copper tubing as a replacement for steel tubing. Copper tubing is subject to fatigue cracking and corrosion which could result in brake system failure. Steel tubing is used to conduct hydraulic pressure to the brakes. All fittings, tubing and hose should be inspected for rusted, damaged or defective flared seats. The tubing is equipped with a double flare/inverted seat or I.S.O. flare to insure more positive seating in the fitting. To repair or reflare tubing, proceed as follows: DOUBLE FLARE/INVERTED SEAT 1. Using the tool shown in Fig. 25 or equivalent, cut off the damaged seat or damaged tubing. 2. Ream out any burrs or rough edges showing on inside edges of tubing. This will make the ends of the tubing square and insure better seating on the flared end. Before flaring tubing, place a compression nut on tubing. 3. Open handles of flaring tool and rotate jaws of tool until mating jaws of tubing size are centered in the area between vertical posts. 4. Slowly close handles with tubing inserted in jaws but do not apply heavy pressure to handle as this will lock tubing in place. 5. Referring to Fig. 25, place gauge on edge over end of tubing and push tubing through jaws until end of tubing contacts recessed notch of gauge matching size of tubing. 6. Squeeze handles of flaring tool and lock tubing in place. 7. Place proper size plug of gauge down in end of tubing. Swing compression disc over gauge and center tapered flaring screw in recess in disc. 8. Lubricate taper of flaring or screw and screw in until plug gauge has seated in jaws of flaring tool. This action has started to invert the extended end of tubing. 9. Remove gauge and apply lubricant to tapered end of flaring screw and continue to screw down until tool is firmly seated in tubing. 10. Remove tubing from flaring tool and inspect the seat. If seat is cracked, cut off cracked end and repeat flaring operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation Brake Proportioning/Combination Valve: Description and Operation Fig. 8 Combination Valve Fig. 9 Diagonally Split System Combination Valve On all models except Capri, the combination valve, Fig. 8 is a metering valve, failure warning switch, and a proportioner in one assembly and is used on disc brake applications. The metering valve delays front disc braking until the rear drum brake shoes contact the drum. The failure warning switch is actuated in event of front or rear brake system failure, in turn activating a dash warning lamp. The proportioner balances front to rear braking action during rapid deceleration. Combination valves used on diagonally split brake systems do not use metering valves instead two proportioning valves are used, Fig. 9. Fig. 10 Metering Valve, Initial Braking Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 5548 Fig. 11 Metering Valve, Continued Braking Fig. 12 Three-way Combination Valve Fig. 13 Two-way Combination Valve Metering Valve When the brakes are not applied, the metering valve permits the brake fluid to flow through the valve, thus allowing the fluid to expand and contract with temperature changes. When the brakes are initially applied, the metering valve stem moves to the left, preventing fluid to flow through the valve to the front disc brakes. This is accomplished by the smooth end of the metering valve stem contacting the metering valve seal lip at 4-30 psi, Fig. 10. The metering valve spring holds the retainer against the seal until a predetermined pressure is produced at the valve inlet port which overcomes the spring pressure and permits hydraulic pressure to actuate the front disc brakes, Fig. 11. The increased pressure into the valve is metered through the valve seal, to the front disc brakes, producing an increased force on the diaphragm. The diaphragm then pulls the pin, in turn pulling the retainer and reduces the spring pressure on the metering valve seal. Eventually, the pressure reaches a point at which the spring is pulled away by the diaphragm pin and retainer, leaving the metering valve unrestricted, permitting full pressure to pass through the metering valve. On some applications, two-way or three-way combination valves are used. The three-way combination valve consists of a metering valve, failure warning switch and a proportioner mounted in an aluminum body, Fig. 12. The two-way combination valve, Fig. 13, consists of a failure warning switch and a proportioner. On models equipped with metering valves, the metering valve release rod must be pushed in during brake bleeding operations on the front wheels. On Capri models, the proportioning valves are an integral part of the master cylinder. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 5549 Fig. 14 Failure Warning Switch, Rear System Failure Failure Warning Switch If the rear brake system fails, the front system pressure forces the switch piston to the right, Fig. 14. The switch pin is then forced up into the switch, completing the electrical circuit and activates the dash warning lamp. When repairs are made and pressure returns to the system, the piston moves to the left, resetting the switch. The detent on the piston requires approximately 100-450 psi to permit full reset of the piston. In event of front brake system failure, the piston moves to the left and the same sequence of events is followed as for rear system failure except the piston resets to the right. Fig. 15 Proportioner, Rapid Deceleration Fig. 15 Proportioner, Rapid Deceleration Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 5550 Fig. 17 Pressure Control Valves Installed In Master Cylinder. Front Wheel Drive Models Proportioner Or Pressure Control Valves During rapid deceleration, a portion of vehicle weight is transferred to the front wheels. This resultant loss of weight at rear wheels must be compensated for to avoid early rear wheel skid. The proportioner or pressure control valve reduces rear brake system pressure, delaying rear wheel skid. When the proportioner or pressure control valve is incorporated in the combination valve assembly, pressure developed within the valve acts against the large end of the piston, overcoming the spring pressure, moving the piston left, Fig. 15. The piston then contacts the stem seat and restricts line pressure through the valve. During normal braking operation, the proportioner or pressure control valve is not functional. Brake fluid flows into the proportioner or pressure control valve between the piston center hole and the valve stem, through the stop plate and to the rear brakes. Spring pressure loads the piston during normal braking, causing it to rest against the stop plate, Fig. 16. On diagonally split brake systems, two proportioners or pressure control valves are used. One controls the left rear brake, the other the right rear brake. On front wheel drive models less power brakes, the proportioners or pressure control valves are located in the combination valve, Fig. 9. On front wheel drive models with power brakes, the proportioners or pressure control valves are installed in the master cylinder rear brake outlet ports, Fig. 17. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination Valve > Component Information > Description and Operation > Page 5551 Brake Proportioning/Combination Valve: Testing and Inspection Fig. 4 Gauge Hook-up For Testing Proportioning Valve (typical) When a premature rear wheel slide is obtained on a brake application, it usually is an indication that the fluid pressure to the rear wheels is above the 50% reduction ratio for the rear line pressure and that malfunction has occurred within the proportioning valve. To test the valve, install gauge set shown in Fig. 4 in brake line between master cylinder and proportioning valve, and at output end of proportioning valve and brake line as shown. Be sure all joints are fluid tight. Have a helper exert pressure on brake pedal (holding pressure). Obtain a reading on master cylinder output of approximately 700 psi. While pressure is being held as above, reading on valve outlet should be 550-610 psi. If the pressure readings do not meet these specifications, the valve should be removed and a new valve installed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications Hydraulic Control Assembly - Antilock Brakes: Specifications Hydraulic Unit-to-Dash Panel Nuts 13-25 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5555 Hydraulic Control Assembly - Antilock Brakes: Locations Engine Compartment Component Locations Part Of Brake Control Unit Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Specifications > Page 5556 Hydraulic Control Assembly - Antilock Brakes: Description and Operation Solenoid valve block assembly The solenoid valve block assembly contains three pairs of solenoid valves, one pair for each front wheel and the third pair for both rear wheels. The paired solenoid valves are inlet and outlet valves, with the inlet valve normally open and the outlet valve normally closed. During anti-lock operation, the inlet and outlet valves are alternately opened and closed approximately 10 times per second to provide pressure modulation to wheel of impending lockup. The solenoid valve block is bolted to the hydraulic actuation unit, behind the lefthand shock tower. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly Hydraulic Control Assembly - Antilock Brakes: Service and Repair Hydraulic Assembly Fig. 2 Hydraulic Actuation Unit. Cougar, Thunderbird & 1989 Continental Fig. 3 Hydraulic Actuation Unit. Mark VII 1. With hydraulic system discharged, disconnect battery ground cable. 2. Remove air cleaner housing and duct assembly. 3. Label, then disconnect electrical connectors from fluid level indicator, main valve, solenoid valve block, pressure warning switch, hydraulic pump motor and ground connector from master cylinder portion of actuation assembly. 4. Disconnect and cap three brake tube fittings. Do not allow brake fluid to come in contact with any of the electrical connectors. 5. Remove trim panel under steering column. Disconnect actuation assembly push rod from brake pedal. Slide switch, push rod and plastic bushings off pedal pin. 6. Remove four retaining nuts, securing actuation assembly to brake pedal support bracket. 7. Remove actuation assembly from engine compartment. 8. Reverse procedure to install. Torque the four hydraulic unit to pedal support and brake tube lock nuts to 13-25 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly - Antilock Brakes > Component Information > Service and Repair > Hydraulic Assembly > Page 5559 Hydraulic Control Assembly - Antilock Brakes: Service and Repair Solenoid Valve Body Relieve system hydraulic pressure by turning ignition off and pumping brake pedal at least 20 times until an increase in pedal force is felt. Removal 1. Discharge system. 2. Disconnect negative battery cable. 3. Remove LH cowl vent screen. 4. Disconnect electrical connector from valve block. 5. Disconnect brake lines at solenoid valve block. 6. Remove solenoid valve block. 7. Reverse procedure to install. Tighten solenoid valve block to 15-21 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Master Cylinder, ABS Brake Master Cylinder: Specifications Reservoir Mounting Bracket Bolt 35-53 in.lb Valve Block-to-Master Cylinder 15-21 ft.lb Middle Brake Tube-to-Solenoid Valve Body 9-13 ft.lb Outer Brake Tube-to-Solenoid Valve Body 6-10 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Master Cylinder, ABS > Page 5564 Brake Master Cylinder: Specifications Master Cylinder Bore Diameter 0.94 in Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5565 Brake Master Cylinder: Description and Operation Fig. 2 Hydraulic Actuation Unit. Cougar, Thunderbird & 1989 Continental The brake fluid reservoir and level indicator assembly is a translucent, plastic container that is mounted on the top of the hydraulic actuation unit. The reservoir is connected to the pump inlet port by a low pressure hose, and to the master cylinder by a sealed feed port. The FLI is connected to the ECU by a five-pin connector located at the lower right hand front corner of the tank. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5566 Brake Master Cylinder: Testing and Inspection Ensure that the master cylinder compensates in both parts. This can be done by applying the brake pedal lightly (engine running with power brakes) and observing for brake fluid squirting up in the reservoirs. This may only occur in the front chamber. To determine if the rear compensating port is open, pump up the brakes rapidly and hold the pedal down. Have an observer watch the fluid in the rear reservoir while the pedal is raised. A disturbance in the fluid indicates that the compensating port is open. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Specifications > Page 5567 Brake Master Cylinder: Adjustments Proper adjustment of the master cylinder pushrod is necessary to ensure proper operation of the power brake system. A pushrod that is too long will prevent the master cylinder piston from completely releasing hydraulic pressure, eventually, causing the brakes to drag. A pushrod that is too short will cause excessive brake pedal travel and cause groaning noises to come from the booster when the brakes are applied. A properly adjusted pushrod that remains assembled to the booster with which is was matched during production should not require service adjustment. However, if the booster, master cylinder or pushrod are serviced, the pushrod may require adjustment. If the power unit pushrod requires an adjustment the Power Unit Repair Kit for the unit being serviced includes a gauge. The gauge measures from the end of the pushrod to the power unit shell. On Capri models, push rod length is not adjustable. To ensure the master cylinder is free to return to its rest position with no residual pressure, verify stoplamp switch adjustment. Fig. 1 Master Cylinder Pushrod Adjustment. Bendix Type Vacuum Booster BENDIX TYPE 1. Disconnect master cylinder from booster leaving brake lines connected, and secure cylinder to prevent lines from being damaged. 2. Start engine and operate engine at idle speed. 3. With engine running, position gauge over pushrod. Gauge should bottom against booster housing with a force of approximately 5 lbs. applied to pushrod, Fig. 1. 4. If force required to seat gauge exceeds 5 lb., shorten length of pushrod. If force required to seat gauge is less than 5 lbs., lengthen pushrod. Ensure that pushrod is properly seated in booster when performing gauge check. 5. Install master cylinder, then remove reservoir cover. 6. With engine running, observe fluid surface in reservoir when brakes are applied and released rapidly. If no movement is observed on fluid surface, pushrod is adjusted too long. SINGLE DIAPHRAGM BOOSTER 1. Remove master cylinder as previously outlined. 2. Position master cylinder gauge T87C-2500-A or equivalent on end of master cylinder. 3. Loosen set screw and push gauge plunger against bottom of primary piston. 4. While holding gauge in position, tighten set screw. 5. Invert gauge and place over brake booster push rod, reading should be 0. 6. If clearance is not 0, loosen push rod locknut and adjust push rod. 7. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir Brake Master Cylinder: Service and Repair Brake Fluid Reservoir Relieve system hydraulic pressure by turning ignition off and pumping brake pedal at least 20 times until an increase in pedal force is felt. 1. Disconnect battery ground cable. 2. Disconnect electrical connectors from reservoir cap, then remove the cap. 3. Remove as much brake fluid as possible from reservoir. 4. Disconnect suction line between reservoir and pump at pump end by twisting and pulling. 5. Disconnect return line between reservoir and master cylinder housing at reservoir end by twisting and pulling. 6. Remove allen head reservoir attaching screw, then pry reservoir from booster housing. Ensure short sleeve and O-ring are remove from booster grommet hole following reservoir removal. 7. Reverse procedure to install, noting the following: a. Torque reservoir attaching screw to 35---53 inch lbs. b. Fill reservoir to MAX line, then perform system brake bleeding procedures as previously described. c. After brake bleeding, top off reservoir to MAX line with a fully charged accumulator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 5570 Brake Master Cylinder: Service and Repair Master Cylinder, Brakes Disassembly and Assembly Fig. 21 Exploded View Of Bendix Dual Master Cylinder Used w/Disc Brakes Fig. 22 Master Cylinder w/Fluid Control Valve Installed. Front Wheel Drive Models Disassemble 1. Remove cover and diaphragm then drain brake fluid from master cylinder, Fig. 21. 2. On front wheel drive models, using a screwdriver, pry up on reservoir and remove primary port from master cylinder, Fig. 22. 3. Rotate reservoir out of way and remove sealing grommet from master cylinder casting. 4. Using a socket, remove fluid control valve. 5. On all models, depress primary piston and remove snap ring from retaining groove at open end of bore. 6. Remove primary and secondary piston assemblies from master cylinder. If secondary piston does not readily come out, apply air pressure to secondary outlet port to remove. Inspection When disassembled, wash all parts in clean brake fluid only. Use an air hose to blow out all passages, orifices and valve holes. Air dry and place parts on clean paper or lint-free cloth. Inspect master cylinder bore for scoring, rust, pitting or etching. Any of these conditions will require replacement of the housing. Inspect master cylinder pistons for scoring, pitting or distortion. Replace piston if any of these conditions exist. If either master cylinder housing or piston is replaced, clean new parts with clean brake fluid and blow out all passages with air hose. Examine reservoirs for foreign matter and check all passages for restrictions. If there is any suspicion of contamination or evidence of corrosion, completely flush hydraulic system as outlined below. When overhauling a master cylinder, use all parts contained in repair kit. Before starting reassembly, dip all cups, seals, pistons, springs, check valves and retainers in clean brake fluid and place in a clean pan or on clean paper. Wash hands with soap and water only to prevent contamination of rubber parts from oil, kerosene or gasoline. During assembly, dip all parts in clean brake fluid. Inspect through side outlet of dual master cylinder housing to make certain cup lips do not hang up on edge of hole or turn back, which would result in faulty operation. A piece of 3/16 inch rod with an end rounded off will be helpful in guiding cups past hole. When overhauling aluminum master cylinders, carefully inspect master cylinder bore for corrosion. If corroded, replace master cylinder. Do not hone or use abrasives on the bore of these cylinders. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder > Component Information > Service and Repair > Brake Fluid Reservoir > Page 5571 Assembly 1. Install secondary piston assembly into bore, spring end first. 2. Install primary piston assembly, spring end first. 3. Depress primary piston and install snap ring. 4. On front wheel drive models, install fluid control valve and torque to 97-115 inch lbs. 5. Lubricate new grommet with brake fluid and install in primary port. 6. Install reservoir in new grommet. 7. On all models, fill and bench bleed master cylinder. Refer to Brake Bleeding. 8. Install cap and diaphragm on master cylinder reservoir. Removal and Installation 1. Disconnect brake lines from master cylinder, then all necessary electrical connectors. 2. Remove nuts retaining master cylinder to brake booster. 3. Remove master cylinder. 4. Reverse procedure to install. After installation is complete, fill master cylinder with manufacturer recommended brake fluid and perform brake bleeding procedure. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications Wheel Cylinder: Specifications Wheel Cylinder Attaching Bolts 5-7 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 5575 Wheel Cylinder: Testing and Inspection 1. Inspect components for damage and unusual wear. Replace as necessary. 2. Inspect wheel cylinders. Boots which are torn, cut, or heat damaged indicate need for wheel cylinder replacement. Fluid spilling from boot center hole, or wetness around wheel cylinder ends indicates cup leakage and need for wheel cylinder replacement. A small amount of fluid is always present and is considered normal, acting as a lubricant for the cylinder pistons. 3. Inspect backing plate for evidence of seal leakage. If leakage exists, refer to individual car chapters for axle seal replacement procedure. 4. Inspect backing plate attaching bolts and ensure they are tight. 5. Check adjuster screw operation. If satisfactory, lightly lubricate adjusting screw and washer with suitable brake lube. If operation is unsatisfactory, replace. 6. Using fine emery cloth or other suitable abrasive, clean rust and dirt from shoe contact surfaces on backing plate. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component Information > Specifications > Page 5576 Wheel Cylinder: Service and Repair REMOVAL 1. Remove wheel, drum and brake shoes. 2. Disconnect hydraulic line at wheel cylinder. Do not pull metal line away from cylinder as the cylinder connection will bend metal line and make installation difficult. Line will separate from cylinder when cylinder is moved away from brake backing plate. 3. Remove screws holding cylinder to brake plate and remove cylinder. Fig. 23 Wheel Cylinder Disassembled OVERHAUL 1. Referring to Fig. 23 as a guide, remove boots, pistons, springs and cups from cylinder. 2. Place all parts, except cylinder casting in clean brake fluid. Wipe cylinder walls with clean brake fluid. 3. Examine cylinder bore. A scored bore may be honed providing the diameter is not increased more than .005 inch. Replace worn or damaged parts from the repair kit. 4. Before assembling, wash hands with soap and water only, as oil, kerosene or gasoline will contaminate rubber parts. 5. Lubricate cylinder wall and rubber cups with brake fluid. 6. Install springs, cups, pistons and boots in housing. 7. Wipe end of hydraulic line to remove any foreign matter. 8. Place hydraulic cylinder in position. Enter tubing into cylinder and start connecting fitting. 9. Secure cylinder to backing plate and then complete tightening of tubing fitting. 10. Install brake shoes, drum and wheel. 11. Perform system brake bleeding procedure as outlined previously, and adjust brakes. INSTALLATION 1. Wipe end of hydraulic line to remove any foreign matter. 2. Place hydraulic cylinder in position. Enter tubing into cylinder and start connecting fitting. 3. Secure cylinder to backing plate and then complete tightening of tubing fitting. 4. Install brake shoes, drum and wheel. 5. Perform system brake bleeding procedure as outlined previously, and adjust brakes. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Adjustments > W/Rear Disc Brake Parking Brake Control: Adjustments W/Rear Disc Brake Cable Adjustment 1. Apply parking brake control fully on 445 N (100 lbs) foot pedal effort, 334 N (75 lbs) hand effort. Release parking brake control. Repeat application and release. 2. Place the transmission in NEUTRAL (N). Raise the vehicle on an axle-type hoist. 3. With parking brake control in OFF position, release tensioner by ROTATING locking lever AWAY from threaded rod. Tensioner spring will take up cable slack and preload cables. NOTE: DO NOT PULL DOWN on locking lever or it will pull cables down and cause the cables to have low tension. NOTE: Lock tensioner by releasing locking lever. Ensure locking lever is secure by ROTATING it TOWARD threaded rod. 4. Examine tensioner for remaining cable take up capability. If none is present, check all cables, parking brake control and brackets for possible damage or deflection. Replace damaged parts and retension system by using the Initial Installation Adjustment procedure. Initial Installation Adjustment 1. Install parking brake control (hand or foot) tensioner and all cables with routing clips. Connect all cables together with tensioner. NOTE: Be sure to install correct adjuster for rear brake usage. 2. Place the transmission in NEUTRAL (N). Raise the vehicle on an axle-type hoist. 3. With parking brake control in the OFF position, release tensioner by ROTATING locking lever AWAY from threaded rod. Tensioner spring will take up cable slack and preload cables. NOTE: DO NOT PULL DOWN on locking lever or it will pull cables down and cause the cables to have low tension. NOTE: Lock tensioner by releasing locking lever. Ensure locking lever is secure by ROTATING it TOWARD threaded rod. 4. Apply parking brake control fully on 445 N (100 lbs) foot pedal effort, 334 N (75 lbs) hand effort. Release parking brake control. Repeat application and release. 5. Repeat Step 3 to take up any additional slack. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Control > Component Information > Adjustments > W/Rear Disc Brake > Page 5582 Parking Brake Control: Adjustments W/Rear Drum Brake Cable Adjustment 1. Apply parking brake control fully on 445 N (100 lbs) foot pedal effort, 334 N (75 lbs) hand effort. Release parking brake control. Repeat application and release. 2. Place the transmission in NEUTRAL (N). Raise the vehicle on an axle-type hoist. 3. With parking brake control in OFF position, release tensioner by ROTATING locking lever AWAY from threaded rod. Tensioner spring will take up cable slack and preload cables. NOTE: DO NOT PULL DOWN on locking lever or it will pull cables down and cause the cables to have low tension. NOTE: Lock tensioner by releasing locking lever. Ensure locking lever is secure by ROTATING it TOWARD threaded rod. 4. Examine tensioner for remaining cable take up capability. If none is present, check all cables, parking brake control and brackets for possible damage or deflection. Replace damaged parts and retension system by using the Initial Installation Adjustment procedure. Initial Installation Adjustment 1. Install parking brake control (hand or foot) tensioner and all cables with routing clips. Connect all cables together with tensioner. NOTE: Be sure to install correct adjuster for rear brake usage. 2. Place the transmission in NEUTRAL (N). Raise the vehicle on an axle-type hoist. 3. With parking brake control in the OFF position, release tensioner by ROTATING locking lever AWAY from threaded rod. Tensioner spring will take up cable slack and preload cables. NOTE: DO NOT PULL DOWN on locking lever or it will pull cables down and cause the cables to have low tension. NOTE: Lock tensioner by releasing locking lever. Ensure locking lever is secure by ROTATING it TOWARD threaded rod. 4. Apply parking brake control fully on 445 N (100 lbs) foot pedal effort, 334 N (75 lbs) hand effort. Release parking brake control. Repeat application and release. 5. Repeat Step 3 to take up any additional slack. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle Parking Brake Lever: Customer Interest Parking Brake Release Button - Separates From Handle BRAKE - PARKING - RELEASE BUTTON SEPARATES FROM THE HANDLE Article No. 90-24-6 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The console mounted parking brake release button may separate from the parking brake handle because its plastic tabs do not have enough retention force. The control will not latch in an up position; the handle will apply parking brake force but will return to the down position as the driver removes his/her hand. ACTION: Install a parking brake release button repair kit that consists of a button, spring and plastic sleeve. The sleeve improves release button retention. Refer to the following procedure for service details. REMOVAL 1. Remove the floor console. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 45-31, for service details. Figure 1 2. Disengage the shield tab. Lift and rotate the plastic wire shield out of the way to provide working room, Figure 1. Figure 2 3. Using a screwdriver, pry the release rod retaining tab .25" (6.35 mm) away from the release rod, Figure 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle > Page 5591 Figure 3 4. Disengage the release rod from the release pawl. Slide the release rod up through the handle, exposing the release button retaining barbs, Figure 3. Figure 4 5. Remove the button return spring from the handle by rotating the spring clockwise. Start the spring out of the handle with needle nose pliers, Figure 4. INSTALLATION 1. Position the new spring onto the release rod. Rotate the spring counterclockwise until it seats on the stop of the steel arm, Figure 4. CAUTION: DO NOT DAMAGE THE LEATHER ON THE BUTTON OPENING OF THE HANDLE. 2. Slide the release rod up through the parking brake handle exposing the barbs. a. Install the plastic sleeve onto the release rod. Figure 5 b. Make sure that the plastic sleeve enters the spring properly and seats on the stop of the steel arm, Figure 5. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle > Page 5592 Figure 6 3. Push the button onto the release rod until the tabs of the button slip over the barbs, Figure 6. Make sure that the tabs do not enter the sleeve until they have locked in place over the tabs. NOTE: A FAILURE TO PERFORM THIS STEP CORRECTLY MAY CAUSE DAMAGE TO THE BUTTON TABS. THE REMAINING LENGTH OF THE SPRING CAN BE PUSHED INTO THE HANDLE BY THE BUTTON DURING ASSEMBLY. 4. Push the release rod back into the assembly. Reconnect the release rod to the release rod pawl. Figure 7 5. Place .030" (.762 mm) feeler gauge stock between the release rod and the release rod retaining tab. Using pliers, squeeze the tab until .030" (.762 mm) clearance is obtained, Figure 7. 6. Move the handle several times to make sure of proper operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Technical Service Bulletins > Customer Interest for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle > Page 5593 Figure 8 7. Rotate the plastic wire shield back into its original position and snap it in place, Figure 8. 8. Install the console assembly. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 45-31, for service details. PART NUMBER PART NAME CLASS FOSZ-2L760-A Release Button Repair Kit C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902406A Install Parking Brake 0.7 Hr. Release Button Kit DEALER CODING BASIC PART NO. CONDITION CODE 2L760 33 OASIS CODES: 302000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle Parking Brake Lever: All Technical Service Bulletins Parking Brake Release Button - Separates From Handle BRAKE - PARKING - RELEASE BUTTON SEPARATES FROM THE HANDLE Article No. 90-24-6 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The console mounted parking brake release button may separate from the parking brake handle because its plastic tabs do not have enough retention force. The control will not latch in an up position; the handle will apply parking brake force but will return to the down position as the driver removes his/her hand. ACTION: Install a parking brake release button repair kit that consists of a button, spring and plastic sleeve. The sleeve improves release button retention. Refer to the following procedure for service details. REMOVAL 1. Remove the floor console. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 45-31, for service details. Figure 1 2. Disengage the shield tab. Lift and rotate the plastic wire shield out of the way to provide working room, Figure 1. Figure 2 3. Using a screwdriver, pry the release rod retaining tab .25" (6.35 mm) away from the release rod, Figure 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle > Page 5599 Figure 3 4. Disengage the release rod from the release pawl. Slide the release rod up through the handle, exposing the release button retaining barbs, Figure 3. Figure 4 5. Remove the button return spring from the handle by rotating the spring clockwise. Start the spring out of the handle with needle nose pliers, Figure 4. INSTALLATION 1. Position the new spring onto the release rod. Rotate the spring counterclockwise until it seats on the stop of the steel arm, Figure 4. CAUTION: DO NOT DAMAGE THE LEATHER ON THE BUTTON OPENING OF THE HANDLE. 2. Slide the release rod up through the parking brake handle exposing the barbs. a. Install the plastic sleeve onto the release rod. Figure 5 b. Make sure that the plastic sleeve enters the spring properly and seats on the stop of the steel arm, Figure 5. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle > Page 5600 Figure 6 3. Push the button onto the release rod until the tabs of the button slip over the barbs, Figure 6. Make sure that the tabs do not enter the sleeve until they have locked in place over the tabs. NOTE: A FAILURE TO PERFORM THIS STEP CORRECTLY MAY CAUSE DAMAGE TO THE BUTTON TABS. THE REMAINING LENGTH OF THE SPRING CAN BE PUSHED INTO THE HANDLE BY THE BUTTON DURING ASSEMBLY. 4. Push the release rod back into the assembly. Reconnect the release rod to the release rod pawl. Figure 7 5. Place .030" (.762 mm) feeler gauge stock between the release rod and the release rod retaining tab. Using pliers, squeeze the tab until .030" (.762 mm) clearance is obtained, Figure 7. 6. Move the handle several times to make sure of proper operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Lever > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle > Page 5601 Figure 8 7. Rotate the plastic wire shield back into its original position and snap it in place, Figure 8. 8. Install the console assembly. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 45-31, for service details. PART NUMBER PART NAME CLASS FOSZ-2L760-A Release Button Repair Kit C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902406A Install Parking Brake 0.7 Hr. Release Button Kit DEALER CODING BASIC PART NO. CONDITION CODE 2L760 33 OASIS CODES: 302000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Body & Chassis Components Top Of Parking Brake Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation Vacuum Brake Booster: Description and Operation Fig. 2 Bendix Single Diaphragm Power Brake Unit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5609 Fig. 3 Bendix Tandem Diaphragm Power Brake (Type B-2) These units are of the vacuum suspended type. Some units are of the single diaphragm type, Fig. 2 while others are of the tandem diaphragm type, Fig. 3. Both single piston and double piston or split system type master cylinders are used. The vacuum suspended diaphragm type units utilize engine manifold vacuum and atmospheric pressure for its power. It consists of three basic elements combined into a single power unit. The three basic elements of the single diaphragm type are: 1. A vacuum power section which includes a front and rear shell, a power diaphragm, a return spring and a pushrod. 2. A control valve, built integral with the power diaphragm and connected through a valve rod to the brake pedal, controls the degree of brake application or release in accordance with the pressure applied to the brake pedal. 3. A hydraulic master cylinder, attached to the vacuum power section which contains all the elements of the conventional brake master cylinder except for the pushrod, supplies fluid under pressure to the wheel brakes in proportion to the pressure applied to the brake pedal. OPERATION Upon application of the brakes, the valve rod and plunger move to the left in the power diaphragm to close the vacuum port and open the atmospheric port to admit air through the air cleaner and valve at the rear diaphragm chamber. With vacuum present in the rear chamber, a force is developed to move the power diaphragm, hydraulic pushrod and hydraulic piston or pistons to close the compensating port or ports and force fluid under pressure through the residual check valve or valves and lines into the front and rear wheel cylinders to actuate the brakes. As pressure is developed within the master cylinder a counter force acting through the hydraulic pushrod and reaction disc against the vacuum power Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5610 diaphragm and valve plunger sets up a reaction force opposing the force applied to the valve rod and plunger. This reaction force tends to close the atmospheric port and reopen the vacuum port. Since this force is in opposition to the force applied to the brake pedal by the driver it gives the driver a ``feel'' of the amount of brake applied. The proportion of reactive force applied to the valve plunger through the reaction disc is designed into the Master-Vac to assure maximum power consistent with maintaining pedal feel. The reaction force is in direct proportion to the hydraulic pressure developed within the brake system. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Description and Operation > Page 5611 Vacuum Brake Booster: Testing and Inspection Complaints about power brake operation should be handled as if two separate systems exist. Check for faults in the hydraulic system first. If it is satisfactory, start inspecting the power brake circuit. For a quick check of proper power unit operation, press the brake pedal firmly and then start the engine. The pedal should fall away slightly and less pressure should be needed to maintain the pedal in any position. Another check begins with installation of a suitable pressure gauge in the brake hydraulic system. Take a reading with the engine off and the power unit not operating. Maintaining the same pedal height, start the engine and take another reading. There should be a substantial pressure increase in the second reading. Pedal free travel and total travel are critical on cars equipped with power brakes. Pedal travel should be kept strictly to specifications. Take a manifold vacuum reading or check operation of the external vacuum pump if the power unit isn't giving enough assistance. Remember, though, currently produced emission controlled engines, manifold vacuum readings may be less than 15 inches Hg at idle. If manifold vacuum is abnormally low, tune the engine and then try the power brakes again. Naturally, loose vacuum lines and clogged air intake filters will cut down brake efficiency. Most units have a check valve that retains some vacuum in the system when the engine is off. A vacuum gauge check of this valve will tell you when it is restricted or stuck open or closed. Failure of the brakes to release in most instances is caused by a tight or misaligned connection between the power unit and the brake linkage. If this connection is free, look for a broken piston, diaphragm or bellows and return spring. A simple check of the hydraulic system should be made before proceeding. Loosen the connection between the master cylinder and the brake booster. If the brakes release, the trouble is in the power unit; if the brakes still will not release, look for a restricted brake line or similar difficulties in the regular hydraulic circuit. A residual pressure check valve is usually included immediately under the brake line connection on hydraulic assist power brakes. This valve maintains a slight hydraulic pressure within the brake lines and wheel cylinders to give better pedal response. If it is sticking, the brakes may not release. Power brakes that have a hard pedal are usually suffering from a milder form of the same ills that cause complete power unit failure. Collapsed or leaking vacuum lines or insufficient manifold vacuum, as well as punctured diaphragms or bellows and leaky piston seals, all lead to weak power unit operation. A steady hiss when the brake is held down means a vacuum leak that will cause poor power unit operation. Do not immediately condemn the power unit if the brakes grab. First look for all the usual causes, such as greasy linings, scored rotors or drums. Then investigate the power unit. When the trouble has been traced to the power unit, check for a damaged reaction control. The reaction control is usually made up of a diaphragm, spring and valves that tends to resist pedal action. It is put in the system to give the pedal ``feel.'' Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation Vacuum Brake Booster: Service and Repair Removal and Installation 1. Disconnect battery ground cable and remove air cleaner. 2. Disconnect manifold vacuum hose from booster check valve. 3. Disconnect brake lines from primary and secondary outlet ports of master cylinder. 4. Remove master cylinder-to-booster attaching nuts and the master cylinder. 5. Working under instrument panel, disconnect electrical connector from stop lamp switch. 6. Remove hairpin type retainer. Slide stop lamp switch off brake pedal pin just far enough for the switch outer hole to clear the pin, then lower switch away from pin. 7. Remove booster-to-dash panel attaching nuts. 8. On models equipped with speed control, unfasten control amplifier from lower outboard booster stud and position aside. 9. On all models, slide booster pushrod, bushing and inner nylon washer off brake pedal pin. 10. Move booster forward in engine compartment until booster studs clear dash panel, then rotate front of booster toward engine and remove booster. 11. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation > Page 5614 Vacuum Brake Booster: Service and Repair Disassembly and Reassembly Single Diaphragm Booster Fig. 4 Exploded View Of Single Diaphragm Booster Disassembly 1. Remove brake booster from vehicle. 2. Place front shell of booster in a vise. 3. Remove clevis from valve rod and plunger assembly. 4. Remove dust boot from rear shell, Fig. 4, then place alignment marks on front and rear shells for proper alignment during assembly. 5. Rotate rear shell counterclockwise until shell unlocks. Rear shell is spring loaded, use caution when removing it. 6. Remove rear shell, then remove front shell return spring and push rod. 7. Remove front shell retainer and dust boot. 8. Remove rear shell from power piston assembly. 9. Remove rear shell bearing retainer, seal and bearing. 10. Remove retainer holding air filters and air silencer from the valve rod and plunger assembly. 11. Remove diaphragm and plate. 12. Slightly push down on valve rod and remove retainer key and stopper. 13. Remove valve rod and plunger assembly from the power piston assembly. 14. Remove air filters and air silencer from the power piston. 15. Remove reaction disc. Assembly Prior to assembly coat the following with silicone grease; reaction disc surface, dust seal lip, push rod, diaphragm-to-shell contact surfaces, power piston and valve plunger oil seal. 1. Install valve rod and plunger assembly into the power piston. 2. Push down on valve rod, then align groove of the valve plunger with the slot of power piston. 3. Install the valve rod retainer key and stopper. 4. Install two air filters and air silencer into power piston. 5. Place diaphragm and plate onto power piston, ensure the diaphragm is fully seated in the groove of the power piston. 6. Install bearing, bearing seal and bearing retainer into rear shell. 7. Slide rear shell onto power piston while carefully guiding power piston through bearing seal. 8. Using the push rod, install reaction disc into the power piston. 9. Install dust seal, front retainer and push rod into front shell. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component Information > Service and Repair > Removal and Installation > Page 5615 10. Place front shell in a vise, then install front shell return spring. 11. Place rear shell onto front shell noting alignment marks. 12. Rotate rear shell clockwise until rear shell locks into place with front shell. 13. Install dust boot onto rear shell then install clevis onto valve rod and plunger assembly. 14. Install master cylinder. Bendix, Teves & Double Diaphragm Booster On Bendix, Teves and Double Diaphragm Booster type power brake units, overhaul is not required. If it has been determined that the brake booster is defective, replace power brake unit as an assembly. In some instances, the only service required is replacement of the check valve and grommet and pushrod adjustment. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Antilock Power Relay <--> [ABS Main Relay] > Component Information > Locations Antilock Power Relay: Locations Engine Compartment Component Locations RH Front Of Dash, On Relay Bracket Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Brake Fluid Pump Relay > Component Information > Locations Brake Fluid Pump Relay: Locations Engine Compartment Component Locations RH Side Of Dash, On Relay Bracket Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations Electronic Brake Control Module: Locations Body & Chassis Components Below Center Of Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5626 Electronic Brake Control Module: Description and Operation The electronic controller is located on a package tray in the upper portion of the luggage compartment of the vehicle, behind the righthand side of the rear seat. It is an on-board self test non-repairable unit, consisting of two microprocessors and the necessary circuitry for their operation. These microprocessors are programmed identically and operate on the principle of two channel redundant data processing and plausibility criteria monitoring. Most failures which occur to the system will be stored as a code in the controllers constant memory. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic Brake Control Module > Component Information > Locations > Page 5627 Electronic Brake Control Module: Service and Repair Fig. 11 Electronic controller replacement Located, Lower RH panel in luggage compartment. 1. Disconnect battery ground cable. 2. Disconnect electrical connector from electronic controller, Fig. 11. 3. Remove electronic controller attaching screws and the controller. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Level Sensor/Switch > Component Information > Locations Brake Fluid Level Sensor/Switch: Locations Engine Compartment Component Locations In Master Cylinder, Below Reservoir Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications > ABS Pressure Switch Brake Fluid Pressure Sensor/Switch: Specifications Pressure Switch 15-25 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Specifications > ABS Pressure Switch > Page 5636 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > ABS Pressure Switch Brake Fluid Pressure Sensor/Switch: Locations ABS Pressure Switch Engine Compartment Component Locations In Brake Control Unit Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > ABS Pressure Switch > Page 5639 Brake Fluid Pressure Sensor/Switch: Locations Brake Pressure Warning Switch Engine Compartment Component Locations In Brake Line, Below Master Cylinder Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 5640 Brake Fluid Pressure Sensor/Switch: Description and Operation Fig. 4 Pressure Differential Valve & Brake Warning Light Switch Fig. 5 Pressure Differential Valve & Brake Warning Light Switch Fig. 6 Pressure Differential Valve & Brake Warning Light Switch There are four basic types of brake warning light switches as shown in Figs. 4 through 6 and usually form a common electrical circuit with the brake warning light. When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 5641 As shown in Fig. 4, movement of the differential valve forces the switch plunger upward over the tapered shoulder of the valve to close the switch contacts and light the dual brake warning lamp, signaling a brake system failure. In Fig. 5, the valve assembly consists of two valves in a common bore that are spring loaded toward the centered position. The spring-loaded switch contact plunger rests on top of the valves in the centered position (right view). When a pressure differential occurs between the front and rear brake systems, the valves will shuttle toward the side with the low pressure. The spring-loaded switch plunger is triggered and the ground circuit for the warning light is completed, lighting the lamp (left view). In Fig. 6, as pressure falls in one system, the other system's normal pressure forces the piston to the inoperative side, contacting the switch terminal, causing the warning light on the instrument panel to glow. On front wheel drive models, a fluid level indicator replaces the pressure differential valve used in previous brake systems. It is contained inside the body of the master cylinder plastic reservoir and activates the brake warning light when fluid level is low. Fig. 7 Typical pressure valve and brake warning light switch Testing Warning Light System If the parking brake light is connected into the service brake warning light system, the brake warning light will flash only when the parking brake is applied with the ignition turned ON. The same light will also glow should one of the two service brake systems fail when the brake pedal is applied. To test the system, turn the ignition on and apply the parking brake. If the lamp fails to light, inspect for a burned out bulb, disconnected socket, a broken or disconnected wire at the switch. Fig. 7 is an exterior view of one of these switches. They are usually mounted on the left frame side rail or on the brake pedal bracket. To test the brake warning system, raise the car and open a wheel bleeder valve while a helper depresses the brake pedal and observes the warning light on the instrument panel. If the bulb fails to light, inspect for a burned out bulb, disconnected socket, or a broken or disconnected wire at the switch. If the bulb is not burned out, and the wire continuity is proven, replace the brake warning switch. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Fluid Pressure Sensor/Switch > Component Information > Locations > Page 5642 Brake Fluid Pressure Sensor/Switch: Service and Repair Fig. 12 Pressure switch replacement 1. Relieve system hydraulic pressure by turning ignition off and pumping brake pedal at least 20 times until an increase in pedal force is felt. 2. Disconnect battery ground cable. 3. Disconnect 7-pin electrical connector from solenoid valve body and 5-pin pressure warning switch connector if equipped, Fig. 12. It may be necessary to remove the lefthand front tie-rod at the steering knuckle to gain access to the switch. 4. Remove pressure switch using a suitable tool. 5. Reverse procedure to install. Torque pressure switch to 15---25 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake Pad Wear Sensor > Component Information > Locations Brake Pad Wear Sensor: Locations At Respective Wheels, On Brake Housing Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Body & Chassis Components Top Of Parking Brake Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications Wheel Speed Sensor: Specifications Front/Rear Sensor Tightening Torque Front/Rear Sensor Tightening Torque Front Sensor Bracket Bolts 10-15 ft.lb Rear Sensor Bolts 14-20 ft.lb Sensor Bracket Post Bolts 40-60 in.lb Sensor Set Screws 21-26 in.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 5652 Wheel Speed Sensor: Locations Body & Chassis Components In Respective Wheelhouse Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 5653 Wheel Speed Sensor: Description and Operation Fig. 7 Wheel Sensor Assembly (righthand Side Shown, Lefthand Side Similar). 1989 Continental Fig. 8 Wheel Sensor Assembly. Cougar & Thunderbird Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Specifications > Page 5654 Fig. 9 Wheel Sensor Assembly. Mark VII This system, Figs. 7 thru 9, uses four sets of variable reluctance sensors and toothed speed indicator rings to determine the rotational speed of each wheel. The sensors operate on magnetic induction principle. For example, as the teeth on the speed indicator ring rotate past the stationary sensor, a signal proportional to the speed of the rotation is generated and transmitted to the electronic control unit (ECU) through a coaxial cable. The front sensors are attached to the suspension knuckles and the speed indicator rings are pressed onto the hubs. The rear sensors are attached to the axle housing and the speed indicator rings are pressed onto the inner CV joints. The sensors and the speed indicator rings are serviced individually. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring Wheel Speed Sensor: Service and Repair Toothed Ring Front Fig. 16 Front toothed sensor ring removal REMOVAL 1. Remove wheel and tire assembly. 2. Remove brake caliper and rotor assemblies. 3. Position rotor assembly on an arbor press with studs facing up, then carefully press each stud individually until they contact sensor ring surface. 4. Press studs and sensor ring out of rotor simultaneously, Fig. 16. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5657 Fig. 17 Front toothed sensor ring installation INSTALLATION 1. Install studs into rotor one at a time. 2. Position sensor ring onto rotor, then press ring until fully seated, Fig. 17. 3. Install rotor and caliper assemblies, then the wheel and tire. Rear Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5658 Fig. 18 Rear toothed sensor ring removal Removal 1. Remove rear axle shaft, refer to Rear Axle Replacement Procedures. 2. Install pinion bearing cone remover tool, Fig. 18, between axle shaft flange and sensor ring. Ensure recessed portion of inner surface of tool is toward axle flange. 3. Position axle in an arbor press and press axle out of sensor ring. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5659 Fig. 19 Rear toothed sensor ring installation Installation 1. To install, position sensor on axle shaft with recessed side facing inboard. 2. Install pinion bearing cone remover tool, Fig. 19, on axle shaft. 3. Position a piece of bar stock on top of axle flange, then press sensor ring onto axle shaft until a 1.8 inch gap between face of sensor ring and flange is obtained. 4. Install axle shaft. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel Speed Sensor > Component Information > Service and Repair > Toothed Ring > Page 5660 Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Front 1. Disconnect sensor electrical connector for RH or LH front sensor from underside of the vehicle (up near radiator support). 2. Remove routing clips along wiring harness. 3. Remove Torx head screw securing sensor to spindle. 4. Reverse procedure to install. Torque Torx head screw to 40-60 inch lbs. Rear 1. Disconnect battery ground cable. 2. Disconnect wheel sensor electrical connector, located behind wheelwell, under carpeting, inside luggage compartment. 3. Push sensor wire grommet through hole in luggage compartment floor. 4. Raise and support vehicle, then remove sensor wire from routing clips. 5. On Cougar and Thunderbird models, remove sensor retaining bolt with a 1/2 inch socket. 6. On Mark VII models, proceed as follows: a. Remove wheel and tire assembly, then caliper and rotor assemblies. b. Remove Torx head retaining bolt, then slip grommet out of rear brake splash shield and pull sensor out through the hole. 7. Reverse procedure to install, noting the following: a. On Cougar and Thunderbird models, align sensor location tab and bolt hole to axle, then push into position. b. Torque retaining bolt to 14-20 ft. lbs. c. On Mark VII models, loosen 5mm setscrew on sensor and ensure sensor slides freely on sensor bracket post. d. If sensor is to be reused or adjusted, ensure sensor face is clean and free of foreign material. Carefully scrape pole face with a dull knife. Glue a new front paper spacer on pole face (spacer is marked with a "R" and is .043 inch thick). Steel sleeve around post bolt must be rotated to provide a new surface for setscrew to indent and lock into. e. Torque Torx head screw to 40-60 inch lbs. f. Push sensor toward toothed ring, until new paper sensor contacts sensor ring. Hold sensor, then torque 5mm setscrew to 21-26 inch lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Clutch Switch Jumper Clutch Pedal Position Switch: Locations Clutch Switch Jumper On Clutch Pedal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Clutch Switch Jumper > Page 5667 Clutch Pedal Position Switch: Locations Clutch Pedal Switch I/P Components On Clutch Pedal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Page 5668 Clutch Pedal Position Switch: Adjustments Fig. 18 Clutch Interlock Three Function Switch. Cougar & Thunderbird 1. Disconnect switch electrical connector, Fig. 18. 2. Using a volt-ohmmeter, check for continuity at the following switch terminals. a. EFI switch terminals 5 and 6 should be open with clutch pedal released. Terminals 5 and 6 should show continuity, within two inches of clutch pedal travel. b. Speed control release switch terminals 3 and 4 should be show continuity with clutch pedal released. Terminals 3 and 4 should open within two inches of clutch pedal travel. c. Clutch interlock switch terminals 1 and 2 should be open with clutch pedal released. Terminals 1 and 2 should close within one inch from full clutch pedal travel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Page 5669 Clutch Pedal Position Switch: Service and Repair Fig. 18 Clutch Interlock Three Function Switch. Cougar & Thunderbird 1. Disconnect switch electrical connector, Fig. 18. 2. Separate switch tab from clip by pulling downward on the clip. 3. Expose switch plastic retainer by rotating switch 1/2 turn. 4. Separate switch from retainer by pressing tabs together and allowing retainer to move rearward. 5. Remove switch from push rod. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: Customer Interest Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair Removal 1. Place the selector lever in the MANUAL LOW position. 2. Disconnect battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the Neutral Start Switch electrical harness from the Neutral Start Switch by PUSHING the harness straight UP OFF the switch using a long-bladed screwdriver underneath the rubber plug section of the harness. 5. Remove the Neutral Start Switch and O-ring using Neutral Start Switch Socket or equivalent, assembled to a ratchet 24 cm (9 1/2 inches) in length. Once the socket and ratchet are on the switch, sufficient clearance for tool movement can be gained by reaching from the REAR of the transmission over the extension housing area while standing on a stool. CAUTION: Use the Neutral Start Switch Socket or equivalent for both removing and installing the switch. Other tools could crush or puncture the walls of the switch. Installation 1. Install the Neutral Start Switch and O-ring. CAUTION: Exercise care not to damage the switch terminals. Tighten to 11-15 Nm (8-11 ft-lbs) using a clicker-type torque wrench, the Neutral Start Switch socket tool, and by following the method in Step 4 of the REMOVAL procedure for tool clearance. 2. Connect the Neutral Start Switch electrical harness to the Neutral Start Switch. 3. Lower the vehicle from the hoist. 4. Connect battery ground cable. 5. Check the operation of the Neutral Start Switch in each position with the parking brake ENGAGED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Neutral Start Relay (Inhibitor Relay) > Component Information > Locations Neutral Start Relay (Inhibitor Relay): Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay > Component Information > Locations Starter Relay: Locations Engine Compartment Component Locations On Left Fender Apron Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Battery > Battery Cable > Component Information > Technical Service Bulletins > Body/Frame - Arc Welding Precautions Battery Cable: Technical Service Bulletins Body/Frame - Arc Welding Precautions Article No. 90-11-6 EEC IV-ELECTRONIC CONTROL MODULES AND PROCESSORS-POSSIBLE DAMAGE FROM ARC WELDING FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE MERKUR: 1985-89 XR4Ti 1988-90 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1986-90 AEROSTAR 1989-90 F SUPER DUTY 1991 EXPLORER ISSUE: Electronic control modules, including EEC processors, may be damaged if the negative battery ground cable is not disconnected before arc welding is done to the vehicle, This occurs because the arc welding process can produce high electrical currents in the body of a vehicle when the negative battery ground cable is left connected. ACTION: If arc welding procedures are to be performed, be sure to disconnect the battery ground cable, CAUTION: DISCONNECT THE NEGATIVE BATTERY GROUND CABLE BEFORE USING ANY ELECTRIC WELDING EQUIPMENT OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800, 680000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Description and Operation Rectifier Diode / Bridge: Description and Operation Six silicon diode rectifiers are used and act as electrical one-way valves. Three of the diodes have ground polarity and are pressed or screwed into a heat sink which is grounded. The other three diodes (ungrounded) are pressed or screwed into and insulated from the end head; these diodes are connected to the alternator output terminal. Since the diodes have a high resistance to the flow of current in one direction and a low resistance in the opposite direction, they may be connected in a manner which allows current to flow from the alternator to the battery in the low resistance direction. The high resistance in the opposite direction prevents the flow of current from the battery to the alternator. Because of this feature no circuit breaker is required between the alternator and battery. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Description and Operation > Page 5704 Rectifier Diode / Bridge: Testing and Inspection Fig. 14 Side Terminal Alternator Rectifier Short Or Grounded & Stator Grounded Test Fig. 15 Rear Terminal Alternator Rectifier Short Or Grounded & Stator Grounded Test Fig. 16 Alternator w/Integral Regulator Rectifier Short Or Grounded & Stator Grounded Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Charging System > Alternator > Rectifier Diode / Bridge, Alternator > Component Information > Description and Operation > Page 5705 Using a suitable ohmmeter, connect one probe to the alternator BAT or B+ terminal, Figs. 14, 15 and 16, the other probe to the STA terminal (rear blade terminal). Then, reverse the ohmmeter probes and repeat the test. A reading of about 6-6.5 ohms should be obtained in one direction and no needle movement with the probes reversed. A reading in both directions indicates a bad positive diode, a grounded positive diode plate, grounded BAT or B+ terminal or a shorted radio suppression capacitor, if equipped. Perform the same test using the STA and GND (ground) terminals of the alternator. A reading in both directions indicates either a bad negative diode, a grounded stator winding, a grounded stator terminal, a grounded positive diode plate, or a shorted radio capacitor, if equipped. Infinite readings (no needle movement) in all four probe positions in the proceeding tests indicates an open terminal lead connection inside the alternator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications Voltage Regulator: Specifications Measure battery voltage and record figure. With engine operating off idle and all secondary electrical systems turned off, regulated voltage should be no greater than 2.5 volts above recorded figure. Turn on headlights and set heater blower to high. Regulated voltage of idle should be no less than 0.5 volts above recorded figure. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Specifications > Page 5709 Voltage Regulator: Locations On Rear Of Alternator Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection > S Circuit Test - With Ammeter Voltage Regulator: Testing and Inspection S Circuit Test - With Ammeter Alternators W/Integral Regulator Fig. 13 Testing Regulator S &/Or I Circuit. Integral Alternator Regulator (IAR) 1. Disconnect electrical connector from regulator. Connect a jumper wire from the regulator A lead to connector plug A lead. Add a jumper wire from the regulator F screw to the alternator rear housing, Fig. 13. 2. With engine idling and voltmeter negative lead connected to alternator rear housing, connect voltmeter positive lead to S terminal and then to I terminal of regulator electrical connector. Voltage at S circuit should read approximately one-half of the I circuit. If voltage readings are normal, remove jumper wire. Replace regulator and connect electrical connector to regulator. 3. If no voltage is present, remove jumper wires and service faulty circuit or alternator. 4. Connect voltmeter positive lead to positive battery terminal. 5. Connect electrical connector to regulator and replace bulb, if equipped. Exc. Alternators W/Integral Regulator Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection > S Circuit Test - With Ammeter > Page 5712 Voltage Meter 1. Connect the positive lead of the voltmeter to the S terminal of the regulator wiring plug. Turn the ignition switch to the ``On.'' position. Do not start the engine. 2. The voltmeter reading should indicate battery voltage. 3. If there is no voltage reading at the S terminal, check for voltage at the battery feed wire at the alternator. ^ If there is no voltage at the battery feed wire, check for an open fusible link or an open wire between the battery and the alternator. ^ If there is voltage, check for an open wire between the S terminal of the regulator wiring plug and the alternator or a defective alternator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection > S Circuit Test - With Ammeter > Page 5713 Voltage Regulator: Testing and Inspection S & I Circuit Test - With Indicator Lamp Alternators W/Integral Regulator Fig. 13 Testing Regulator S &/Or I Circuit. Integral Alternator Regulator (IAR) 1. Disconnect electrical connector from regulator. Connect a jumper wire from the regulator A lead to connector plug A lead. Add a jumper wire from the regulator F screw to the alternator rear housing, Fig. 13. 2. With engine idling and voltmeter negative lead connected to alternator rear housing, connect voltmeter positive lead to S terminal and then to I terminal of regulator electrical connector. Voltage at S circuit should read approximately one-half of the I circuit. If voltage readings are normal, remove jumper wire. Replace regulator and connect electrical connector to regulator. 3. If no voltage is present, remove jumper wires and service faulty circuit or alternator. 4. Connect voltmeter positive lead to positive battery terminal. 5. Connect electrical connector to regulator and replace bulb, if equipped. Exc. Alternators W/Integral Regulator Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection > S Circuit Test - With Ammeter > Page 5714 Fig. 11 Regulator Plug Voltage Test Fig. 12 Testing Regulator S &/Or I Circuit. External Voltage Regulator (EVR) 1. Disconnect regulator wiring plug, then install a suitable jumper wire between connector ``A'' and ``F'' terminals, Fig. 12. 2. With the engine idling and negative voltmeter lead connected to battery ground, connect positive lead of voltmeter to S terminal and then to I terminal of regulator wiring plug, Fig. 11. Voltage of S circuit should read approximately 1/2 of the I circuit. If voltage readings are as specified, remove jumper wire, replace regulator and connect wiring plug. 3. If no voltage is present, the wiring is at fault. Service the faulty circuit. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information > Testing and Inspection > Page 5715 Voltage Regulator: Adjustments These regulators are factory calibrated and sealed and no adjustment is possible. If regulator calibration values are not within specifications, the regulator must be replaced. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Clutch Switch Jumper Clutch Pedal Position Switch: Locations Clutch Switch Jumper On Clutch Pedal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Clutch Switch Jumper > Page 5721 Clutch Pedal Position Switch: Locations Clutch Pedal Switch I/P Components On Clutch Pedal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Page 5722 Clutch Pedal Position Switch: Adjustments Fig. 18 Clutch Interlock Three Function Switch. Cougar & Thunderbird 1. Disconnect switch electrical connector, Fig. 18. 2. Using a volt-ohmmeter, check for continuity at the following switch terminals. a. EFI switch terminals 5 and 6 should be open with clutch pedal released. Terminals 5 and 6 should show continuity, within two inches of clutch pedal travel. b. Speed control release switch terminals 3 and 4 should be show continuity with clutch pedal released. Terminals 3 and 4 should open within two inches of clutch pedal travel. c. Clutch interlock switch terminals 1 and 2 should be open with clutch pedal released. Terminals 1 and 2 should close within one inch from full clutch pedal travel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Clutch Pedal Position Switch <--> [Clutch Switch] > Component Information > Locations > Page 5723 Clutch Pedal Position Switch: Service and Repair Fig. 18 Clutch Interlock Three Function Switch. Cougar & Thunderbird 1. Disconnect switch electrical connector, Fig. 18. 2. Separate switch tab from clip by pulling downward on the clip. 3. Expose switch plastic retainer by rotating switch 1/2 turn. 4. Separate switch from retainer by pressing tabs together and allowing retainer to move rearward. 5. Remove switch from push rod. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Ignition Key Warning Switch - Replacement Procedure Ignition Lock: Technical Service Bulletins Ignition Key Warning Switch - Replacement Procedure IGNITION SYSTEM-IGNITION KEY WARNING SWITCH-REPLACEMENT PROCEDURE SWITCH-IGNITION KEY WARNING-REPLACEMENT PROCEDURE Article No. 89-19-2 FORD: 1986-90 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1986-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR ISSUE: A new procedure for servicing the ignition key warning switch has been developed. The new procedure is not published in the shop manual. ACTION: Use the following service procedure to remove and install the ignition key warning switch. Figure 1 REMOVAL 1. Remove the ignition lock assembly from the steering column lock housing. Refer to the appropriate Car Shop Manual, Section 13-04 for service details. NOTE: LEAVE THE LOCK IN THE RUN POSITION. DO NOT TURN THE IGNITION KEY. 2. Remove the switch from the lock assembly using a screwdriver as shown in Figure 1. 3. Throw away the switch. Figure 2 INSTALLATION 1. Obtain a new key warning switch (11A127). 2. Place the switch halfway on the lock cylinder case. Note proper alignment as shown in Figure 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Technical Service Bulletins > Ignition Key Warning Switch - Replacement Procedure > Page 5728 Figure 3 3. While pressing down on the switch with the thumb, slide the switch into place making sure all tabs are in place, Figure 3. 4. Install the lock cylinder assembly. Refer to the procedure in Section 13-04 of the appropriate Car Shop Manual. PART NUMBER PART NAME CLASS E7DZ-11A127-A Key Warning Switch C (Continental, Taurus, Sable) E6SZ-11A127-A Key Warning Switch (All Other C Car Lines) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2500, 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions Ignition Lock: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 5731 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 5732 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 5733 Ignition Lock: Connector Views For Connector Views, please refer to: Ignition Switch/Diagrams, Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Actuator & Steering Wheel Lock Pawl Ignition Lock: Service and Repair Ignition Lock Actuator & Steering Wheel Lock Pawl Fig. 4 Steering Column Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Actuator & Steering Wheel Lock Pawl > Page 5736 Fig. 5 Steering Column Exploded View Refer to Figs. 4 and 5 for component identification. Removal 1. Remove lock cylinder housing, ignition lock switch, lock cylinder assembly and lock drive gear as described previously. 2. Slide actuator assembly out of the rear of the track in the lock cylinder housing. 3. Remove lock pawl and spring. Installation 1. Install lock pawl and spring on actuator assembly. 2. Install actuator assembly into track on lock cylinder housing and install the lock drive gear and lock cylinder assembly. 3. Install ignition switch and lock cylinder housing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Actuator & Steering Wheel Lock Pawl > Page 5737 Ignition Lock: Service and Repair Ignition Lock Drive Gear Silver Colored Lock Cylinder Fig. 4 Steering Column Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Actuator & Steering Wheel Lock Pawl > Page 5738 Fig. 5 Steering Column Exploded View Refer to Figs. 4 and 5 for component identification. Removal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Actuator & Steering Wheel Lock Pawl > Page 5739 Fig. 30 Ignition Lock Drive Gear Removal & Installation. Models w/Modular Steering Columns & Silver Lock Cylinder 1. Remove lock cylinder assembly. 2. Insert a flat screwdriver into recess of drive gear at bottom of lock cylinder housing and turn drive gear three notches counterclockwise. 3. Remove snap ring, washer and lock driver gear from lock cylinder housing. Carefully note relationship of lock drive gear to position of rack teeth, Fig. 30. Installation 1. Place lock drive gear in base of lock cylinder housing in same position as that noted during removal. The position of lock drive gear will be correct if the last tooth on the drive gear is meshed with the last tooth on the rack, Fig. 30. 2. Install washer and snap ring, then insert a flat screwdriver into recess of lock drive gear at bottom of lock cylinder housing and turn drive gear three notches in a clockwise direction. 3. Install lock cylinder assembly. Gold Colored Lock Cylinder Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Actuator & Steering Wheel Lock Pawl > Page 5740 Fig. 4 Steering Column Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Actuator & Steering Wheel Lock Pawl > Page 5741 Fig. 5 Steering Column Exploded View Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service and Repair > Ignition Lock Actuator & Steering Wheel Lock Pawl > Page 5742 Fig. 31 Ignition Lock Drive Gear Removal & Installation. Models w/Modular Steering Columns & Gold Lock Cylinder Removal 1. Remove lock cylinder assembly. 2. Note position of bearing retainer. Remove plastic bearing retainer by inserting tool with 90 degree bend on tip between bearing retainer and bearing, then prying upward. 3. Note position of lock drive gear to position of rack teeth, Fig. 31. Insert tip of screwdriver into double D slot in bearing and rotate 1/4 turn. Remove bearing and lock drive gear. Installation 1. Install lock drive gear in lock cylinder housing as shown in Fig. 31. Position of lock drive gear is correct if last tooth on drive gear is meshed with last tooth on rack. 2. Install bearing retainer in lock cylinder housing. Insert tip of screwdriver into double D slot of bearing and turn 1/4 turn. 3. Press plastic bearing retainer into housing in original position. 4. Pull down on column lock actuator to line up flats of drive gear with flats on washer. Install lock cylinder assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: Customer Interest Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89251 > Dec > 89 > Ignition Lock Ignition Key Hard to Remove Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times Valve: All Technical Service Bulletins Engine - Stalls/Hesitates/Long Cranking Times Article No. 93-12-6 06/09/93 ^ HESITATION ON ACCELERATION AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ IDLE - ROUGH - AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ LONG CRANK TIMES - 2.3L, 2.3L OHC, 3.8L NA ^ STALL AT IDLE AND UPON GEAR ENGAGEMENT AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ STALL AT IDLE AND UPON GEAR ENGAGEMENT AFTER COLD START - 2.3L, 2.3L OHC. 3.8L NA ^ ENGINE - INTAKE VALVE CLEANING PROCEDURE - 2.3L, 2.3L OHC, 3.8L NATURALLY ASPIRATED FORD: 1988-92 MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-92 CONTINENTAL, COUGAR, SABLE, TOPAZ LIGHT TRUCK: 1988-92 RANGER This TSB Article is being republished in its entirety to update the Intake Valve Deposit (IVD) inspection/cleaning procedure and to provide technical service tips for the 2.3L OHC engine. ISSUE: Vehicles with excessive intake valve deposit (IVD) may exhibit the following driveability concerns after a cold start. These drive concerns may also result from the use of fuels that have low volatility, such as high octane, "premium" fuels. ^ Long crank times ^ Idle stall after initial cold start ^ Stall upon gear engagement ^ Rough idle after cold start ^ Hesitation on acceleration after cold start ^ Hesitation/Stall on initial acceleration (3.8L N/A applications) When these deposits are dry, they act like sponges which absorb engine fuel. This may result in a lean engine run condition after an initial cold start. The drive conditions normally occur at ambient temperatures of 40~ F (4~ C) to 70~ F (21~ C). ACTION: An IVD inspection and cleaning procedure has been developed using the Rotunda 014-00975 Carbon Blaster Kit. If service is required, use the following procedure to correct the stated driveability concerns. NOTE: MANY FLUIDS ARE AVAILABLE TO CLEAN FUEL INJECTORS. SOME INJECTOR CLEANING FLUIDS ALSO CLAIM TO REMOVE INTAKE VALVE DEPOSITS (IVD). ENGINEERING EVALUATION OF THESE FLUIDS INDICATES NO ABILITY TO REMOVE THE IVD CAUSING THE STATED DRIVEABILITY CONCERNS. IF DRIVEABILITY CONCERNS HAVE BEEN AFFECTED BY INJECTOR CLEANING FLUIDS, IT IS MOST LIKELY DUE TO CLEAN-UP OF PORT FUEL INJECTOR DEPOSITS. IVD IS MORE DIFFICULT TO REMOVE THAN PORT FUEL INJECTOR DEPOSITS. IVD MUST BE COMPLETELY REMOVED AS OUTLINED IN THIS TSB ARTICLE TO RESTORE COLD-START DRIVEABILITY PERFORMANCE. THE OVERUSE OF THESE FLUIDS MAY CAUSE ENGINE DAMAGE NOT COVERED UNDER WARRANTY. 1. Perform underhood inspection of vacuum lines and wiring. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 5762 2. Perform normal Engine Emissions Diagnostics. Refer to the Engine/Emissions Diagnostics Shop Manual or the Powertrain Control/Emissions Diagnosis Manual. 3. If normal Engine/Emissions Diagnostics have not resolved the driveability concerns, proceed with the following IVD inspection. INTAKE VALVE DEPOSIT INSPECTION PROCEDURE 1. Remove any two (2) spark plugs. Use a remote starter switch to bump the engine over until the intake valve is fully open in the cylinder to be inspected. 2. Using the 014-00975 Automotive Borescope or equivalent, inspect the backside of the intake valves through the spark plug holes for the presence of carbon deposits. CAUTION: DO NOT BUMP THE ENGINE WITH THE BORESCOPE IN THE SPARK PLUG HOLE OR ATTEMPT TO VIEW THE VALVE WHILE ROTATING THE ENGINE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. CAUTION: DO NOT POWER THE BORESCOPE LIGHT SOURCE FROM A CAR BATTERY WHILE IT IS UNDER CHARGE. FOR EXAMPLE, IF THE ENGINE IS RUNNING, THE LAMP MAY FAIL. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 5763 3. Compare the deposits with the Intake Valve Deposit Rating System Chart, Figure 1. a. If either of the intake valves appear to have a carbon deposit level of 7 or less (lower number rating), intake valve cleaning is required. b. Proceed to the IVD Cleaning Procedure. 4. If no carbon deposits are seen or the deposit level is 8 or cleaner, the drive concern may be the result of low volatility fuel. Refer to TSB 91-8-13 and proceed to Fuel Recommendation. CLEANING PROCEDURE NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 5764 BEFORE BEGINNING THE IVD CLEANING PROCEDURE, USE THE FOLLOWING CARBON BLASTER TIPS: ^ Be sure that compressed shop air is dry. Drain compressor of water regularly. ^ remove any in-line equipment oilers from the air line to be used with the carbon blaster ^ Be sure to store walnut shells in a water tight container with the lid on. ^ Remove unused walnut shells from the carbon blaster when IVD procedure is completed. Do not store walnut shells in carbon blaster. 1. Remove the upper intake manifold assembly, fuel rail and injectors. Refer to the instructions in the appropriate Service Manual. 2. Insert the Rotunda 014-00975 Automotive Borescope or equivalent through the fuel injector holes into the lower intake manifold to determine which intake valves are in the closed position. CAUTION: DO NOT ROTATE THE ENGINE WITH THE BORESCOPE IN THE FUEL INJECTOR HOLE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. 3. Perform the intake valve carbon cleaning procedure, using the Rotunda Tool 014-00975 Carbon Blaster and Automotive Borescope Kit, or equivalent, on the intake valves that are in the closed position. NOTE: DETAILED WRITTEN INSTRUCTIONS AND A PROCEDURAL VIDEO TAPE ARE INCLUDED WITH THE ROTUNDA CARBON BLASTER AND AUTOMOTIVE BORESCOPE KIT. TECHNICAL TIP - 2.3L OHC ENGINE When IVD cleaning is performed on the 2.3L OHC dual plug engine, the vacuum should be connected to the lower intake manifold as follows: ^ Remove flex hose and manifold adapter from the hand held vacuum. ^ Insert tapered end of vacuum hose into intake port of manifold using a twisting motion to ensure a tight fit. ^ Proceed with the IVD cleaning process. (CLEANING PROCEDURE CONTINUED) When the cleaning procedure is complete, the backside of the intake valve and cylinder port area surrounding the valve will be free of deposits. Confirm complete deposit removal by borescope inspection. (Normal IVD cleaning time is 1 to 1-1/2 minutes per valve.) 4. Bump the engine until the remaining intake valves to be cleaned are in the closed position. Repeat Cleaning Procedure Step # 3. 5. Inspect all intake valves to verify complete carbon deposit removal. 6. Install the fuel rail, fuel injectors, and upper intake manifold using a new intake manifold gasket. Refer to the Dealer Master Parts Catalog for correct part number. 7. Proceed to FUEL RECOMMENDATION. FUEL RECOMMENDATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 5765 Fuels that do not contain the proper detergent additives may result in the formation of intake system deposits, including clogged port fuel injectors and intake valve deposits. To assist the customer in selecting the proper fuel, provide the customer with a copy of the "Clean Gasoline" Flyer, Figure 2. Refer to OASIS special service messages 9000 through 9023 to identify appropriate brands of fuel. To access these messages, enter the vehicle VIN and Service Code 404000. The fuel list will be updated periodically. Gasolines on this list are advertised as having intake system deposit control detergents. Regular use of these fuels should minimize or eliminate accumulation of intake system deposits. NOTE: IF A HIGH QUALITY FUEL IS CONTINUOUSLY USED WHICH CONTAINS INTAKE SYSTEM DEPOSIT CONTROL DETERGENTS AND OTHER ADDITIVES, AFTERMARKET ADDITIVES SHOULD NEVER NEED TO BE ADDED TO THE FUEL TANK. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 5766 Fuels that vaporize poorly may cause similar symptoms or may contribute to symptoms related to intake system deposits. Refer to TSB 91-8-13 for additional information. OTHER APPLICABLE ARTICLES: 91-10-9, 91-11-4, 91-8-13 SUPERSEDES: 92-19-3 WARRANTY STATUS: Eligible Under Basic Warranty Coverage and Powertrain For 1991 And Prior Cars And Light Trucks (Excluding Lincolns), Eligible For Bumper To Bumper For 1991 Lincolns And All 1992 Cars And Light Trucks OPERATION DESCRIPTION TIME 931206A Perform Engine Emission 0.5 Hr. Test And Underhood Inspection 931206B Perform Engine Emission 1.0 Hr. Test, Underhood Inspection And Intake Valve Inspection 931206C Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Ranger 931206D Perform Engine Emission 3.3 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Tempo/Topaz 931206E Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Mustang 931206F Perform Engine Emission 4.1 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Taurus/Sable And Continental 931206G Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Thunderbird/Cougar DEALER CODING BASIC PART NO. CONDITION CODE 6507 49 OASIS CODES: 499000, 602300, 607000, 607400, 608000, 608400, 609000, 609400, 611000, 611500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 5772 2. Perform normal Engine Emissions Diagnostics. Refer to the Engine/Emissions Diagnostics Shop Manual or the Powertrain Control/Emissions Diagnosis Manual. 3. If normal Engine/Emissions Diagnostics have not resolved the driveability concerns, proceed with the following IVD inspection. INTAKE VALVE DEPOSIT INSPECTION PROCEDURE 1. Remove any two (2) spark plugs. Use a remote starter switch to bump the engine over until the intake valve is fully open in the cylinder to be inspected. 2. Using the 014-00975 Automotive Borescope or equivalent, inspect the backside of the intake valves through the spark plug holes for the presence of carbon deposits. CAUTION: DO NOT BUMP THE ENGINE WITH THE BORESCOPE IN THE SPARK PLUG HOLE OR ATTEMPT TO VIEW THE VALVE WHILE ROTATING THE ENGINE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. CAUTION: DO NOT POWER THE BORESCOPE LIGHT SOURCE FROM A CAR BATTERY WHILE IT IS UNDER CHARGE. FOR EXAMPLE, IF THE ENGINE IS RUNNING, THE LAMP MAY FAIL. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 5773 3. Compare the deposits with the Intake Valve Deposit Rating System Chart, Figure 1. a. If either of the intake valves appear to have a carbon deposit level of 7 or less (lower number rating), intake valve cleaning is required. b. Proceed to the IVD Cleaning Procedure. 4. If no carbon deposits are seen or the deposit level is 8 or cleaner, the drive concern may be the result of low volatility fuel. Refer to TSB 91-8-13 and proceed to Fuel Recommendation. CLEANING PROCEDURE NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 5774 BEFORE BEGINNING THE IVD CLEANING PROCEDURE, USE THE FOLLOWING CARBON BLASTER TIPS: ^ Be sure that compressed shop air is dry. Drain compressor of water regularly. ^ remove any in-line equipment oilers from the air line to be used with the carbon blaster ^ Be sure to store walnut shells in a water tight container with the lid on. ^ Remove unused walnut shells from the carbon blaster when IVD procedure is completed. Do not store walnut shells in carbon blaster. 1. Remove the upper intake manifold assembly, fuel rail and injectors. Refer to the instructions in the appropriate Service Manual. 2. Insert the Rotunda 014-00975 Automotive Borescope or equivalent through the fuel injector holes into the lower intake manifold to determine which intake valves are in the closed position. CAUTION: DO NOT ROTATE THE ENGINE WITH THE BORESCOPE IN THE FUEL INJECTOR HOLE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. 3. Perform the intake valve carbon cleaning procedure, using the Rotunda Tool 014-00975 Carbon Blaster and Automotive Borescope Kit, or equivalent, on the intake valves that are in the closed position. NOTE: DETAILED WRITTEN INSTRUCTIONS AND A PROCEDURAL VIDEO TAPE ARE INCLUDED WITH THE ROTUNDA CARBON BLASTER AND AUTOMOTIVE BORESCOPE KIT. TECHNICAL TIP - 2.3L OHC ENGINE When IVD cleaning is performed on the 2.3L OHC dual plug engine, the vacuum should be connected to the lower intake manifold as follows: ^ Remove flex hose and manifold adapter from the hand held vacuum. ^ Insert tapered end of vacuum hose into intake port of manifold using a twisting motion to ensure a tight fit. ^ Proceed with the IVD cleaning process. (CLEANING PROCEDURE CONTINUED) When the cleaning procedure is complete, the backside of the intake valve and cylinder port area surrounding the valve will be free of deposits. Confirm complete deposit removal by borescope inspection. (Normal IVD cleaning time is 1 to 1-1/2 minutes per valve.) 4. Bump the engine until the remaining intake valves to be cleaned are in the closed position. Repeat Cleaning Procedure Step # 3. 5. Inspect all intake valves to verify complete carbon deposit removal. 6. Install the fuel rail, fuel injectors, and upper intake manifold using a new intake manifold gasket. Refer to the Dealer Master Parts Catalog for correct part number. 7. Proceed to FUEL RECOMMENDATION. FUEL RECOMMENDATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 5775 Fuels that do not contain the proper detergent additives may result in the formation of intake system deposits, including clogged port fuel injectors and intake valve deposits. To assist the customer in selecting the proper fuel, provide the customer with a copy of the "Clean Gasoline" Flyer, Figure 2. Refer to OASIS special service messages 9000 through 9023 to identify appropriate brands of fuel. To access these messages, enter the vehicle VIN and Service Code 404000. The fuel list will be updated periodically. Gasolines on this list are advertised as having intake system deposit control detergents. Regular use of these fuels should minimize or eliminate accumulation of intake system deposits. NOTE: IF A HIGH QUALITY FUEL IS CONTINUOUSLY USED WHICH CONTAINS INTAKE SYSTEM DEPOSIT CONTROL DETERGENTS AND OTHER ADDITIVES, AFTERMARKET ADDITIVES SHOULD NEVER NEED TO BE ADDED TO THE FUEL TANK. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 5776 Fuels that vaporize poorly may cause similar symptoms or may contribute to symptoms related to intake system deposits. Refer to TSB 91-8-13 for additional information. OTHER APPLICABLE ARTICLES: 91-10-9, 91-11-4, 91-8-13 SUPERSEDES: 92-19-3 WARRANTY STATUS: Eligible Under Basic Warranty Coverage and Powertrain For 1991 And Prior Cars And Light Trucks (Excluding Lincolns), Eligible For Bumper To Bumper For 1991 Lincolns And All 1992 Cars And Light Trucks OPERATION DESCRIPTION TIME 931206A Perform Engine Emission 0.5 Hr. Test And Underhood Inspection 931206B Perform Engine Emission 1.0 Hr. Test, Underhood Inspection And Intake Valve Inspection 931206C Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Ranger 931206D Perform Engine Emission 3.3 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Tempo/Topaz 931206E Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Mustang 931206F Perform Engine Emission 4.1 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Taurus/Sable And Continental 931206G Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Thunderbird/Cougar DEALER CODING BASIC PART NO. CONDITION CODE 6507 49 OASIS CODES: 499000, 602300, 607000, 607400, 608000, 608400, 609000, 609400, 611000, 611500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information > Service and Repair Neutral Safety Switch: Service and Repair Removal 1. Place the selector lever in the MANUAL LOW position. 2. Disconnect battery ground cable. 3. Raise the vehicle on a hoist. 4. Disconnect the Neutral Start Switch electrical harness from the Neutral Start Switch by PUSHING the harness straight UP OFF the switch using a long-bladed screwdriver underneath the rubber plug section of the harness. 5. Remove the Neutral Start Switch and O-ring using Neutral Start Switch Socket or equivalent, assembled to a ratchet 24 cm (9 1/2 inches) in length. Once the socket and ratchet are on the switch, sufficient clearance for tool movement can be gained by reaching from the REAR of the transmission over the extension housing area while standing on a stool. CAUTION: Use the Neutral Start Switch Socket or equivalent for both removing and installing the switch. Other tools could crush or puncture the walls of the switch. Installation 1. Install the Neutral Start Switch and O-ring. CAUTION: Exercise care not to damage the switch terminals. Tighten to 11-15 Nm (8-11 ft-lbs) using a clicker-type torque wrench, the Neutral Start Switch socket tool, and by following the method in Step 4 of the REMOVAL procedure for tool clearance. 2. Connect the Neutral Start Switch electrical harness to the Neutral Start Switch. 3. Lower the vehicle from the hoist. 4. Connect battery ground cable. 5. Check the operation of the Neutral Start Switch in each position with the parking brake ENGAGED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Neutral Start Relay (Inhibitor Relay) > Component Information > Locations Neutral Start Relay (Inhibitor Relay): Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision Technical Service Bulletin # 9211B1 Date: 920605 Starter Motor Brushes - Replacement Revision Article No. 92-11B-1 06/05/92 ^ SHOP MANUAL - 1982 THROUGH 1991 AS APPLICABLE - STARTER - POSITIVE ENGAGEMENT - STARTER MOTOR BRUSHES REPLACEMENT PROCEDURE FOR 4-INCH STARTERS REVISED/ADDED ^ SHOP MANUAL - 1990 AND 1991 AS APPLICABLE - STARTER - POSITIVE ENGAGEMENT STARTER SIZE SPECFICATION REVISED FORD: 1989 CROWN VICTORIA, ESCORT, TEMPO 1989-90 THUNDERBIRD 1989-91 MUSTANG, TAURUS LINCOLN-MERCURY: 1989 CONTINENTAL, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1989-90 COUGAR 1989-91 SABLE LIGHT TRUCK: 1982-91 BRONCO, ECONOLINE, F-150-350 SERIES 1983-91 RANGER 1984-90 BRONCO II 1986-91 AEROSTAR 1988-91 F SUPER DUTY ISSUE: The procedure for Starter Motor Brushes Replacement applicable to vehicles with 4-inch starters only is missing or incorrect in the "Starter-Positive Engagement" section of certain Shop Manuals. Additionally, the 1990 and 1991 Light Truck Shop Manuals incorrectly show a 3-inch starter in the Specifications Chart; the correct size is 4-inch. The following Shop Manuals are affected in the Sections indicated: ^ 1989 Domestic Car Lines: Section 28-02 ^ 1990 Mustang, Taurus/Sable, Thunderbird/Cougar: Section 28-02 ^ 1991 Mustang, Taurus/Sable: Section 28-02 ^ 1986 through 1988 Aerostar: Section 11-02 ^ 1989 Aerostar, Ranger, Bronco II: Section 03-06 ^ 1990 and 1991 Aerostar, Ranger, Bronco II: Section 03-06A ^ 1983 Ranger/1984 Bronco II (Reprint), 1984 through 1988 Ranger/Bronco II, 1982 through 1990 Light Truck-Engine: Section 28-02 ^ 1991 Light Truck-Engine: Section 03-06A ACTION: Refer to Disassembly and Assembly in this TSB article for the additional information. NOTE: THIS TSB ARTICLE INCLUDES REVISED PAGES FROM THE 1989, 1990 AND 1991 CAR SHOP MANUALS LISTED ABOVE, THE 1991 COMPACT TRUCK SHOP MANUAL AND THE 1990 AND 1991 LIGHT TRUCK SHOP MANUALS. ALTHOUGH NOT SHOWN, THE REVISIONS APPLY TO ALL LIGHT TRUCK AND COMPACT TRUCK MANUALS LISTED ABOVE. NOTE: THE PROCEDURE IN THIS TSB ARTICLE APPLIES TO VEHICLES WITH 4-INCH STARTERS ONLY. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5788 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5789 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5790 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5791 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5792 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5793 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5794 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5795 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5796 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5797 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5798 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5799 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5801 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5802 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5803 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5804 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5805 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5806 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5807 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Brush > Component Information > Technical Service Bulletins > Starter Motor Brushes - Replacement Revision > Page 5808 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Technical Service Bulletins > Starter Solenoids and Drives - Obsolete Parts Return Starter Drive/Bendix: Technical Service Bulletins Starter Solenoids and Drives - Obsolete Parts Return Article No. 93-26-12 ^ SERVICE PARTS RETURN OF OBSOLETE STARTER SOLENOIDS AND STARTER MOTOR DRIVES - ALL SOLENOIDS, BUT ONLY STARTER DRIVES WITH PACKAGING DATE CODES BEFORE "01 1693" ^ SERVICE STARTER - SERVICE PARTS RETURN OF OBSOLETE STARTER SOLENOIDS AND STARTER MOTOR DRIVES - ALL SOLENOIDS, BUT ONLY STARTER DRIVES WITH PACKAGING DATE CODES BEFORE "011693" FORD: 1989-94 THUNDERBIRD 1990-94 CROWN VICTORIA, TAURUS 1991-94 TEMPO LINCOLN-MERCURY: 1989-94 COUGAR, TOWN CAR 1990 MARK VII 1990-94 GRAND MARQUIS, SABLE 1991 TOPAZ LIGHT TRUCK: 1990 BRONCO 1990-94 AEROSTAR, F-150-350 SERIES 1991-94 RANGER 1992-94 ECONOLINE ISSUE: Improved starter solenoid and starter drives replace the obsolete parts. ACTION: Remove the obsolete parts from your dealership's inventory. All of the starter solenoids (E90Z-11390-B) regardless of build date and the obsolete starter drives (F2TZ-11002-A and F2TZ-11002-C) with packaging date codes before "011693" should be returned to your facing PDC within thirty (30) days of this TSB. 1. Sort dealership stock of F2TZ-11002-A and F2TZ-11002-C. Receivals with a packaging date code of 011693 or later will contain OK stock and may be released for normal sale. 2. Packaging date codes before 011693 are suspect and should be rejected and returned to your facing PDC using the least expensive transportation. 3. If claim is processed electronically using DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". 4. In the "Remarks" section, write "Returned Per TSB 93-26-12". 5. Issue Form 291 to reject suspect stock. LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts must have been purchased from FCSD in accordance with Policy And Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. NOTE: THE PART NUMBER HAS NOT BEEN CHANGED. OBSOLETE STOCK CAN ONLY BE DETERMINED VIA PACKAGING DATE CODE. DO NOT RETURN PARTS HAVING PACKAGING DATE CODES OF "011693" OR LATER. NOTE: REPLACEMENT STOCK IS AVAILABLE FOR ORDERING IMMEDIATELY. OTHER APPLICABLE ARTICLES:NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Starter Drive/Bendix > Component Information > Technical Service Bulletins > Page 5813 Starter Drive/Bendix: Testing and Inspection Starter drive troubles are easy to diagnose and they usually cannot be confused with ordinary starter difficulties. If the starter does not turn over at all or if it drags, look for trouble in the starter or electrical supply system. Concentrate on the starter drive or ring gear if the starter is noisy, if it turns but does not engage the engine, or if the starter won't disengage after the engine is started. After the starter is removed, the trouble can usually be located quickly. Worn or chipped ring gear or starter pinion are the usual causes of noisy operation. Before replacing either or both of these parts try to find out what caused the damage. With the Bendix type drive, incomplete engagement of the pinion with the ring gear is a common cause of tooth damage. The wrong pinion clearance on starter drives of the over-running clutch type leads to poor meshing of the pinion and ring gear and too rapid tooth wear. A less common cause of noise with either type of drive is a bent starter armature shaft. When this shaft is bent, the pinion gear alternately binds and then only partly meshes with the ring gear. Most manufacturers specify a maximum of .003 inch radial runout on the armature shaft. WHEN CLUTCH DRIVE FAILS The over-running clutch type drive seldom becomes so worn that it fails to engage since it is directly activated by a fork and lever. The only thing that is likely to happen is that, once engaged, it will not turn the engine because the clutch itself is worn out. A much more frequent difficulty and one that rapidly wears ring gear and teeth is partial engagement. Proper meshing of the pinion is controlled by the end clearance between the pinion gear and the starter housing or pinion stop, if used. On some starters, the solenoids are completely enclosed in the starter housing and the pinion clearance is not adjustable. If the clearance is not correct, the starter must be disassembled and checked for excessive wear of solenoid linkage, shift lever mechanism, or improper assembly of parts. Failure of the over-running clutch drive to disengage is usually caused by binding between the armature shaft and the drive. If the drive, particularly the clutch, shows signs of overheating it indicates that it is not disengaging immediately after the engine starts. If the clutch is forced to over-run too long, it overheats and turns a bluish color. For the cause of the binding, look for rust or gum between the armature shaft and the drive, or for burred splines. Excess oil on the drive will lead to gumming, and inadequate air circulation in the flywheel housing will cause rust. Over-running clutch drives cannot be overhauled in the field so they must be replaced. In cleaning, never soak them in a solvent because the solvent may enter the clutch and dissolve the sealed-in lubricant. Wipe them off lightly with kerosene and lubricate them sparingly with Lubriplate 777 or equivalent. WHEN BENDIX DRIVE FAILS When a Bendix type drive doesn't engage the cause usually is one of three things: either the drive spring is broken, one of the drive spring bolts has sheared off, or the screw shaft threads won't allow the pinion to travel toward the flywheel. In the first two cases, remove the drive by unscrewing the set screw under the last coil of the drive spring and replace the broken parts. Gummed or rusty screw shaft threads are fairly common causes of Bendix drive failure and are easily cleaned with a little kerosene or steel wool, depending on the trouble. Here again, as in the case of over-running clutch drives, use light oil sparingly, and be sure the flywheel housing has adequate ventilation. There is usually a breather hole in the bottom of the flywheel housing which should be open. The failure of a Bendix drive to disengage or to mesh properly is most often caused by gummed or rusty screw shaft threads. When this is not true, look for mechanical failure within the drive itself. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations Starter Relay: Locations Engine Compartment Component Locations On Left Fender Apron Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Technical Service Bulletins > Starter Solenoids and Drives - Obsolete Parts Return Starter Solenoid: Technical Service Bulletins Starter Solenoids and Drives - Obsolete Parts Return Article No. 93-26-12 ^ SERVICE PARTS RETURN OF OBSOLETE STARTER SOLENOIDS AND STARTER MOTOR DRIVES - ALL SOLENOIDS, BUT ONLY STARTER DRIVES WITH PACKAGING DATE CODES BEFORE "01 1693" ^ SERVICE STARTER - SERVICE PARTS RETURN OF OBSOLETE STARTER SOLENOIDS AND STARTER MOTOR DRIVES - ALL SOLENOIDS, BUT ONLY STARTER DRIVES WITH PACKAGING DATE CODES BEFORE "011693" FORD: 1989-94 THUNDERBIRD 1990-94 CROWN VICTORIA, TAURUS 1991-94 TEMPO LINCOLN-MERCURY: 1989-94 COUGAR, TOWN CAR 1990 MARK VII 1990-94 GRAND MARQUIS, SABLE 1991 TOPAZ LIGHT TRUCK: 1990 BRONCO 1990-94 AEROSTAR, F-150-350 SERIES 1991-94 RANGER 1992-94 ECONOLINE ISSUE: Improved starter solenoid and starter drives replace the obsolete parts. ACTION: Remove the obsolete parts from your dealership's inventory. All of the starter solenoids (E90Z-11390-B) regardless of build date and the obsolete starter drives (F2TZ-11002-A and F2TZ-11002-C) with packaging date codes before "011693" should be returned to your facing PDC within thirty (30) days of this TSB. 1. Sort dealership stock of F2TZ-11002-A and F2TZ-11002-C. Receivals with a packaging date code of 011693 or later will contain OK stock and may be released for normal sale. 2. Packaging date codes before 011693 are suspect and should be rejected and returned to your facing PDC using the least expensive transportation. 3. If claim is processed electronically using DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". 4. In the "Remarks" section, write "Returned Per TSB 93-26-12". 5. Issue Form 291 to reject suspect stock. LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts must have been purchased from FCSD in accordance with Policy And Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. NOTE: THE PART NUMBER HAS NOT BEEN CHANGED. OBSOLETE STOCK CAN ONLY BE DETERMINED VIA PACKAGING DATE CODE. DO NOT RETURN PARTS HAVING PACKAGING DATE CODES OF "011693" OR LATER. NOTE: REPLACEMENT STOCK IS AVAILABLE FOR ORDERING IMMEDIATELY. OTHER APPLICABLE ARTICLES:NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Starting System > Starter Solenoid > Component Information > Technical Service Bulletins > Page 5821 Starter Solenoid: Testing and Inspection The solenoid switch on a cranking motor not only closes the circuit between the battery and the cranking motor but also shifts the drive pinion into mesh with the engine flywheel ring gear. This is done by means of a linkage between the solenoid switch plunger and the shift lever on the cranking motor. There are two windings in the solenoid; a pull-in winding and a hold-in winding. Both windings are energized when the external control switch is closed. They produce a magnetic field which pulls the plunger in so that the drive pinion is shifted into mesh, and the main contacts in the solenoid switch are closed to connect the battery directly to the cranking motor. Closing the main switch contacts shorts out the pull-in winding since this winding is connected across the main contacts. The magnetism produced by the hold-in winding is sufficient to hold the plunger in, and shorting out the pull-in winding reduces drain on the battery. When the control switch is opened, it disconnects the hold-in winding from the battery. When the hold-in winding is disconnected from the battery, the shift lever spring withdraws the plunger from the solenoid, opening the solenoid switch contacts and at the same time withdrawing the drive pinion from mesh. Proper operation of the switch depends on maintaining a definite balance between the magnetic strength of the pull-in and hold-in windings. This balance is established in the design by the size of the wire and the number of turns specified. An open circuit in the hold-in winding or attempts to crank with a discharged battery will cause the switch to chatter. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Circuit Location Amp Cigar Lighter Fuse Panel 20 Power Door Locks Fuse Panel 20 Power Moon Roof Fuse Panel 20 Power Seats Fuse Panel 20 Power Windows Fuse Panel 20 Windshield Wiper Fuse Panel 8.25 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 5830 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Page 5831 Diode: Locations In Window Regulator Harness, Near G300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Electrical Accessory Panel: Locations Engine Compartment Component Locations LH Fender Apron, Near Battery Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Fuse: Customer Interest Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Fuse: All Technical Service Bulletins Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuse: > NHTSA88V165000 > Oct > 88 > Recall 88V165000: Fuel Tank Leaks Rollover Valve: All Technical Service Bulletins Recall 88V165000: Fuel Tank Leaks PLASTIC ROLL-OVER VALVE MOUNTING PLATE MAY NOT BE PROPERLY SEALED TO THE PLASTIC FUEL TANK. FUEL OR VAPOR COULD LEAK, WHICH COULD RESULT IN A VEHICLE FIRE. REPLACE FUEL TANK. SYSTEM: FUEL TANK. VEHICLE DESCRIPTION: PASSENGER CARS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5858 Fuse: Locations Behind LH Rear Wheelwell, In Window Regulator Harness Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised Fuse Block: Technical Service Bulletins EEC IV Test Step TA3 Check Fuse - Revised Article No. 89-25A-4 12/15/89 ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1989 - PAGE 22 - CIRCUIT PROTECTION/JUNCTION BLOCKS - FUSE PANEL DISTRIBUTION BOX TITLE REVISED ^ SHOP MANUAL - 1989 - PAGE 33-05-11 - TEST STEP TA3, CHECK FUSE - REVISED FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Page 22 of the 1989 Thunderbird/Cougar Electrical/Vacuum Troubleshooting Manual and page 33-05-11 of the 1989 Thunderbird/Cougar Shop Manual, have been revised to better describe the circuits protected by the "Memory" fuse. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 5863 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 5864 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 5865 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 5866 ACTION: Refer to the pages in this TSB article for the revised circuit protection junction block and diagnostic procedures. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Panel Fuse Panel Details Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Panel > Page 5869 Fuse Block: Locations Fuse Panel & Flasher Location Fuse panel is on LH side of lower instrument panel. Combination turn signal/hazard flasher is located to RH side of steering column opening reinforcement, mounted on a bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5872 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5873 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5874 Fuse Panel Details Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link A Fusible Link: Locations Fuse Link A LH Front Of Engine Compartment, At Starter Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link A > Page 5879 Fusible Link: Locations Fuse Link B LH Front Of Engine Compartment, Near Starter Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link A > Page 5880 Fusible Link: Locations Fuse Link C LH Front Of Engine Compartment, Near Starter Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work Multiple Junction Connector: Customer Interest Vehicle - No Start Condition/Accessories Don't Work Article No. 89-6-6 ^ NO START - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE ^ POWER ACCESSORIES - INOPERATIVE - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A no start condition or power accessories that do not work may be caused by a loose or disconnected wire at the ground buss connector. The wire leads from the ground buss connectors may be looped under the carpet at the lower edge of the cowl trim panel. This type of routing allows the occupants feet to apply enough downward pressure on the carpet to pull one or more ground terminals from the ground buss connector. Accessories and systems that could be affected are in the 1989 Electrical Vacuum Troubleshooting Manual (EVTM), pages 16 through 19. A partial list of these accessories and systems are: ^ Power door locks ^ Power windows ^ Power seats ^ Keyless entry ^ Luggage compartment remote release ^ Interior courtesy lamps ^ Passive restraints ACTION: Inspect the driver's side ground buss connector (G-300) and the passenger's side ground buss connector (G-301) for loose or disconnected ground wires. Refer to the following procedure for service details. FIGURE 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest for Multiple Junction Connector: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work > Page 5889 FIGURE 2 1. Using the 1989 Thunderbird/Cougar EVTM, pages 16 through 19, determine which ground buss connector (G-300 or G-301) requires service, Figure 1 and 2. 2. Remove the cowl trim panel. 3. Detach the ground buss connector from the cowl. 4. Inspect each terminal for a proper connection. NOTE: THE TERMINALS ARE EASILY SEEN THROUGH THE WHITE PLASTIC COVER OF THE GROUND BUSS CONNECTOR. 5. If a wire(s) is loose or pulled out of a terminal(s), remove the terminal(s) from the ground buss connector and solder the wire(s) to the terminal(s). 6. Reinstall the repaired terminal(s) in the ground buss connector. 7. Reposition the ground buss connector. Rotate the ground buss connector either forward or rearward to allow the ground wire leads to be as close to the cowl as possible. 8. Install a 4-6 inch piece of body tape on the wire harness to hold it to the cowl panel, Figures 1 and 2. 9. Reinstall the cowl trim panel. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 890606A Inspect & Repair Ground 0.6 Hr. Buss (one side) 890606B Inspect & repair Ground 1.0 Hr. Buss (both sides) DEALER CODING BASIC PART NO. CONDITION CODE 14A488 44 OASIS CODES: 2100, 2150, 2700, 2770, 2900, 610200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work Multiple Junction Connector: All Technical Service Bulletins Vehicle - No Start Condition/Accessories Don't Work Article No. 89-6-6 ^ NO START - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE ^ POWER ACCESSORIES - INOPERATIVE - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A no start condition or power accessories that do not work may be caused by a loose or disconnected wire at the ground buss connector. The wire leads from the ground buss connectors may be looped under the carpet at the lower edge of the cowl trim panel. This type of routing allows the occupants feet to apply enough downward pressure on the carpet to pull one or more ground terminals from the ground buss connector. Accessories and systems that could be affected are in the 1989 Electrical Vacuum Troubleshooting Manual (EVTM), pages 16 through 19. A partial list of these accessories and systems are: ^ Power door locks ^ Power windows ^ Power seats ^ Keyless entry ^ Luggage compartment remote release ^ Interior courtesy lamps ^ Passive restraints ACTION: Inspect the driver's side ground buss connector (G-300) and the passenger's side ground buss connector (G-301) for loose or disconnected ground wires. Refer to the following procedure for service details. FIGURE 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Multiple Junction Connector: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work > Page 5895 FIGURE 2 1. Using the 1989 Thunderbird/Cougar EVTM, pages 16 through 19, determine which ground buss connector (G-300 or G-301) requires service, Figure 1 and 2. 2. Remove the cowl trim panel. 3. Detach the ground buss connector from the cowl. 4. Inspect each terminal for a proper connection. NOTE: THE TERMINALS ARE EASILY SEEN THROUGH THE WHITE PLASTIC COVER OF THE GROUND BUSS CONNECTOR. 5. If a wire(s) is loose or pulled out of a terminal(s), remove the terminal(s) from the ground buss connector and solder the wire(s) to the terminal(s). 6. Reinstall the repaired terminal(s) in the ground buss connector. 7. Reposition the ground buss connector. Rotate the ground buss connector either forward or rearward to allow the ground wire leads to be as close to the cowl as possible. 8. Install a 4-6 inch piece of body tape on the wire harness to hold it to the cowl panel, Figures 1 and 2. 9. Reinstall the cowl trim panel. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 890606A Inspect & Repair Ground 0.6 Hr. Buss (one side) 890606B Inspect & repair Ground 1.0 Hr. Buss (both sides) DEALER CODING BASIC PART NO. CONDITION CODE 14A488 44 OASIS CODES: 2100, 2150, 2700, 2770, 2900, 610200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations > Secondary Junction Block Multiple Junction Connector: Locations Secondary Junction Block I/P Components LH Side Of I/P, RH Side Of Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations > Secondary Junction Block > Page 5898 Multiple Junction Connector: Locations Primary Junction Block I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Circuit Breaker > Component Information > Locations Circuit Breaker: Locations Circuit Location Amp Cigar Lighter Fuse Panel 20 Power Door Locks Fuse Panel 20 Power Moon Roof Fuse Panel 20 Power Seats Fuse Panel 20 Power Windows Fuse Panel 20 Windshield Wiper Fuse Panel 8.25 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement Diode: Technical Service Bulletins Electrical Diode - Identification and Replacement Article No. 96-24-6 11/18/96 WIRING - ELECTRICAL DIODE IDENTIFICATION AND SERVICE REPLACEMENTS FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1983-97 RANGER 1984-90 BRONCO II 1984-97 ECONOLINE, F-150-350 SERIES 1986-97 AEROSTAR 1991-97 EXPLORER 1995-97 WINDSTAR MEDIUM/HEAVY TRUCK: 1984-91 C SERIES, CL-CLT-9000 SERIES 1984-97 F & B SERIES, L SERIES 1986-97 CARGO SERIES 1996-97 AEROMAX, LOUISVILLE This TSB article is being republished in its entirety to update the applicable model years. ISSUE: Electrical system concerns that are due to diode failure may be serviced with an approved Ford service diode. Some electrical diodes used in early production vehicles are color coded for the purpose of size identification while others are stamped with a manufacture number. All Ford service diodes and current production diodes are identified by manufacture number. ACTION: If service is required, refer to the appropriate model/year Electrical and Vacuum Troubleshooting Manual (EVTM) to determine the size and location of the diode(s). Refer to the following Electrical Diode Application Chart for the correct service part number. NOTE: IF THE DIODE REQUIRING REPLACEMENT DOES NOT HAVE THE SAME RATING AS LISTED IN THE APPLICATION CHART, USE THE NEXT HIGHER RATED DIODE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Electrical Diode - Identification and Replacement > Page 5907 ELECTRICAL DIODE APPLICATION CHART PART NUMBER PART NAME E8DZ-10C912-A Diode - 1.0 Amp - 400V E8DZ-10C912-B Diode - 6.0 Amp - 400V OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 89-2-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 2770 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Technical Service Bulletins > Page 5908 Diode: Locations In Window Regulator Harness, Near G300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Electrical Accessory Panel > Component Information > Locations Electrical Accessory Panel: Locations Engine Compartment Component Locations LH Fender Apron, Near Battery Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuse: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Fuse: All Technical Service Bulletins Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Customer Interest for Fuse: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Fuse: Customer Interest Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Technical Service Bulletins > Page 5925 Fuse: Locations Behind LH Rear Wheelwell, In Window Regulator Harness Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised Fuse Block: Technical Service Bulletins EEC IV Test Step TA3 Check Fuse - Revised Article No. 89-25A-4 12/15/89 ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1989 - PAGE 22 - CIRCUIT PROTECTION/JUNCTION BLOCKS - FUSE PANEL DISTRIBUTION BOX TITLE REVISED ^ SHOP MANUAL - 1989 - PAGE 33-05-11 - TEST STEP TA3, CHECK FUSE - REVISED FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Page 22 of the 1989 Thunderbird/Cougar Electrical/Vacuum Troubleshooting Manual and page 33-05-11 of the 1989 Thunderbird/Cougar Shop Manual, have been revised to better describe the circuits protected by the "Memory" fuse. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 5930 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 5931 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 5932 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Technical Service Bulletins > EEC IV Test Step TA3 Check Fuse - Revised > Page 5933 ACTION: Refer to the pages in this TSB article for the revised circuit protection junction block and diagnostic procedures. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Panel Fuse Panel Details Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Locations > Fuse Panel > Page 5936 Fuse Block: Locations Fuse Panel & Flasher Location Fuse panel is on LH side of lower instrument panel. Combination turn signal/hazard flasher is located to RH side of steering column opening reinforcement, mounted on a bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions Fuse Block: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5939 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5940 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Diagram Information and Instructions > Page 5941 Fuse Panel Details Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link A Fusible Link: Locations Fuse Link A LH Front Of Engine Compartment, At Starter Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link A > Page 5946 Fusible Link: Locations Fuse Link B LH Front Of Engine Compartment, Near Starter Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Fusible Link > Component Information > Locations > Fuse Link A > Page 5947 Fusible Link: Locations Fuse Link C LH Front Of Engine Compartment, Near Starter Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work Multiple Junction Connector: Customer Interest Vehicle - No Start Condition/Accessories Don't Work Article No. 89-6-6 ^ NO START - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE ^ POWER ACCESSORIES - INOPERATIVE - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A no start condition or power accessories that do not work may be caused by a loose or disconnected wire at the ground buss connector. The wire leads from the ground buss connectors may be looped under the carpet at the lower edge of the cowl trim panel. This type of routing allows the occupants feet to apply enough downward pressure on the carpet to pull one or more ground terminals from the ground buss connector. Accessories and systems that could be affected are in the 1989 Electrical Vacuum Troubleshooting Manual (EVTM), pages 16 through 19. A partial list of these accessories and systems are: ^ Power door locks ^ Power windows ^ Power seats ^ Keyless entry ^ Luggage compartment remote release ^ Interior courtesy lamps ^ Passive restraints ACTION: Inspect the driver's side ground buss connector (G-300) and the passenger's side ground buss connector (G-301) for loose or disconnected ground wires. Refer to the following procedure for service details. FIGURE 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > Customer Interest: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work > Page 5956 FIGURE 2 1. Using the 1989 Thunderbird/Cougar EVTM, pages 16 through 19, determine which ground buss connector (G-300 or G-301) requires service, Figure 1 and 2. 2. Remove the cowl trim panel. 3. Detach the ground buss connector from the cowl. 4. Inspect each terminal for a proper connection. NOTE: THE TERMINALS ARE EASILY SEEN THROUGH THE WHITE PLASTIC COVER OF THE GROUND BUSS CONNECTOR. 5. If a wire(s) is loose or pulled out of a terminal(s), remove the terminal(s) from the ground buss connector and solder the wire(s) to the terminal(s). 6. Reinstall the repaired terminal(s) in the ground buss connector. 7. Reposition the ground buss connector. Rotate the ground buss connector either forward or rearward to allow the ground wire leads to be as close to the cowl as possible. 8. Install a 4-6 inch piece of body tape on the wire harness to hold it to the cowl panel, Figures 1 and 2. 9. Reinstall the cowl trim panel. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 890606A Inspect & Repair Ground 0.6 Hr. Buss (one side) 890606B Inspect & repair Ground 1.0 Hr. Buss (both sides) DEALER CODING BASIC PART NO. CONDITION CODE 14A488 44 OASIS CODES: 2100, 2150, 2700, 2770, 2900, 610200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work Multiple Junction Connector: All Technical Service Bulletins Vehicle - No Start Condition/Accessories Don't Work Article No. 89-6-6 ^ NO START - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE ^ POWER ACCESSORIES - INOPERATIVE - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A no start condition or power accessories that do not work may be caused by a loose or disconnected wire at the ground buss connector. The wire leads from the ground buss connectors may be looped under the carpet at the lower edge of the cowl trim panel. This type of routing allows the occupants feet to apply enough downward pressure on the carpet to pull one or more ground terminals from the ground buss connector. Accessories and systems that could be affected are in the 1989 Electrical Vacuum Troubleshooting Manual (EVTM), pages 16 through 19. A partial list of these accessories and systems are: ^ Power door locks ^ Power windows ^ Power seats ^ Keyless entry ^ Luggage compartment remote release ^ Interior courtesy lamps ^ Passive restraints ACTION: Inspect the driver's side ground buss connector (G-300) and the passenger's side ground buss connector (G-301) for loose or disconnected ground wires. Refer to the following procedure for service details. FIGURE 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work > Page 5962 FIGURE 2 1. Using the 1989 Thunderbird/Cougar EVTM, pages 16 through 19, determine which ground buss connector (G-300 or G-301) requires service, Figure 1 and 2. 2. Remove the cowl trim panel. 3. Detach the ground buss connector from the cowl. 4. Inspect each terminal for a proper connection. NOTE: THE TERMINALS ARE EASILY SEEN THROUGH THE WHITE PLASTIC COVER OF THE GROUND BUSS CONNECTOR. 5. If a wire(s) is loose or pulled out of a terminal(s), remove the terminal(s) from the ground buss connector and solder the wire(s) to the terminal(s). 6. Reinstall the repaired terminal(s) in the ground buss connector. 7. Reposition the ground buss connector. Rotate the ground buss connector either forward or rearward to allow the ground wire leads to be as close to the cowl as possible. 8. Install a 4-6 inch piece of body tape on the wire harness to hold it to the cowl panel, Figures 1 and 2. 9. Reinstall the cowl trim panel. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 890606A Inspect & Repair Ground 0.6 Hr. Buss (one side) 890606B Inspect & repair Ground 1.0 Hr. Buss (both sides) DEALER CODING BASIC PART NO. CONDITION CODE 14A488 44 OASIS CODES: 2100, 2150, 2700, 2770, 2900, 610200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 96129 > Jun > 96 > Differential Chatter On Turns Differential Clutch: All Technical Service Bulletins Differential - Chatter On Turns Article No. 96-12-9 06/03/96 ^ NOISE - "CHATTER" DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING - TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR REAR AXLES ^ AXLE - NEW SERVICE KIT AVAILABLE FOR TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR ^ AXLE - TRACTION-LOK DIFFERENTIAL - 7.5 AND 8.8 INCH RING GEAR - "CHATTER" NOISE DURING TIGHT TURNS OR TURNS AFTER AN EXTENDED PERIOD OF HIGHWAY DRIVING FORD: 1989-96 CROWN VICTORIA, MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1989-96 COUGAR, GRAND MARQUIS, TOWN CAR LIGHT TRUCK: 1989-96 AEROSTAR, BRONCO, E-150, RANGER 1989-97 F-150 1991-96 EXPLORER ISSUE: A "chatter" noise can be felt and/or heard during tight turns or turns after an extended period of highway driving. This is due to insufficient specified friction modifier, or over-shimming of the clutch packs within Traction-Lok differentials. ACTION: Install revised Clutch Pack Replacement Kit (F5ZZ-4947-BA for 7.5" ring gear and F5AZ-4947-BA for 8.8" ring gear), with improved friction material, in the differential after confirming the "chatter" concern with a road test of the vehicle. Refer to the Instruction Sheet within the kit for details. NOTE: THE CLUTCH PACK REPLACEMENT KIT INCLUDES SELECTED SHIMS. IT WILL NOT REQUIRE THE ORDERING OF INDIVIDUAL SHIMS BASED UPON TEARDOWN MEASUREMENTS. REAR AXLE ASSEMBLY IDENTIFICATION See metal Service Identification tag for rear axle ring gear size and differential type. The identification tag is attached to the rear axle cover by means of a cover bolt. The Clutch Pack Replacement kit (F5ZZ-4947-BA) for the 7.5" ring gear traction-lok rear axle contains the following: ^ Two (2) Clutch Packs ^ One (1) Pinion Shaft Lockbolt ^ One (1) 4 oz. bottle of Friction Modifier ^ Two (2) Shims - 0.025" thick ^ Two (2) Shims - 0.030" thick ^ Two (2) Shims - 0.035" thick ^ Two (2) Shims - 0.040" thick ^ Two (2) Shims - 0.045" thick ^ One (1) Instruction Sheet (I.S. # 7145) The Clutch Pack Replacement Kit (F5AZ-4947-BA) for the 8.8" ring gear traction-lok rear axle contains the following: ^ Two (2) Clutch Packs Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 96129 > Jun > 96 > Differential Chatter On Turns > Page 5968 ^ One (1) Pinion Shaft Lockbolt ^ One (1) 4 oz. bottle of Friction Modifier ^ Two (2) Shims - 0.025" thick ^ Two (2) Shims - 0.030" thick ^ Two (2) Shims - 0.035" thick ^ Two (2) Shims - 0.040" thick ^ Two (2) Shims - 0.045" thick ^ One (1) Instruction Sheet (I.S. # 7146) Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Vehicles And Basic Warranty Coverage For All Other Vehicles OPERATION DESCRIPTION TIME 961209A Replace Traction-Lok 1.4 Hrs. Differential Clutch Packs - Crown Victoria/Grand Marquis, Mustang, Town Car, E/F-150, Bronco, Aerostar, Explorer, Ranger 961209B Replace Traction-Lok 2.9 Hrs. Differential Clutch Packs - Thunderbird/Cougar DEALER CODING CONDITION BASIC PART NO. CODE 4001 56 OASIS CODES: 509000, 597997, 702200, 702300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Technical Service Bulletins > All Other Service Bulletins for Multiple Junction Connector: > 96129 > Jun > 96 > Differential Chatter On Turns > Page 5974 ^ One (1) Pinion Shaft Lockbolt ^ One (1) 4 oz. bottle of Friction Modifier ^ Two (2) Shims - 0.025" thick ^ Two (2) Shims - 0.030" thick ^ Two (2) Shims - 0.035" thick ^ Two (2) Shims - 0.040" thick ^ Two (2) Shims - 0.045" thick ^ One (1) Instruction Sheet (I.S. # 7146) Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Vehicles And Basic Warranty Coverage For All Other Vehicles OPERATION DESCRIPTION TIME 961209A Replace Traction-Lok 1.4 Hrs. Differential Clutch Packs - Crown Victoria/Grand Marquis, Mustang, Town Car, E/F-150, Bronco, Aerostar, Explorer, Ranger 961209B Replace Traction-Lok 2.9 Hrs. Differential Clutch Packs - Thunderbird/Cougar DEALER CODING CONDITION BASIC PART NO. CODE 4001 56 OASIS CODES: 509000, 597997, 702200, 702300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations > Secondary Junction Block Multiple Junction Connector: Locations Secondary Junction Block I/P Components LH Side Of I/P, RH Side Of Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information > Locations > Secondary Junction Block > Page 5977 Multiple Junction Connector: Locations Primary Junction Block I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Wheel Alignment Wheel Alignment Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Front Wheel Alignment > Page 5983 Control System And Capacity Data Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber Alignment: Service and Repair Camber Camber is adjusted by rotating a cam bolt at lower control arm inner pivot. Loosen nut securing adjustment and adjust by rotating bolt head. Lock adjustment by holding bolt and torque nut to 125 ft lb. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber > Page 5986 Alignment: Service and Repair Caster Caster is adjusted by moving the tension strut relative to the front sub-frame. Loosen nuts securing strut to sub-frame and adjust caster by running the nuts in appropriate direction until desired setting is achieved. The setting should be locked by holding adjusting nut and torquing locknut to 117 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber > Page 5987 Alignment: Service and Repair Rear Camber Camber is adjusted by rotating a cam bolt at upper control arm inner pivot. Loosen nut securing adjustment and adjust by rotating head of bolt. Lock adjustment by holding bolt and torque nut to 98 ft lb. Toe The recommended adjustment sequence for rear alignment is to set toe then camber. Toe should be rechecked before final tightening. Toe is adjusted by rotating a cam bolt at lower arm inner pivot. Loosen nut securing adjustment and adjust by rotating bolt head. Lock adjustment by holding bolt and torque nut to 170 ft lb. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Camber > Page 5988 Alignment: Service and Repair Toe Toe-in Adjustment 1. Check to see that steering shaft and steering wheel marks are in alignment and in the top position. 2. Loosen clamp screw on tie rod bellows and free the seal on the rod to prevent twisting of bellows, Fig. 1. 3. Place opened end wrench on flats of tie rod socket to prevent socket from turning, then loosen tie rod jam nuts. 4. Use suitable pliers to turn tie rod inner end to correct the adjustment to specifications. Do not use pliers on tie rod threads. Turning to reduce number of threads showing will increase toe-in. Turning in opposite direction will reduce toe-in. 5. Torque tie rod jam nuts to 43-50 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information Steering Control Module: Technical Service Bulletins Rotunda EVO System Tester - Revised Information ^ SHOP MANUAL- 1989 - PAGE 13-52-7 - EVO SYSTEM TESTER REPLACES FABRICATED TEST LAMP ^ SHOP MANUAL - 1990 - PAGE 13-54-7 - EVO SYSTEM TESTER REPLACES FABRICATED TEST LAMP Article No. 90-18B-7 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The Rotunda EVO System Tester 105-00007 is to be used for system diagnosis on the Variable Assist Steering System in place of the fabricated test lamp referenced on Page 13-52-7 of the 1989 Thunderbird/Cougar Shop Manual and Page 13-54-7 of the 1990 Thunderbird/Cougar Shop Manual. ACTION: Refer to the pages following this TSB article for the revised information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 390000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 5995 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 5996 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 5997 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 5998 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 5999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 6000 Steering Control Module: Locations Body & Chassis Components Under Center Of Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 6001 Steering Control Module: Service and Repair With Anti-Lock Brakes 1. Turn ignition switch Off. 2. Locate module tray in luggage compartment, behind LH rear seat. 3. Disengage push-pin on LH side of tray, then swing tray down. 4. Release locking tabs retaining control module to tray, then remove control module. 5. Disconnect electrical connector from module. 6. Reverse procedure to install. Less Anti-Lock Brakes 1. Turn ignition switch Off. 2. Locate module tray in luggage compartment, behind LH rear seat under package tray. 3. Disconnect electrical connector from module. 4. Unscrew two plastic rivets on sides of module, then pull down rivet and head assembly from module. 5. Remove control module from mounting bracket. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations Body & Chassis Components Under Center Of Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 6006 Suspension Control Module: Service and Repair 1. Turn ignition switch to OFF or LOCK position. 2. Working from inside of luggage compartment, remove attaching screws and carefully lower righthand panel located behind rear seat back. 3. Remove screws retaining control module or relay assembly from brackets. 4. Disconnect electrical connectors from control module or relays. 5. Remove control module or relays from mounting brackets. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Main Relay > Component Information > Locations > Hard Ride Relay Suspension Main Relay: Locations Hard Ride Relay Body & Chassis Components Under Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Main Relay > Component Information > Locations > Hard Ride Relay > Page 6011 Suspension Main Relay: Locations Soft Ride Relay Body & Chassis Components Under Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Relays and Modules - Steering and Suspension > Relays and Modules - Suspension > Suspension Main Relay > Component Information > Locations > Page 6012 Suspension Main Relay: Service and Repair 1. Turn ignition switch to Off or LOCK position. 2. Working from inside luggage compartment, disconnect push pin at left side of package tray. 3. Swing tray downward. 4. Disconnect control module or relay electrical connectors, then remove control module or relays. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations I/P Components LH Side Of I/P, On Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair The steering sensor is located at the lower end of the steering column. It may be removed with the steering column either in or out of the vehicle. 1. Disconnect sensor electrical connectors from wiring harness. 2. Disconnect sensor electrical connectors at bracket under instrument panel. 3. Remove speed sensor attaching screws, then remove sensor. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Brake Switch, Suspension Control > Component Information > Service and Repair Brake Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from brake sensor switch. 3. Remove sensor switch from brake control valve body. 4. Reverse procedure to install. Torque brake sensor switch to 8---10 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair The steering sensor is located at the lower end of the steering column. It may be removed with the steering column either in or out of the vehicle. 1. Disconnect sensor electrical connectors from wiring harness. 2. Disconnect sensor electrical connectors at bracket under instrument panel. 3. Remove speed sensor attaching screws, then remove sensor. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Sensors and Switches - Steering and Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair 1. Remove console top to console base attaching screws, then disconnect top panel from console base. 2. Disconnect fog lamp switch and ride control switch electrical connectors. 3. Remove switch attaching screws under panel. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Pinch Bolt & Nut 38-49 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Pitman Arm > Component Information > Specifications Pitman Arm: Specifications Pitman Arm Nut 44-46 ft.lb Pitman Arm To Sector Shaft Retaining Nut 200-250 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose > Component Information > Specifications Power Steering Line/Hose: Specifications Pressure Hose To Gear 16-25 ft.lb Quick Connect Tube Nut 35-45 ft.lb Return Hose To Gear 25-34 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Locations Power Steering Pressure Control Valve: Locations Lower LH Side Of Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pressure Control Valve > Component Information > Locations > Page 6045 Power Steering Pressure Control Valve: Service and Repair ACTUATOR Fig. 13 Actuator Removal 1. Remove windshield washer reservoir. 2. Disconnect electrical connector from actuator. 3. Disconnect return hose from power steering pump, then the pressure hose from the actuator. 4. Remove threaded actuator from power steering pump, Fig. 13. Flow control valve and spring may fall out. 5. Reverse procedure to install. Torque actuator to 25-34 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Pump Mounting Bracket Power Steering Pump: Specifications Pressure Hose Fitting At Pump 10-15 ft.lb Pump Mounting Bracket 30-45 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Pump Mounting Bracket > Page 6050 Power Steering Pump: Specifications Steering Pump To Engine 15-22 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6051 Applications Charts Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Specifications > Page 6052 Power Steering Pump: Description and Operation The Ford model CII power steering pump is a belt driven 10-slipper type pump incorporating a fiberglass filled nylon reservoir. The reservoir is attached to the rear side of the aluminum pump housing assembly. The pump body is encased within the housing and reservoir assembly. The pump design incorporates a pump pressure fitting which allows the pump pressure line to swivel. A pressure sensitive identification tag is attached to the reservoir body. This tag indicates the basic model number and the suffix. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation Power Steering Pump: Service and Repair Removal and Installation On Supercharged engines, intercooler and intercooler tubes must be removed to gain access to power steering pump. 1. On all engines, disconnect return hose from power steering pump reservoir and allow fluid to drain into a suitable container. 2. Disconnect pressure hose from pump fitting, then remove pump mounting bracket and disconnect drive belt from pulley. 3. On models w/fixed pump system, remove pulley. 4. On all models, remove power steering pump. 5. Reverse procedure to install. Tighten to specifications. 6. Do not overtighten pressure hose fitting. Swivel and/or end play of the fitting is normal and does not indicate a loose fitting. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 6055 Power Steering Pump: Service and Repair Disassembly and Assembly Fig. 1 Exploded View Of Ford Model CII Power Steering Pump Fig. 2 Positioning Pump In C-clamp Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 6056 Fig. 3 Valve Cover Retaining Ring Removal Disassemble 1. Remove pulley from pump, Fig. 1. 2. Remove outlet fitting, flow control valve and flow control valve spring from pump, then remove reservoir. 3. Place a suitable C-clamp in a vise. 4. Position lower support plate T78P-3733-A2, or equivalent, over pump rotor shaft. 5. Install upper compressor plate T78P-3733-A1, or equivalent, into upper portion of C-clamp. 6. While holding compressor tool, place pump assembly into C-clamp with rotor shaft facing downward, Fig. 2. 7. Tighten C-clamp until a slight bottoming of valve cover is observed. 8. Through small hole located on side of pump housing, insert a suitable drift and push inward on valve cover snap ring. While pushing inward on snap ring, place a screwdriver under snap ring edge and remove ring from housing, Fig. 3. 9. Loosen C-clamp and remove upper compressor plate T78P-3733-A2, or equivalent, then remove pump assembly. 10. Remove pump valve cover and O-ring. 11. Remove rotor shaft, upper plate, cam and rotor assembly and two dowel pins. 12. Remove lower plate and spring, by tapping housing on a flat surface. 13. Using a suitable screwdriver, remove rotor shaft seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 6057 Fig. 1 Exploded View Of Ford Model CII Power Steering Pump Fig. 4 Slipper Springs Installation Fig. 5 Slippers Installation Assemble 1. Position rotor on rotor shaft splines with triangle detent on rotor counterbore facing upward, Fig. 1. 2. Install snap ring into groove on end of rotor shaft. 3. Position insert cam over rotor. Ensure recessed notch on insert cam is facing upward. 4. With rotor extended upward approximately half out of cam, insert spring into rotor pocket, Fig. 4. 5. Use a slipper to compress spring, then install slipper with groove facing cam, Fig. 5. 6. Perform steps 4 and 5 on slipper cavity beneath opposite inlet recess. 7. While holding cam stationary, index rotor left or right one space and install another spring and slipper until all ten rotor cavities have been filled. Use care when turning rotor that springs and slippers remain in position. 8. Apply Loctite No. 242 or 271 adhesive or equivalent to outside diameter of seal and Loctite NF or T primer or equivalent to seal bore in housing. Install rotor shaft seal using tool No. T78P-3733-A3, or equivalent. Using a plastic mallet, drive seal into bore until properly seated. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 6058 9. Position pump plate on flat surface with pulley side facing downward. 10. Install two dowel pins and spring into housing. Spring must be inserted with dished surface facing upward. 11. Lubricate inner and outer O-ring seals with power steering fluid, then install seals on lower pressure plate. 12. Install lower pressure plate into housing and over dowel pin with O-ring seals facing toward front of pump. Position assembly on C-clamp. Place tool No. T78P-3733-A3, or equivalent, into rotor shaft hole and press on lower plate lightly until it bottoms in pump housing. This will seat the outer O-ring seal. Fig. 6 Assembling Cam, Slippers & Rotor Fig. 7 Upper Pressure Plate Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component Information > Service and Repair > Removal and Installation > Page 6059 Fig. 8 Valve Cover Installation 13. Install cam, rotor, rotor and slippers and rotor shaft assembly into pump housing over dowel pins. When installing assembly into pump housing, stepped holes must be used for dowel pins and notch in cam insert must be toward reservoir and approximately 180 degrees opposite square mounting lug on housing, Fig. 6. 14. Position upper pressure plate over dowel pins with recess directly over recessed notch on cam insert and approximately 180 degrees opposite square mounting lug, Fig. 7. 15. Lubricate O-ring seal with power steering fluid, then position O-ring on valve cover. Ensure plastic baffle is securely in position on valve cover. A coat of petroleum jelly may be used to hold baffle in position. 16. Insert valve cover over dowel pins. Ensure outlet fitting hole in valve cover is aligned with square mounting lug on housing, Fig. 8. 17. Place assembly in C-clamp and compress valve cover into pump housing until snap ring groove on housing is exposed. 18. Install valve cover snap ring in pump housing. Ensure snap ring ends are near access hole in pump housing. 19. Remove pump assembly from C-clamp. 20. Lubricate O-ring seal with power steering fluid, then place seal on pump housing. 21. Install reservoir on pump housing. 22. Install flow control valve and spring into valve cover. 23. Lubricate O-ring seals with power steering fluid, then place seals on outlet fitting. 24. Install outlet fitting on valve cover. Tighten outlet fitting to specifications. Use care not to cock flow control valve when installing. Do not force valve forward otherwise damage to housing may result. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information Power Steering Valve: Technical Service Bulletins Rotunda EVO System Tester - Revised Information ^ SHOP MANUAL- 1989 - PAGE 13-52-7 - EVO SYSTEM TESTER REPLACES FABRICATED TEST LAMP ^ SHOP MANUAL - 1990 - PAGE 13-54-7 - EVO SYSTEM TESTER REPLACES FABRICATED TEST LAMP Article No. 90-18B-7 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The Rotunda EVO System Tester 105-00007 is to be used for system diagnosis on the Variable Assist Steering System in place of the fabricated test lamp referenced on Page 13-52-7 of the 1989 Thunderbird/Cougar Shop Manual and Page 13-54-7 of the 1990 Thunderbird/Cougar Shop Manual. ACTION: Refer to the pages following this TSB article for the revised information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 390000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6064 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6065 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6066 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6067 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Valve > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6068 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information Steering Control Module: Technical Service Bulletins Rotunda EVO System Tester - Revised Information ^ SHOP MANUAL- 1989 - PAGE 13-52-7 - EVO SYSTEM TESTER REPLACES FABRICATED TEST LAMP ^ SHOP MANUAL - 1990 - PAGE 13-54-7 - EVO SYSTEM TESTER REPLACES FABRICATED TEST LAMP Article No. 90-18B-7 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The Rotunda EVO System Tester 105-00007 is to be used for system diagnosis on the Variable Assist Steering System in place of the fabricated test lamp referenced on Page 13-52-7 of the 1989 Thunderbird/Cougar Shop Manual and Page 13-54-7 of the 1990 Thunderbird/Cougar Shop Manual. ACTION: Refer to the pages following this TSB article for the revised information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 390000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6073 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6074 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6075 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6076 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6077 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 6078 Steering Control Module: Locations Body & Chassis Components Under Center Of Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Power Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 6079 Steering Control Module: Service and Repair With Anti-Lock Brakes 1. Turn ignition switch Off. 2. Locate module tray in luggage compartment, behind LH rear seat. 3. Disengage push-pin on LH side of tray, then swing tray down. 4. Release locking tabs retaining control module to tray, then remove control module. 5. Disconnect electrical connector from module. 6. Reverse procedure to install. Less Anti-Lock Brakes 1. Turn ignition switch Off. 2. Locate module tray in luggage compartment, behind LH rear seat under package tray. 3. Disconnect electrical connector from module. 4. Unscrew two plastic rivets on sides of module, then pull down rivet and head assembly from module. 5. Remove control module from mounting bracket. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information Steering Control Module: Technical Service Bulletins Rotunda EVO System Tester - Revised Information ^ SHOP MANUAL- 1989 - PAGE 13-52-7 - EVO SYSTEM TESTER REPLACES FABRICATED TEST LAMP ^ SHOP MANUAL - 1990 - PAGE 13-54-7 - EVO SYSTEM TESTER REPLACES FABRICATED TEST LAMP Article No. 90-18B-7 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The Rotunda EVO System Tester 105-00007 is to be used for system diagnosis on the Variable Assist Steering System in place of the fabricated test lamp referenced on Page 13-52-7 of the 1989 Thunderbird/Cougar Shop Manual and Page 13-54-7 of the 1990 Thunderbird/Cougar Shop Manual. ACTION: Refer to the pages following this TSB article for the revised information. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 390000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6085 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6086 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6087 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6088 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Rotunda EVO System Tester - Revised Information > Page 6089 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 6090 Steering Control Module: Locations Body & Chassis Components Under Center Of Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Relays and Modules - Steering > Steering Control Module > Component Information > Technical Service Bulletins > Page 6091 Steering Control Module: Service and Repair With Anti-Lock Brakes 1. Turn ignition switch Off. 2. Locate module tray in luggage compartment, behind LH rear seat. 3. Disengage push-pin on LH side of tray, then swing tray down. 4. Release locking tabs retaining control module to tray, then remove control module. 5. Disconnect electrical connector from module. 6. Reverse procedure to install. Less Anti-Lock Brakes 1. Turn ignition switch Off. 2. Locate module tray in luggage compartment, behind LH rear seat under package tray. 3. Disconnect electrical connector from module. 4. Unscrew two plastic rivets on sides of module, then pull down rivet and head assembly from module. 5. Remove control module from mounting bracket. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Power Steering Pressure Switch > Component Information > Locations Power Steering Pressure Switch: Locations I/P Components LH Side Of I/P, On Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Sensors and Switches - Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair The steering sensor is located at the lower end of the steering column. It may be removed with the steering column either in or out of the vehicle. 1. Disconnect sensor electrical connectors from wiring harness. 2. Disconnect sensor electrical connectors at bracket under instrument panel. 3. Remove speed sensor attaching screws, then remove sensor. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair The steering sensor is located at the lower end of the steering column. It may be removed with the steering column either in or out of the vehicle. 1. Disconnect sensor electrical connectors from wiring harness. 2. Disconnect sensor electrical connectors at bracket under instrument panel. 3. Remove speed sensor attaching screws, then remove sensor. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Technical Service Bulletins > Ignition Key Warning Switch - Replacement Procedure Key Reminder Switch: Technical Service Bulletins Ignition Key Warning Switch - Replacement Procedure IGNITION SYSTEM-IGNITION KEY WARNING SWITCH-REPLACEMENT PROCEDURE SWITCH-IGNITION KEY WARNING-REPLACEMENT PROCEDURE Article No. 89-19-2 FORD: 1986-90 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1986-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR ISSUE: A new procedure for servicing the ignition key warning switch has been developed. The new procedure is not published in the shop manual. ACTION: Use the following service procedure to remove and install the ignition key warning switch. Figure 1 REMOVAL 1. Remove the ignition lock assembly from the steering column lock housing. Refer to the appropriate Car Shop Manual, Section 13-04 for service details. NOTE: LEAVE THE LOCK IN THE RUN POSITION. DO NOT TURN THE IGNITION KEY. 2. Remove the switch from the lock assembly using a screwdriver as shown in Figure 1. 3. Throw away the switch. Figure 2 INSTALLATION 1. Obtain a new key warning switch (11A127). 2. Place the switch halfway on the lock cylinder case. Note proper alignment as shown in Figure 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Technical Service Bulletins > Ignition Key Warning Switch - Replacement Procedure > Page 6107 Figure 3 3. While pressing down on the switch with the thumb, slide the switch into place making sure all tabs are in place, Figure 3. 4. Install the lock cylinder assembly. Refer to the procedure in Section 13-04 of the appropriate Car Shop Manual. PART NUMBER PART NAME CLASS E7DZ-11A127-A Key Warning Switch C (Continental, Taurus, Sable) E6SZ-11A127-A Key Warning Switch (All Other C Car Lines) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2500, 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Key Reminder Switch > Component Information > Technical Service Bulletins > Page 6108 Key Reminder Switch: Locations I/P Components Part Of Ignition Switch Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace Steering Column Lock: Service and Repair Ignition Lock Drive Gear Replace Silver Colored Lock Cylinder Fig. 4 Steering Column Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace > Page 6113 Fig. 5 Steering Column Exploded View Refer to Figs. 4 and 5 for component identification. Removal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace > Page 6114 Fig. 30 Ignition Lock Drive Gear Removal & Installation. Models w/Modular Steering Columns & Silver Lock Cylinder 1. Remove lock cylinder assembly. 2. Insert a flat screwdriver into recess of drive gear at bottom of lock cylinder housing and turn drive gear three notches counterclockwise. 3. Remove snap ring, washer and lock driver gear from lock cylinder housing. Carefully note relationship of lock drive gear to position of rack teeth, Fig. 30. Installation 1. Place lock drive gear in base of lock cylinder housing in same position as that noted during removal. The position of lock drive gear will be correct if the last tooth on the drive gear is meshed with the last tooth on the rack, Fig. 30. 2. Install washer and snap ring, then insert a flat screwdriver into recess of lock drive gear at bottom of lock cylinder housing and turn drive gear three notches in a clockwise direction. 3. Install lock cylinder assembly. Gold Colored Lock Cylinder Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace > Page 6115 Fig. 4 Steering Column Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace > Page 6116 Fig. 5 Steering Column Exploded View Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace > Page 6117 Fig. 31 Ignition Lock Drive Gear Removal & Installation. Models w/Modular Steering Columns & Gold Lock Cylinder Removal 1. Remove lock cylinder assembly. 2. Note position of bearing retainer. Remove plastic bearing retainer by inserting tool with 90 degree bend on tip between bearing retainer and bearing, then prying upward. 3. Note position of lock drive gear to position of rack teeth, Fig. 31. Insert tip of screwdriver into double D slot in bearing and rotate 1/4 turn. Remove bearing and lock drive gear. Installation 1. Install lock drive gear in lock cylinder housing as shown in Fig. 31. Position of lock drive gear is correct if last tooth on drive gear is meshed with last tooth on rack. 2. Install bearing retainer in lock cylinder housing. Insert tip of screwdriver into double D slot of bearing and turn 1/4 turn. 3. Press plastic bearing retainer into housing in original position. 4. Pull down on column lock actuator to line up flats of drive gear with flats on washer. Install lock cylinder assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace > Page 6118 Steering Column Lock: Service and Repair Lock Cylinder Housing Replace Non-Tilt Column Fig. 4 Steering Column Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace > Page 6119 Fig. 5 Steering Column Exploded View Refer to Figs. 4 and 5 replacement procedure. Removal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace > Page 6120 Fig. 26 Steering Shaft From Bearing Removal 1. Remove steering column as described previously. 2. Remove two screws retaining multi-function switch, then the switch. 3. Remove two lock cylinder housing-to-outer tube flange bracket retaining bolts. 4. Remove two screws retaining upper bearing retainer plate. 5. Remove upper bearing snap ring. 6. If equipped remove sensor ring shield, two sensor switch retaining screws, then the switch. 7. Remove and discard spring retainer. 8. Remove spring and sensor ring. 9. Using a suitable tool, remove shaft bearing sleeve. 10. Remove shaft and lock cylinder housing assembly from column tube. 11. Using a soft hammer, separate shaft from the bearing as shown Fig. 26. 12. Remove shaft from the tube, then the lock cylinder housing from the shaft. 13. Remove bearing from lock cylinder housing. Installation 1. Hand press upper steering shaft bearing and sleeve into lock cylinder housing bearing bore. 2. Position lock cylinder housing assembly onto the shaft assembly. Install the assemblies into the column tube. 3. Install and torque two lock cylinder housing retaining bolts to 12-21 ft. lbs. 4. Install new bearing snap ring as follows: a. Position a pipe spacer (3/4 inch ID X 3-1/2 inch long) over end of the upper shaft. b. Install steering wheel attaching bolt through the pipe spacer and into the steering shaft. c. Tighten the bolt until there is enough room to allow installation of a new bearing snap ring. d. Install new snap ring in shaft groove, then remove steering wheel attaching bolt and pipe spacer. 5. Install multi-function switch. 6. Install lower bearing sleeve, sensor ring, spring and new spring retainer. 7. If equipped, install sensor switch and sensor ring shield. 8. Install U-joint assembly. Torque attaching bolt to 30-42 ft. lbs. 9. Install steering column as described previously. Tilt Columns Removal 1. Remove steering column as described previously. 2. Remove two screws retaining multi-function switch, then the switch. 3. Remove conical coil spring and upper bearing retainer plate. 4. Remove shaft C-clip at top of bearing. 5. Set tilt casting in the upper position. 6. Using Pivot Pin Remover Handle tool No. T67P-3D739-C and Pivot Pin Remover tools No. T67P-3D739-B or equivalent, carefully remove pivot pins. Use caution when removing pivot pins, they are under pressure and will expand with force. 7. Remove upper tilt casting from lock cylinder over end of shaft. 8. Separate U-joint from lower end of shaft. 9. If equipped remove sensor ring shield, two sensor switch retaining screws, then the switch. 10. Remove and discard spring retainer. 11. Remove spring and sensor ring. 12. Using a suitable tool, remove shaft bearing sleeve. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace > Page 6121 13. Remove steering shaft assembly from top end of column. 14. Remove two lock cylinder housing-to-outer tube retaining bolts. Installation 1. Position lock cylinder housing onto upper steering flange bracket. Install and torque two lock cylinder housing-to-bracket retaining bolts to 12-20 ft. lbs. 2. Install steering shaft assembly through lock cylinder housing top hole, into column tube and through the lower bearing. Use caution not to damage the bearing. 3. Ensure tilt spring is properly positioned, then install upper casting assembly over the shaft and down into lock cylinder housing ears. Ensure lock lever is latched in the top tilt position. 4. Align the tilt castings, then using a C-clamp install two pivot pins until flush with casting surface. 5. Install upper bearing snap ring and retainer plate. 6. Install conical coil spring by snapping it into shaft groove. 7. Install multi-function switch. 8. Install lower bearing sleeve, sensor ring, spring and new spring retainer. 9. If equipped, install sensor switch and sensor ring shield. 10. Install U-joint assembly. Torque attaching bolt to 30-42 ft. lbs. 11. Install steering column as described previously. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace > Page 6122 Steering Column Lock: Service and Repair Removal and Installation Fig. 4 Steering Column Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Lock > Component Information > Service and Repair > Ignition Lock Drive Gear Replace > Page 6123 Fig. 5 Steering Column Exploded View Refer to Figs. 4 and 5 for component identification. Removal 1. Remove lock cylinder housing, ignition lock switch, lock cylinder assembly and lock drive gear as described previously. 2. Slide actuator assembly out of the rear of the track in the lock cylinder housing. 3. Remove lock pawl and spring. Installation 1. Install lock pawl and spring on actuator assembly. 2. Install actuator assembly into track on lock cylinder housing and install the lock drive gear and lock cylinder assembly. 3. Install ignition switch and lock cylinder housing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Sector Shaft > Component Information > Specifications Sector Shaft: Specifications Sector Shaft Cover Bolts 55-70 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Non-Tilt Column Steering Shaft: Service and Repair Non-Tilt Column Upper Shaft Bearing Fig. 4 Steering Column Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Non-Tilt Column > Page 6132 Fig. 5 Steering Column Exploded View Refer to Figs. 4 and 5 for replacement procedure. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Non-Tilt Column > Page 6133 Fig. 26 Steering Shaft From Bearing Removal Removal 1. Remove steering column as described previously. 2. Separate lower steering column U-joint assembly from steering shaft. 3. Remove two screws retaining multi-function switch, then the switch. 4. Remove two screws retaining upper bearing retainer plate, then the plate. 5. Remove upper bearing snap ring. 6. Remove two lock cylinder housing assembly-to-column tube retaining bolts, then the housing assembly. 7. If equipped remove sensor ring shield, two sensor switch retaining screws, then the switch. 8. Remove and discard spring retainer. 9. Remove spring and sensor ring. 10. Using a suitable tool, remove shaft bearing sleeve. 11. Remove shaft and lock cylinder housing assembly from column tube. 12. Using a soft hammer, separate shaft from bearing as shown Fig. 26. Installation 1. Position lock cylinder housing assembly on shaft assembly and install assemblies into column tube. 2. Install and torque two lock cylinder housing retaining bolts to 12-21 ft. lbs. 3. Position upper steering shaft bearing and sleeve on shaft. Install sleeve and shaft assembly into lock cylinder housing bearing bore. 4. Install new bearing snap ring as follows: a. Position a pipe spacer (3/4 inch ID X 3-1/2 inch long) over end of upper shaft. b. Install steering wheel attaching bolt through pipe spacer and into steering shaft. c. Tighten bolt until there is enough room to allow installation of a new bearing snap ring. d. Install new snap ring in shaft groove, then remove steering wheel attaching bolt and pipe spacer. 5. Install multi-function switch. 6. Install lower bearing sleeve, sensor ring, spring and new spring retainer. 7. If equipped, install sensor switch and sensor ring shield. 8. Install U-joint assembly. Torque attaching bolt to 30-42 ft. lbs. 9. Install steering column as described previously. Lower Shaft Bearing Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Non-Tilt Column > Page 6134 Fig. 4 Steering Column Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Non-Tilt Column > Page 6135 Fig. 5 Steering Column Exploded View Refer to Figs. 4 and 5 for component identification. Removal 1. Remove steering column as described previously. 2. Separate lower steering column U-joint assembly from steering shaft. 3. Remove two screws retaining multi-function switch, then the switch. 4. Remove two lock cylinder housing assembly-to-column outer tube retaining bolts. 5. If equipped remove sensor ring shield, two sensor switch retaining screws, then the switch. 6. Remove and discard spring retainer. 7. Remove spring and sensor ring. 8. Using a suitable tool, remove shaft bearing sleeve. 9. Remove shaft and lock cylinder housing assembly from column tube. 10. Using a suitable tool, pry lower bearing and sleeve from outer tube. Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Non-Tilt Column > Page 6136 1. Position lock cylinder housing assembly on the shaft assembly. Install the assemblies into the column tube. 2. Install and torque two lock cylinder housing retaining bolts to 12-21 ft. lbs. 3. Press sleeve and bearing into outer tube until seated to tabs. Ensure sleeve is not deformed. 4. Press shaft sleeve into lower bearing. 5. Install sensor ring, spring and new spring retainer. 6. If equipped, install sensor switch and sensor ring shield. 7. Install U-joint assembly. Torque attaching bolt to 30-42 ft. lbs. 8. Install multi-function switch. 9. Install steering column as described previously. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Non-Tilt Column > Page 6137 Steering Shaft: Service and Repair Tilt Column Upper Shaft Bearing Fig. 4 Steering Column Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Non-Tilt Column > Page 6138 Fig. 5 Steering Column Exploded View Refer to Figs. 4 and 5 for replacement procedures. Removal 1. Disconnect battery ground cable. 2. Separate horn pad and cover assembly from steering wheel, then disconnect horn electrical connector from contact plate terminal. If equipped disconnect speed control electrical connector. 3. Remove and discard steering wheel attaching bolt. 4. Using a suitable puller, separate steering wheel from steering shaft. To prevent damage to steering shaft bearing, never hit steering wheel attaching bolt or use a knock-off type steering wheel puller. 5. Unsnap upper extension shroud from retainer clips at the 9 o'clock position. 6. Remove three screws retaining upper and lower shrouds, then the shrouds. 7. Remove conical coil spring and upper bearing retainer plate. 8. Remove shaft C-clip at top of bearing. 9. Set tilt casting in the upper position. 10. Using Pivot Pin Remover Handle tool No. T67P-3D739-C and Pivot Pin Remover tools No. T67P-3D739-B or equivalent, carefully remove pivot pins. Use caution when removing pivot pins, they are under pressure and will expand with force. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Non-Tilt Column > Page 6139 11. Remove tilt casting assembly and tilt spring from the column. 12. Working from bottom side of tilt casting, use a suitable drift and a hammer to remove upper bearing. 13. Working from tilt casting side-to-side relief areas, use a suitable drift and hammer to remove the lower bearing. Installation 1. Press fit new bearings into tilt casting. Use caution not to press on inner race. 2. Install tilt spring between upper and lower tilt castings. Latch tilt release lever in upper position. 3. Align the tilt castings, then using a C-clamp install two pivot pins until flush with casting surface. 4. Install upper bearing snap ring and retainer plate. 5. Install conical coil spring by snapping it into shaft groove. 6. Install upper, lower and extension shrouds. 7. Align and install steering wheel. Torque new steering wheel attaching bolt to 23-33 ft. lbs. 8. Reconnect horn electrical connector and if equipped the speed control electrical connector, to the contact plate terminal. Install horn pad and cover assembly to the steering wheel. 9. Reconnect battery ground cable. 10. Ensure steering column tilt operation is proper. Lower Shaft Bearing Fig. 4 Steering Column Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Non-Tilt Column > Page 6140 Fig. 5 Steering Column Exploded View Refer to Figs. 4 and 5 for component identification. Removal 1. Remove steering column as described previously. 2. Remove two screws retaining multi-function switch, then the switch. 3. Remove conical coil spring and upper bearing retainer plate. 4. Remove shaft C-clip at top of bearing. 5. Set tilt casting in the upper position. 6. Using Pivot Pin Remover Handle tool No. T67P-3D739-C and Pivot Pin Remover tools No. T67P-3D739-B or equivalent, carefully remove pivot pins. Use caution when removing pivot pins, they are under pressure and will expand with force. 7. Remove upper tilt casting from lock cylinder over end of shaft. 8. Separate U-joint from lower end of shaft. 9. If equipped remove sensor ring shield, two sensor switch retaining screws, then the switch. 10. Remove and discard spring retainer. 11. Remove spring and sensor ring. 12. Using a suitable tool, remove shaft bearing sleeve. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Service and Repair > Non-Tilt Column > Page 6141 13. Remove steering shaft assembly from top end of column. 14. Remove lower bearing assembly from column tube. Installation 1. Press lower bearing and sleeve into column tube. 2. Install steering shaft assembly through lock cylinder housing top hole, into column tube and through the lower bearing. Use caution not to damage the bearing. 3. Ensure tilt spring is properly positioned, then install upper casting assembly over the shaft and down into lock cylinder housing ears. Ensure lock lever is latched in the top tilt position. 4. Align the tilt castings, then using a C-clamp install two pivot pins until flush with casting surface. 5. Install upper bearing snap ring and retainer plate. 6. Install conical coil spring by snapping it into shaft groove. 7. Install multi-function switch. 8. Install lower bearing sleeve, sensor ring, spring and new spring retainer. 9. If equipped, install sensor switch and sensor ring shield. 10. Install U-joint assembly. Torque attaching bolt to 30-42 ft. lbs. 11. Install steering column as described previously. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Shaft Coupler > Component Information > Specifications Steering Shaft Coupler: Specifications Flex Coupling Bolt Torque Flex Coupling Bolt Torque Intermediate Shaft To Flex-Coupling Bolt 30 - 40 ft.lb Intermediate Shaft To U-Joint Bolt 30 - 40 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information > Service and Repair Steering Wheel: Service and Repair MODELS LESS PASSIVE RESTRAINT SYSTEM 1. Disconnect battery ground cable. 2. Remove horn pad and cover assembly. 3. Disconnect horn wire and speed control wiring, if equipped. 4. Remove and discard steering wheel nut. 5. Mark relationship between steering shaft and steering wheel hub for proper reinstallation. 6. Remove steering wheel with a suitable puller. 7. Reverse procedure to install. Torque new steering wheel bolt to 23-33 ft. lbs. MODELS w/PASSIVE RESTRAINT SYSTEM 1. On models equipped with airbag disable airbag system as described under Air Bags and Seat Belts/Air Bags (Supplemental Restraint Systems)/Service and Repair/Airbag System Disarming 2. Center front wheels to straight ahead position. 3. Remove airbag module from steering wheel. 4. Disconnect speed control wire harness from steering wheel. 5. Remove and discard steering wheel retaining bolt, then install steering wheel puller tool No. T67L-3600-A or equivalent and remove steering wheel. 6. Route contact assembly wire harness through steering wheel as wheel is lifted off of shaft. 7. Reverse procedure to install, noting the following: a. Route contact assembly wire harness through steering wheel opening at three o'clock position. Steering wheel and shaft alignment marks should be aligned. b. Ensure airbag contact wire is not pinched and speed control wiring does not get trapped between steering wheel and contact assembly. c. Torque steering wheel retaining bolt to 22-33 ft. lbs. d. Torque module retaining nuts to 36-47 inch lbs. e. On models equipped with airbag activate airbag system as described under Air Bags and Seat Belts/Air Bags (Supplemental Restraint Systems)/Service and Repair/Airbag System Disarming. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information > Specifications Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear Tie Rod End: Customer Interest Steering - Clunk/Rattle/Premature Tire Wear Article No. 93-13-2 06/23/93 ^ STEERING - POWER - INNER TIE ROD IN-VEHICLE REPLACEMENT PROCEDURE ^ STEERING - POWER - LACK OF CENTER FEEL AND VEHICLE WANDER ^ TIE ROD - INNER - IN-VEHICLE REPLACEMENT PROCEDURE ^ TIRES - FRONT - PREMATURE WEAR ^ NOISE - "CLUNK" OR "RATTLE" FROM FRONT END - INNER TIE ROD IN-VEHICLE REPLACEMENT PROCEDURE ^ SHUDDER DURING DECELERATION/BRAKING FORD: 1986-93 MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1991-93 ESCORT LINCOLN-MERCURY: 1986-92 MARK VII 1986-93 CONTINENTAL, COUGAR, SABLE, TOPAZ 1991-93 TRACER 1993 MARK VIII LIGHT TRUCK: 1986-93 AEROSTAR ISSUE: An inner tie rod in-vehicle replacement procedure has been developed for the subject vehicles. The inner tie rod is worn if it exhibits any lash or axial free-play. Worn inner tie rods may exhibit some of the following symptoms: ^ "Clunk" or "rattle" noise in the front end during vehicle deceleration or cruise operation modes when going over small bumps, etc. ^ Front tire wear ^ Inconsistent alignment toe setting by the service specialist ^ Lack of center feel ^ Vehicle wanders ^ Vehicle shudder during decel/braking ACTION: If service is required, use the following service procedure to install the inner tie rod assemblies. CAUTION: SERVICE AND REPAIR PROCEDURES DESCRIBED IN THE SERVICE MANUALS ARE TO BE MODIFIED PER THIS TSB ARTICLE. ALL SERVICE MANUAL NOTES, CAUTIONS AND WARNINGS SHOULD BE OBSERVED. THESE INNER TIE ROD PARTS MUST BE INSTALLED BY A QUALIFIED TECHNICIAN, OTHERWISE AN UNSAFE VEHICLE AND PERSONAL INJURY MAY RESULT. SAFE AND RELIABLE INSTALLATION OF STEERING/CHASSIS PARTS REQUIRE EXPERIENCE AND TOOLS SPECIALLY DESIGNED FOR THE JOB. DIAGNOSIS 1. Check for "clunk" noise, with the window down, engine OFF, steering column unlocked, by turning the steering wheel +/- 45~. ^ For the steel on steel type ball joints, a metal "clunk" noise may be heard. ^ For the steel on plastic type joints, refer to Step 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 6160 2. Raise the front of the vehicle. a. With the tires unweighted, shake the tire from top/bottom (12/6 o'clock position) to determine wheel bearing play. b. Compare with left/right (9/3 o'clock position) tire shake which will also include the outer and inner tie rod lash. c. Holding the inner tie rod spindle during the latter tire shake may help verify the inner versus outer tie rod looseness. See Figure 1. NOTE: A MECHANICALLY LEVERAGED TOOL SUCH AS A CROWBAR MAY BE USEFUL FOR THIS DIAGNOSIS WHEN APPLIED TO THE TIRE. 3. Disregard the Service Manual pull test with two (2) to ten (10) pound pull requirement, since this may not be a reliable test. 4. The inner tie rod is worn and must be replaced if it exhibits any lash or axial free-play. INNER TIE ROD (GEAR IN-VEHICLE) REMOVAL 1. Prepare the vehicle for servicing. a. Unlock the steering column by turning the ignition key. b. Engage the parking brake. c. Raise and support the vehicle. d. Clean any loose dirt or oil from the power steering gear and boot bellows. 2. Disconnect the outer tie rod end from the steering knuckle. a. Loosen the jam nut and keep flush with outer tie rod. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 6161 b. Disconnect the outer tie rod from the steering knuckle. Remove the cotter pin and castle nut by using Tie Rod End Remover TOOL-3290-D or equivalent, Figure 2. 3. Mark the threads at the jam nut location. a. Count and record the number of turns to remove the outer tie rod end from the inner tie rod. This information is useful in estimating the alignment setting. b. Remove the jam nut from the inner tie rod spindle. 4. Remove the left and right steering gear boot bellows along with the breather tube. NOTE MARK THE BREATHER TUBE AND BOOT BELLOWS LARGE ID CLAMP'S ORIENTATION ON THE HOUSING FOR LATER INSTALLATION REFERENCE. CAUTION: USE CARE NOT TO DAMAGE THE BELLOWS. 5. FOR STEEL ON STEEL BALL JOINTS, remove the rivet or rollpin securing the inner tie rod to the steering gear rack. a. Use a sharp chisel to gently pry up the rivet or rollpin. DO NOT CUT OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 6162 b. Use side cutters or equivalent to remove the rivet, Figures 3 & 4. CAUTION: THE RIVET HAS A STEEL CORE WHICH WILL DEFORM THE STEERING GEAR RACK THREADS IF IT IS NOT COMPLETELY REMOVED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 6163 c. Use Locknut Pin Remover D81P-3504-N or equivalent to remove the rollpin, Figure 5. If the rivet is not accessible, unscrew (see Step 6) the inner tie rod until it is accessible (less than 1 full turn). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 6164 6. Remove the inner tie rod from the steering gear rack using a wrench on the rack teeth in combination with the following tools as shown in Figures 6 and 7. ^ Yoke Locknut Wrench T81P-3504-G or Inner Tie Rod Socket Tool D90P-3290-A - Tempo/Topaz ^ Nut Wrench T74P-3504-U - Aerostar, Thunderbird, Cougar, Continental, Mark VII & Mark VIII, Mustang, Taurus and Sable An adjustable wrench may be used on the rack teeth. CAUTION: HAVE STEERING GEAR AT OR NEAR THE FULL TURN (LOCK) POSITION. USE A WRENCH ON THE RACK TEETH (FLAT) TO RESIST RACK ROTATION AND PREVENT DAMAGE TO THE PINION DURING REMOVAL AND INSTALLATION. ALLOWING THE RACK AND PINION TO INTERNALLY RESIST TIGHTENING OR LOOSENING TORQUES MAY CAUSE DAMAGE TO THE STEERING GEAR. 7. Clean the following components. ^ The steering gear housing OD interface and boot bellows ID (each end). ^ The steering gear housing ID and rack as required. ^ All parts to be inspected and replaced if necessary. Make sure the rack threads are clean and dry. CAUTION: THOROUGHLY REMOVE ANY ABRASIVE MATERIAL. THESE CONTAMINANTS ARE EXTREMELY HARMFUL TO THE HIGH PRESSURE STEERING GEAR RACK SEAL INTERFACE. INSTALLATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 6165 1. Refer to the Parts Block in this article for correct parts usage. 2. Replenish any grease (C3AZ-19578-A) which may have been removed from the rack teeth. 3. For replacement plastic on steel ball joints that do not have the rivet feature, proceed as follows: a. Clean any contamination, dirt or oil from the rack threads and wipe dry. CAUTION: THOROUGHLY REMOVE ANY ABRASIVE MATERIAL. THESE CONTAMINANTS ARE EXTREMELY HARMFUL TO THE HIGH PRESSURE STEERING GEAR RACK SEAL INTERFACE. b. Apply locking compound (E2FZ-19544-B) (Loctite 262 or equivalent) to the steering gear rack threads. The thread locking compound will set sufficiently so that the vehicle may be driven when the remove and replace procedure is complete, including the alignment toe. 4. Hold the rack securely as shown in Figure 7. If both inner tie rods are replaced, tighten each inner tie rod separately. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 55-60 lb.ft. (75-81 N-m). ^ For Tempo/Topaz, the torque specification is 40-50 lb.ft. (54-68 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 6166 5. For ball joints that use the rivet (N804152-S), install rivet (which replaces the rollpin) using channel locks or equivalent, Figure 8. 6. Check the inner tie rod function by moving the tie rod spindle. Handshake in various directions. 7. Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the inner tie rod groove where the boot bellows attach with a clamp to the inner tie rod. This allows for toe-in adjustments without twisting the bellows. 8. Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the steering gear housing OD/boot bellows' large OD interface. This layer of grease will help keep water and contamination from entering the ball joint and rack sealing sur faces. 9. Install the boot bellows and breather tube. a. Check to see that the boot bellows are properly positioned over the steering gear housing bead at the large ID, and are in the tie rod groove at the small ID. b. Check to see that the boot bellows are not twisted and that the vent tube is securely inserted into the vent nipple AT BOTH BOOTS. c. At the boot bellows/housing large ID, install screw type (hose) clamps and position screw axis as shown in Figure 9. Tighten screw to 1.7-2.5 lb.ft. (2.3-3.4 N-m). CAUTION: DO NOT USE TIE STRAPS TO SECURE BOOT BELLOWS TO STEERING GEAR HOUSING. d. At the boot bellows/inner tie rod small ID, install clamp. 10. Install the jam nut and apply Disc Brake Caliper Slide Grease (D7AZ-19590-A) or equivalent, to the inner tie rod threads. 11. Install the outer tie rod to the inner tie rod. Count the number of turns recorded earlier. This approximates the previous alignment toe setting. 12. Tighten the jam nut against the outer tie rod end. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-50 lb.ft. (47-68 N-m). ^ For Tempo/Topaz, the torque specification is 42-50 lb.ft. (57-68 N-m). 13. Connect the outer tie rod to the steering knuckle. a. Tighten the castle nut at the steering knuckle to a minimum 27 lb.ft. (36 N-m). b. Continue tightening direction until the hole allows installation of a new cotter pin. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-47 lb.ft. (47-64 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Customer Interest for Tie Rod End: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 6167 ^ For Tempo/Topaz, the torque specification is 27-32 lb.ft. (36-43 N-m). 14. Align the front end to specification. Refer to the appropriate Vehicle Service Manual for service details. OTHER APPLICABLE ARTICLES: 90-11-3 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1991 Lincolns And All 1992/93 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 931302A Install Both Tie Rod End 1.5 Hrs. Assemblies - Escort/Tracer 931302B Install Both Tie Rod End 1.9 Hrs. Assemblies - Tempo/Topaz 931302C Install Both Tie Rod End 1.6 Hrs. Assemblies - Taurus/Sable 931302D Install Both Tie Rod End 1.6 Hrs. Assemblies - Continental 931302E Install Both Tie Rod End 1.5 Hrs. Assemblies - Thunderbird/Cougar/ Mark/Mustang 931302F Install Both Tie Rod End 1.7 Hrs. Assemblies - Aerostar DEALER CODING BASIC PART NO. CONDITION CODE 3280 30 OASIS CODES: 303000, 390000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 93132 > Jun > 93 > Steering Clunk/Rattle/Premature Tire Wear Tie Rod End: All Technical Service Bulletins Steering - Clunk/Rattle/Premature Tire Wear Article No. 93-13-2 06/23/93 ^ STEERING - POWER - INNER TIE ROD IN-VEHICLE REPLACEMENT PROCEDURE ^ STEERING - POWER - LACK OF CENTER FEEL AND VEHICLE WANDER ^ TIE ROD - INNER - IN-VEHICLE REPLACEMENT PROCEDURE ^ TIRES - FRONT - PREMATURE WEAR ^ NOISE - "CLUNK" OR "RATTLE" FROM FRONT END - INNER TIE ROD IN-VEHICLE REPLACEMENT PROCEDURE ^ SHUDDER DURING DECELERATION/BRAKING FORD: 1986-93 MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1991-93 ESCORT LINCOLN-MERCURY: 1986-92 MARK VII 1986-93 CONTINENTAL, COUGAR, SABLE, TOPAZ 1991-93 TRACER 1993 MARK VIII LIGHT TRUCK: 1986-93 AEROSTAR ISSUE: An inner tie rod in-vehicle replacement procedure has been developed for the subject vehicles. The inner tie rod is worn if it exhibits any lash or axial free-play. Worn inner tie rods may exhibit some of the following symptoms: ^ "Clunk" or "rattle" noise in the front end during vehicle deceleration or cruise operation modes when going over small bumps, etc. ^ Front tire wear ^ Inconsistent alignment toe setting by the service specialist ^ Lack of center feel ^ Vehicle wanders ^ Vehicle shudder during decel/braking ACTION: If service is required, use the following service procedure to install the inner tie rod assemblies. CAUTION: SERVICE AND REPAIR PROCEDURES DESCRIBED IN THE SERVICE MANUALS ARE TO BE MODIFIED PER THIS TSB ARTICLE. ALL SERVICE MANUAL NOTES, CAUTIONS AND WARNINGS SHOULD BE OBSERVED. THESE INNER TIE ROD PARTS MUST BE INSTALLED BY A QUALIFIED TECHNICIAN, OTHERWISE AN UNSAFE VEHICLE AND PERSONAL INJURY MAY RESULT. SAFE AND RELIABLE INSTALLATION OF STEERING/CHASSIS PARTS REQUIRE EXPERIENCE AND TOOLS SPECIALLY DESIGNED FOR THE JOB. DIAGNOSIS 1. Check for "clunk" noise, with the window down, engine OFF, steering column unlocked, by turning the steering wheel +/- 45~. ^ For the steel on steel type ball joints, a metal "clunk" noise may be heard. ^ For the steel on plastic type joints, refer to Step 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 93132 > Jun > 93 > Steering Clunk/Rattle/Premature Tire Wear > Page 6173 2. Raise the front of the vehicle. a. With the tires unweighted, shake the tire from top/bottom (12/6 o'clock position) to determine wheel bearing play. b. Compare with left/right (9/3 o'clock position) tire shake which will also include the outer and inner tie rod lash. c. Holding the inner tie rod spindle during the latter tire shake may help verify the inner versus outer tie rod looseness. See Figure 1. NOTE: A MECHANICALLY LEVERAGED TOOL SUCH AS A CROWBAR MAY BE USEFUL FOR THIS DIAGNOSIS WHEN APPLIED TO THE TIRE. 3. Disregard the Service Manual pull test with two (2) to ten (10) pound pull requirement, since this may not be a reliable test. 4. The inner tie rod is worn and must be replaced if it exhibits any lash or axial free-play. INNER TIE ROD (GEAR IN-VEHICLE) REMOVAL 1. Prepare the vehicle for servicing. a. Unlock the steering column by turning the ignition key. b. Engage the parking brake. c. Raise and support the vehicle. d. Clean any loose dirt or oil from the power steering gear and boot bellows. 2. Disconnect the outer tie rod end from the steering knuckle. a. Loosen the jam nut and keep flush with outer tie rod. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 93132 > Jun > 93 > Steering Clunk/Rattle/Premature Tire Wear > Page 6174 b. Disconnect the outer tie rod from the steering knuckle. Remove the cotter pin and castle nut by using Tie Rod End Remover TOOL-3290-D or equivalent, Figure 2. 3. Mark the threads at the jam nut location. a. Count and record the number of turns to remove the outer tie rod end from the inner tie rod. This information is useful in estimating the alignment setting. b. Remove the jam nut from the inner tie rod spindle. 4. Remove the left and right steering gear boot bellows along with the breather tube. NOTE MARK THE BREATHER TUBE AND BOOT BELLOWS LARGE ID CLAMP'S ORIENTATION ON THE HOUSING FOR LATER INSTALLATION REFERENCE. CAUTION: USE CARE NOT TO DAMAGE THE BELLOWS. 5. FOR STEEL ON STEEL BALL JOINTS, remove the rivet or rollpin securing the inner tie rod to the steering gear rack. a. Use a sharp chisel to gently pry up the rivet or rollpin. DO NOT CUT OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 93132 > Jun > 93 > Steering Clunk/Rattle/Premature Tire Wear > Page 6175 b. Use side cutters or equivalent to remove the rivet, Figures 3 & 4. CAUTION: THE RIVET HAS A STEEL CORE WHICH WILL DEFORM THE STEERING GEAR RACK THREADS IF IT IS NOT COMPLETELY REMOVED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 93132 > Jun > 93 > Steering Clunk/Rattle/Premature Tire Wear > Page 6176 c. Use Locknut Pin Remover D81P-3504-N or equivalent to remove the rollpin, Figure 5. If the rivet is not accessible, unscrew (see Step 6) the inner tie rod until it is accessible (less than 1 full turn). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 93132 > Jun > 93 > Steering Clunk/Rattle/Premature Tire Wear > Page 6177 6. Remove the inner tie rod from the steering gear rack using a wrench on the rack teeth in combination with the following tools as shown in Figures 6 and 7. ^ Yoke Locknut Wrench T81P-3504-G or Inner Tie Rod Socket Tool D90P-3290-A - Tempo/Topaz ^ Nut Wrench T74P-3504-U - Aerostar, Thunderbird, Cougar, Continental, Mark VII & Mark VIII, Mustang, Taurus and Sable An adjustable wrench may be used on the rack teeth. CAUTION: HAVE STEERING GEAR AT OR NEAR THE FULL TURN (LOCK) POSITION. USE A WRENCH ON THE RACK TEETH (FLAT) TO RESIST RACK ROTATION AND PREVENT DAMAGE TO THE PINION DURING REMOVAL AND INSTALLATION. ALLOWING THE RACK AND PINION TO INTERNALLY RESIST TIGHTENING OR LOOSENING TORQUES MAY CAUSE DAMAGE TO THE STEERING GEAR. 7. Clean the following components. ^ The steering gear housing OD interface and boot bellows ID (each end). ^ The steering gear housing ID and rack as required. ^ All parts to be inspected and replaced if necessary. Make sure the rack threads are clean and dry. CAUTION: THOROUGHLY REMOVE ANY ABRASIVE MATERIAL. THESE CONTAMINANTS ARE EXTREMELY HARMFUL TO THE HIGH PRESSURE STEERING GEAR RACK SEAL INTERFACE. INSTALLATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 93132 > Jun > 93 > Steering Clunk/Rattle/Premature Tire Wear > Page 6178 1. Refer to the Parts Block in this article for correct parts usage. 2. Replenish any grease (C3AZ-19578-A) which may have been removed from the rack teeth. 3. For replacement plastic on steel ball joints that do not have the rivet feature, proceed as follows: a. Clean any contamination, dirt or oil from the rack threads and wipe dry. CAUTION: THOROUGHLY REMOVE ANY ABRASIVE MATERIAL. THESE CONTAMINANTS ARE EXTREMELY HARMFUL TO THE HIGH PRESSURE STEERING GEAR RACK SEAL INTERFACE. b. Apply locking compound (E2FZ-19544-B) (Loctite 262 or equivalent) to the steering gear rack threads. The thread locking compound will set sufficiently so that the vehicle may be driven when the remove and replace procedure is complete, including the alignment toe. 4. Hold the rack securely as shown in Figure 7. If both inner tie rods are replaced, tighten each inner tie rod separately. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 55-60 lb.ft. (75-81 N-m). ^ For Tempo/Topaz, the torque specification is 40-50 lb.ft. (54-68 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 93132 > Jun > 93 > Steering Clunk/Rattle/Premature Tire Wear > Page 6179 5. For ball joints that use the rivet (N804152-S), install rivet (which replaces the rollpin) using channel locks or equivalent, Figure 8. 6. Check the inner tie rod function by moving the tie rod spindle. Handshake in various directions. 7. Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the inner tie rod groove where the boot bellows attach with a clamp to the inner tie rod. This allows for toe-in adjustments without twisting the bellows. 8. Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the steering gear housing OD/boot bellows' large OD interface. This layer of grease will help keep water and contamination from entering the ball joint and rack sealing sur faces. 9. Install the boot bellows and breather tube. a. Check to see that the boot bellows are properly positioned over the steering gear housing bead at the large ID, and are in the tie rod groove at the small ID. b. Check to see that the boot bellows are not twisted and that the vent tube is securely inserted into the vent nipple AT BOTH BOOTS. c. At the boot bellows/housing large ID, install screw type (hose) clamps and position screw axis as shown in Figure 9. Tighten screw to 1.7-2.5 lb.ft. (2.3-3.4 N-m). CAUTION: DO NOT USE TIE STRAPS TO SECURE BOOT BELLOWS TO STEERING GEAR HOUSING. d. At the boot bellows/inner tie rod small ID, install clamp. 10. Install the jam nut and apply Disc Brake Caliper Slide Grease (D7AZ-19590-A) or equivalent, to the inner tie rod threads. 11. Install the outer tie rod to the inner tie rod. Count the number of turns recorded earlier. This approximates the previous alignment toe setting. 12. Tighten the jam nut against the outer tie rod end. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-50 lb.ft. (47-68 N-m). ^ For Tempo/Topaz, the torque specification is 42-50 lb.ft. (57-68 N-m). 13. Connect the outer tie rod to the steering knuckle. a. Tighten the castle nut at the steering knuckle to a minimum 27 lb.ft. (36 N-m). b. Continue tightening direction until the hole allows installation of a new cotter pin. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-47 lb.ft. (47-64 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tie Rod End: > 93132 > Jun > 93 > Steering Clunk/Rattle/Premature Tire Wear > Page 6180 ^ For Tempo/Topaz, the torque specification is 27-32 lb.ft. (36-43 N-m). 14. Align the front end to specification. Refer to the appropriate Vehicle Service Manual for service details. OTHER APPLICABLE ARTICLES: 90-11-3 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1991 Lincolns And All 1992/93 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 931302A Install Both Tie Rod End 1.5 Hrs. Assemblies - Escort/Tracer 931302B Install Both Tie Rod End 1.9 Hrs. Assemblies - Tempo/Topaz 931302C Install Both Tie Rod End 1.6 Hrs. Assemblies - Taurus/Sable 931302D Install Both Tie Rod End 1.6 Hrs. Assemblies - Continental 931302E Install Both Tie Rod End 1.5 Hrs. Assemblies - Thunderbird/Cougar/ Mark/Mustang 931302F Install Both Tie Rod End 1.7 Hrs. Assemblies - Aerostar DEALER CODING BASIC PART NO. CONDITION CODE 3280 30 OASIS CODES: 303000, 390000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information > Technical Service Bulletins > Page 6181 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Axle Beam Bushing > Component Information > Technical Service Bulletins > Customer Interest: > 93312 > Feb > 93 > Rear Axle - Moan or Slow Beating Noise At 55 MPH Axle Beam Bushing: Customer Interest Rear Axle - Moan or Slow Beating Noise At 55 MPH Article No. 93-3-12 February 3, 1993 ^ NOISE - "MOAN" OR "SLOW BEATING" NOISE FROM AXLE ^ AXLE - "MOAN" OR "SLOW BEATING" NOISE WHILE DRIVING 55 M.P.H. (88 KM/H) OR OVER FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: A "moan" or "slow beating" noise may be heard near the axle, while driving 55 m.p.h. (88 KM/H) or over, due to the axle ring and pinion gears. This condition can occur with the transmission in either Drive (D) or Overdrive (OD). ACTION: Use the following service procedure to check and, if necessary, replace the axle isolator bushings. SERVICE PROCEDURE 1. Test drive the vehicle. At a speed of 55 m.p.h. (88 KM/H) or over, shift the transmission from Overdrive (OD) to Drive (D). 2. If the "moan" or "slow beating" noise is still heard, replace the axle isolator bushings (F3SZ-4B424-A or F3SZ-4B431-B). Refer to the 1992 Thunderbird/Cougar Service Manual, Section 02-01, for removal and installation procedures. NOTE: THE DESIGN OF THE NEW AXLE ISOLATOR BUSHINGS MOAN ELIMINATE OR REDUCE THE "MOAN" NOISE, BUT IT WILL NOT CHANGE OR REDUCE VIBRATIONS CAUSED BY THE DRIVESHAFT OR TIRES. PART NUMBER PART NAME CLASS F3SZ-4B424-A Upper Axle Isolator Bushing (2 C Required) F3SZ-4B431-B Lower Axle Isolator Bushing (2 C Required) WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models. Eligible Under Bumper To Bumper Coverage For 1992 Models. OPERATION DESCRIPTION TIME 930312A Replace Rear Axle Insulator 1.5 Hrs. Bushings DEALER CODING BASIC PART NO. CONDITION CODE 4209 56 OASIS CODES: 509000, 597997, 702000, 702300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Axle Beam Bushing > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 93312 > Feb > 93 > Rear Axle - Moan or Slow Beating Noise At 55 MPH Axle Beam Bushing: All Technical Service Bulletins Rear Axle - Moan or Slow Beating Noise At 55 MPH Article No. 93-3-12 February 3, 1993 ^ NOISE - "MOAN" OR "SLOW BEATING" NOISE FROM AXLE ^ AXLE - "MOAN" OR "SLOW BEATING" NOISE WHILE DRIVING 55 M.P.H. (88 KM/H) OR OVER FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: A "moan" or "slow beating" noise may be heard near the axle, while driving 55 m.p.h. (88 KM/H) or over, due to the axle ring and pinion gears. This condition can occur with the transmission in either Drive (D) or Overdrive (OD). ACTION: Use the following service procedure to check and, if necessary, replace the axle isolator bushings. SERVICE PROCEDURE 1. Test drive the vehicle. At a speed of 55 m.p.h. (88 KM/H) or over, shift the transmission from Overdrive (OD) to Drive (D). 2. If the "moan" or "slow beating" noise is still heard, replace the axle isolator bushings (F3SZ-4B424-A or F3SZ-4B431-B). Refer to the 1992 Thunderbird/Cougar Service Manual, Section 02-01, for removal and installation procedures. NOTE: THE DESIGN OF THE NEW AXLE ISOLATOR BUSHINGS MOAN ELIMINATE OR REDUCE THE "MOAN" NOISE, BUT IT WILL NOT CHANGE OR REDUCE VIBRATIONS CAUSED BY THE DRIVESHAFT OR TIRES. PART NUMBER PART NAME CLASS F3SZ-4B424-A Upper Axle Isolator Bushing (2 C Required) F3SZ-4B431-B Lower Axle Isolator Bushing (2 C Required) WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models. Eligible Under Bumper To Bumper Coverage For 1992 Models. OPERATION DESCRIPTION TIME 930312A Replace Rear Axle Insulator 1.5 Hrs. Bushings DEALER CODING BASIC PART NO. CONDITION CODE 4209 56 OASIS CODES: 509000, 597997, 702000, 702300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Axle Beam > Axle Beam Bushing > Component Information > Technical Service Bulletins > All Other Service Bulletins for Axle Beam Bushing: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Ball Joint, Lower Ball Joint: Specifications Ball Joint To Lower Spindle 80-119 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Specifications > Ball Joint, Lower > Page 6211 Ball Joint: Specifications Ball Joint To Upper Spindle 51-67 ft.lb Upper Ball Joint To Upper Arm 107-129 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint, Lower Ball Joint: Testing and Inspection Ball Joint, Lower 1. Raise front of vehicle and position jacks under sub-frame. 2. Position a suitable dial indicator to ball joint to be checked, in such a manner that lateral movement between spindle and arm can be measured. 3. Grasp tire at top and bottom, then slowly move tire inward and outward while noting indicator reading. 4. If dial indicator reading exceeds .015 inch, replace ball joint. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Testing and Inspection > Ball Joint, Lower > Page 6214 Ball Joint: Testing and Inspection Ball Joint, Upper 1. Raise front of vehicle and position jacks under sub-frame. 2. Position a suitable dial indicator to ball joint to be checked, in such a manner that lateral movement between spindle and arm can be measured. 3. Grasp tire at top and bottom, then slowly move tire inward and outward while noting indicator reading. 4. If dial indicator reading exceeds .015 inch, replace ball joint. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower Ball Joint: Service and Repair Ball Joint, Lower Lower Ball Joint Replacement Upper Ball Joint The upper ball joint and upper control arm must be replaced as an assembly. Refer to CONTROL ARM. Lower Ball Joint 1. Remove lower control arm as described under CONTROL ARM. 2. Remove and discard ball joint boot seal, then position lower control arm in a vise. 3. Press ball joint from lower control arm using removal tools No. D89P-3010-A, D84P-3395-A4 and T74P-4635-C or equivalent, Fig. 6. 4. Reverse procedure to install. Do not remove protective cover from ball joint until after it has been installed. Press ball joint into lower control arm until fully seated. After installing lower control arm, check and adjust wheel alignment as necessary. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and Repair > Ball Joint, Lower > Page 6217 Ball Joint: Service and Repair Ball Joint, Upper Lower Ball Joint Replacement Upper Ball Joint The upper ball joint and upper control arm must be replaced as an assembly. Refer to CONTROL ARM. Lower Ball Joint 1. Remove lower control arm as described under CONTROL ARM. 2. Remove and discard ball joint boot seal, then position lower control arm in a vise. 3. Press ball joint from lower control arm using removal tools No. D89P-3010-A, D84P-3395-A4 and T74P-4635-C or equivalent, Fig. 6. 4. Reverse procedure to install. Do not remove protective cover from ball joint until after it has been installed. Press ball joint into lower control arm until fully seated. After installing lower control arm, check and adjust wheel alignment as necessary. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification Technical Service Bulletin # 89S63 Date: 890601 Recall - Front Suspension Hardware Modification RECALL NUMBER 89S63 Date: June, 1989 TO: All Ford and Lincoln Mercury Dealers SUBJECT: Safety Recall 89S63 - 1989 Thunderbird and Cougar - Extended Brake Pedal Travel AFFECTED VEHICLES 1989 Thunderbird and Cougar - Built from Job # 1 through March 27, 1989 REASONS FOR RECALL EXCESSIVE BRAKE PEDAL TRAVEL During full-lock, low speed turns (less than 5 MPH) the inboard front brake caliper may contact the stabilizer bar or stabilizer link. This can push the front disc caliper piston back and force brake fluid back into the master cylinder reservoir. This results in increased brake pedal travel during the next brake application. After one brake application, the piston is repositioned and proper pedal travel and brake performance is restored. The sequence could repeat, however, following the next low speed full-lock turn. ATTACHMENTS Attachment I - Administrative Information Attachment II - Labor Allowances - Parts Ordering Information Attachment III - Technical Information Attachment I Administrative Information CARES/OASIS YOU MUST USE CARES OR OASIS TO DETERMINE IF A VEHICLEIS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT CONTACT Advise district office if: - an owner cannot be contacted. - an owner does not make a service date FPSD CONTACT Talk with your FPSD Service Zone Manager about recallconcerns. REIMBURSEMENT FORM 1864 Submit 1864 claims for all completed vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 6226 WARRANTY AND POLICY MANUAL See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation. Attachment II Parts & Time Information SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) LABOR ALLOWANCES Inspect for Tension Strut Hex Cap Nut 0.1 Hrs. - Insert in Box "A" on Form 1864 Install two Tension Strut Hex Cap Nuts (Includes inspection) 0.3 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS N806301-S150 HEX CAP NUTS SG (pack of 2) ( tension strut) Attachment III Technical Instructions SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 6227 TECHNICAL INSTRUCTIONS The front tension strut-to-lower control arm nuts are to be replaced with special acorn type nuts that serve as steering stops and eliminate the potential for caliper contact. INSPECTION/REPLACEMENT PROCEDURE ^ Put car on hoist. ^ Inspect for acorn type nuts on tension strut-to-lower control arm. If acorn type nuts are in place, claim inspection time on Form 1864 and release car from Recall 89S63. ^ If acorn type are not found follow steps listed below for installation. PASSENGER SIDE ^ Turn front wheels to full left and remove tension strut nut from lower control arm on passenger side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). DRIVERS SIDE ^ Turn front wheels to full right and remove tension strut nut from lower control arm on drivers side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). ^ Lower and remove car from hoist. ^ Complete Form 1864 and release car from recall 89S63. Owner Letter Dear Owner: June, 1989 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Thunderbirds and Cougars. Safety Defect During slow speed extreme turns (less than 5 MPH)the right or left front brake caliper may contact a part of the front suspension. If this happens, extended brake pedal travel could occur during the next brake application. This may result in reduced braking capability and increased stopping distance. A vehicle crash may result. Subsequent brake applications will result in normal braking, until another slow speed extreme turn is made. Repairs At no cost to you, your dealer will modify thefront suspension of your car by installing special nuts to eliminate the contact condition. How long will it take? The time needed to repair your car is less than one hour. Call your dealer Call your dealer without delay and ask for a service date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > Recalls for Control Arm: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 6228 Changed address or sold the car? If you have changed your address or sold the car, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your Owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification Technical Service Bulletin # 89S63 Date: 890601 Recall - Front Suspension Hardware Modification RECALL NUMBER 89S63 Date: June, 1989 TO: All Ford and Lincoln Mercury Dealers SUBJECT: Safety Recall 89S63 - 1989 Thunderbird and Cougar - Extended Brake Pedal Travel AFFECTED VEHICLES 1989 Thunderbird and Cougar - Built from Job # 1 through March 27, 1989 REASONS FOR RECALL EXCESSIVE BRAKE PEDAL TRAVEL During full-lock, low speed turns (less than 5 MPH) the inboard front brake caliper may contact the stabilizer bar or stabilizer link. This can push the front disc caliper piston back and force brake fluid back into the master cylinder reservoir. This results in increased brake pedal travel during the next brake application. After one brake application, the piston is repositioned and proper pedal travel and brake performance is restored. The sequence could repeat, however, following the next low speed full-lock turn. ATTACHMENTS Attachment I - Administrative Information Attachment II - Labor Allowances - Parts Ordering Information Attachment III - Technical Information Attachment I Administrative Information CARES/OASIS YOU MUST USE CARES OR OASIS TO DETERMINE IF A VEHICLEIS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT CONTACT Advise district office if: - an owner cannot be contacted. - an owner does not make a service date FPSD CONTACT Talk with your FPSD Service Zone Manager about recallconcerns. REIMBURSEMENT FORM 1864 Submit 1864 claims for all completed vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 6234 WARRANTY AND POLICY MANUAL See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation. Attachment II Parts & Time Information SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) LABOR ALLOWANCES Inspect for Tension Strut Hex Cap Nut 0.1 Hrs. - Insert in Box "A" on Form 1864 Install two Tension Strut Hex Cap Nuts (Includes inspection) 0.3 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS N806301-S150 HEX CAP NUTS SG (pack of 2) ( tension strut) Attachment III Technical Instructions SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 6235 TECHNICAL INSTRUCTIONS The front tension strut-to-lower control arm nuts are to be replaced with special acorn type nuts that serve as steering stops and eliminate the potential for caliper contact. INSPECTION/REPLACEMENT PROCEDURE ^ Put car on hoist. ^ Inspect for acorn type nuts on tension strut-to-lower control arm. If acorn type nuts are in place, claim inspection time on Form 1864 and release car from Recall 89S63. ^ If acorn type are not found follow steps listed below for installation. PASSENGER SIDE ^ Turn front wheels to full left and remove tension strut nut from lower control arm on passenger side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). DRIVERS SIDE ^ Turn front wheels to full right and remove tension strut nut from lower control arm on drivers side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). ^ Lower and remove car from hoist. ^ Complete Form 1864 and release car from recall 89S63. Owner Letter Dear Owner: June, 1989 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Thunderbirds and Cougars. Safety Defect During slow speed extreme turns (less than 5 MPH)the right or left front brake caliper may contact a part of the front suspension. If this happens, extended brake pedal travel could occur during the next brake application. This may result in reduced braking capability and increased stopping distance. A vehicle crash may result. Subsequent brake applications will result in normal braking, until another slow speed extreme turn is made. Repairs At no cost to you, your dealer will modify thefront suspension of your car by installing special nuts to eliminate the contact condition. How long will it take? The time needed to repair your car is less than one hour. Call your dealer Call your dealer without delay and ask for a service date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Arm: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 6236 Changed address or sold the car? If you have changed your address or sold the car, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your Owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications > Front Upper and Lower Control Arm Torque Specifications Control Arm: Specifications Lower Control Arm To Shock 103-144 ft.lb Lower Control Arm To Spindle (Ball Joint) 80-120 ft.lb Lower Control Arm To Sub-frame 92-125 ft.lb Upper Control Arm To Body 55-90 ft.lb Upper Control Arm To Spindle (Ball Joint) 50-65 ft.lb Lower Control Arm To Tension Strut 90-120 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Specifications > Front Upper and Lower Control Arm Torque Specifications > Page 6239 Control Arm: Specifications Lower Control Arm To Toe Compensator Link Nut 118-148 ft.lb Lower Control Arm To Knuckle Bolts 118-148 ft.lb Lower Control Arm To Subframe Nut (Front) 184-229 ft.lb Lower Control Arm To Subframe Nut (Rear) 125-170 ft.lb Upper Control Arm To Knuckle 118-148 ft.lb Upper Control Arm To Subframe 81-98 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front Control Arm: Service and Repair Front Control Arms & Steering Knuckle Tension Strut Upper Control Arm 1. Raise and support vehicle. 2. Remove tire and wheel assembly. 3. Remove and discard upper spindle to ball joint bolt and nut. Slightly spread spindle at slot and remove ball joint. 4. Lower vehicle, then brake off flags on upper control arm pivot bolt heads. 5. Remove upper control arm bolts, then upper control arm, Fig. 10. 6. Reverse procedure to install. Tighten to specifications. Lower Control Arm 1. Raise and support vehicle. 2. Remove tire and wheel assembly. 3. Loosen lower ball joint nut three or four turns. 4. Rap spindle to separate ball joint. Leave nut attached. 5. Support spindle by wire to prevent excessive sagging of upper control arm. 6. Mark position of camber adjustment cam. 7. Remove nut attaching tension strut to control arm. hold strut by flats with wrench while turning nut. Do not hold strut or damage surface in area shown in Fig. 11, damage to tension strut may result. 8. Remove lower shock bolt and nut. 9. Remove pivot (camber) bolt and nut. 10. Remove nut at lower ball joint and remove control arm, Fig. 10. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6242 11. Reverse procedure to install, after installation check front end alignment and adjust as necessary. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Component Information > Service and Repair > Front > Page 6243 Control Arm: Service and Repair Rear LOWER ARM 1. Remove coil spring as described in COIL SPRING. 2. Remove inner control arm pivot bolts and nuts, then remove arm assembly. 3. Remove toe compensating link from control arm. 4. Reverse procedure to install. Tighten to specifications. UPPER ARM 1. Raise and support vehicle. 2. Remove rear wheel and tire assembly. 3. Support knuckle and hub assembly so that it cannot swing outward. 4. Remove inner and outer pivot bolts and nuts at upper control arm, then remove upper control arm. 5. Reverse procedure to install, noting that inner pivot bolt used for camber adjustment has a specially-shaped washer under bolt head. Ensure fasteners are used in correct locations. Set camber adjustment as described in ADJUSTMENT PROCEDURES/WHEEL ALIGNMENT. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 8921 > Jan > 89 > Driveshaft - Vibration Cross-Member: Customer Interest Driveshaft - Vibration ^ CROSSMEMBER - CENTER SUPPORT BRACKET INSTALLATION - VEHICLES BUILT BEFORE 2/01/89 ^ VIBRATION - CENTER SUPPORT BRACKET CONTACTS DRIVESHAFT - VEHICLES BUILT BEFORE 2/01/89 Article No. 89-2-1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A driveline vibration between 5-10 MPH (8-16 Km/h) may be caused by the driveshaft contacting the crossmember center support bracket. The crossmember center support bracket may have been initially installed backwards. ACTION: Inspect the position of the crossmember center support bracket to determine if service is required. Refer to the following procedure for service details. FIGURE 1 1. Remove the four (4) bolts holding the body reinforcement, Figure 1. 2. Remove the two (2) bolts and one (1) nut retaining the heat shield. 3. Position the heat shield aside. 4. Make sure the arrow on the center support bracket is pointing toward the rear of the vehicle, Figure 1. If not proceed to Step 5. If okay proceed to Step 8. 5. Remove the two (2) bolts that hold the center support bracket to the body reinforcement, Figure 1. 6. Rotate the center support bracket 180 degrees so the arrow on the bracket points toward the rear of the vehicle. 7. Install the two (2) bolts that hold the center support bracket to the body reinforcement. 8. Reposition the heat shield. 9. Reinstall the two (2) bolts and one (1) nut that retains the heat shield. 10. Reinstall the four (4) bolts that retain the body reinforcement, Figure 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION : 890201A - Inspect TIME: 0.4 Hr. OPERATION: 890201B - Inspect and Correct TIME: 0.5 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 8921 > Jan > 89 > Driveshaft - Vibration > Page 6252 DLR. CODING: Basic Part No. 5A041 Condition Code: 79 OASIS CODES: 5950, 7210, 7211, 7212, 7213 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 8921 > Jan > 89 > Driveshaft - Vibration Cross-Member: All Technical Service Bulletins Driveshaft - Vibration ^ CROSSMEMBER - CENTER SUPPORT BRACKET INSTALLATION - VEHICLES BUILT BEFORE 2/01/89 ^ VIBRATION - CENTER SUPPORT BRACKET CONTACTS DRIVESHAFT - VEHICLES BUILT BEFORE 2/01/89 Article No. 89-2-1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A driveline vibration between 5-10 MPH (8-16 Km/h) may be caused by the driveshaft contacting the crossmember center support bracket. The crossmember center support bracket may have been initially installed backwards. ACTION: Inspect the position of the crossmember center support bracket to determine if service is required. Refer to the following procedure for service details. FIGURE 1 1. Remove the four (4) bolts holding the body reinforcement, Figure 1. 2. Remove the two (2) bolts and one (1) nut retaining the heat shield. 3. Position the heat shield aside. 4. Make sure the arrow on the center support bracket is pointing toward the rear of the vehicle, Figure 1. If not proceed to Step 5. If okay proceed to Step 8. 5. Remove the two (2) bolts that hold the center support bracket to the body reinforcement, Figure 1. 6. Rotate the center support bracket 180 degrees so the arrow on the bracket points toward the rear of the vehicle. 7. Install the two (2) bolts that hold the center support bracket to the body reinforcement. 8. Reposition the heat shield. 9. Reinstall the two (2) bolts and one (1) nut that retains the heat shield. 10. Reinstall the four (4) bolts that retain the body reinforcement, Figure 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION : 890201A - Inspect TIME: 0.4 Hr. OPERATION: 890201B - Inspect and Correct TIME: 0.5 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 8921 > Jan > 89 > Driveshaft - Vibration > Page 6258 DLR. CODING: Basic Part No. 5A041 Condition Code: 79 OASIS CODES: 5950, 7210, 7211, 7212, 7213 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications > Tightening Specifications Fig. 15 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information > Specifications > Tightening Specifications > Page 6261 Cross-Member: Specifications Crossmember Bolt 12-17 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information > Specifications Front Steering Knuckle: Specifications Pinch Bolt & Nut 38-49 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Service and Repair Radius Arm: Service and Repair Tension Strut REMOVAL 1. Raise and support vehicle. 2. Remove tire and wheel assembly. 3. Hold tension strut on flats with wrench. Remove front sub-frame attaching nut and insulator. CAUTION: Do not hold strut or damage surface in area shown in Fig. 11, damage to tension strut may result. 4. Mark position, or note number of visible threads at tension strut rear sub-frame nut. 5. Back off tension strut rear sub-frame nut. 6. Remove tension strut to lower control arm attaching nut. 7. Remove lower shock bolt and nut. 8. Remove brake hose bracket to body attaching bolt. 9. Remove ABS sensor attaching bolt and position sensor out of the way. 10. Pry lower control arm rearward and remove tension strut. Tension Strut Installation INSTALLATION 1. If front tension strut insulators were removed, de-burr insulator sleeves before reassembly. If new sleeves are used, inner sleeve must be shorter than outer sleeve. Cut up to 1/4 inch off inner sleeve if necessary, Fig. 12. 2. Install tension strut retaining nut all the way down on threads. Install with nylon insert facing forward. 3. Install outer sleeve and rear washer. Word REAR must face outward. 4. Install rear insulator (without metal flange) with large end toward sub-frame. 5. Install tension strut in sub-frame. 6. Install front insulator, with the word FRONT toward front of vehicle and metal flange toward sub-frame. 7. Install front washer, with the words ``THIS SIDE OUT'' toward front of vehicle. 8. Install inner sleeve, loosely install front nut. 9. Install front washer and insulator on rear of tension strut, cup to face away from insulator. 10. Install tension strut into lower control arm. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Radius Arm > Component Information > Service and Repair > Page 6268 11. Install rear insulator with small end toward control arm. 12. Install washer and cup facing rear of vehicle. 13. Return torsion strut-to-sub-frame nut to original position. 14. Install lower shock bolt and nut. 15. Holding tension strut with wrench, tighten strut to sub-frame to specification. 16. Tighten tension strut to lower control arm attaching nut to specification. 17. Install brake hose bracket, tighten to specifications. 18. Install ABS sensor, tighten to specifications. 19. Install tire and wheel assembly, check front wheel alignment. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > Recalls for Rear Knuckle: > 89S64S1 > Sep > 89 > Recall - Rear Suspension Knuckle, Supplement Technical Service Bulletin # 89S64S1 Date: 890901 Recall - Rear Suspension Knuckle, Supplement At Dealers By__________ ___% of Parts Direct Shipped to Dealers At PDC By NOW Date in Owner Letter: Sept., 1989 RECALL NUMBER 89S64 - S1 Date: Sept., 1989 To: All Ford and Lincoln-Mercury Dealers Reference: Safety Recall, 89S64 dated May 31, 1989 Subject: Safety Recall 89S64 Supplement - 1989 Thunderbird and Cougar - Rear Suspension Knuckles The purpose of this supplemental bulletin is to advise you that Recall 89S64 is being expanded to include vehicles produced from 1/21/89 thru 2/6/89. According to our records, the expanded production dates will affect the cars on the enclosed list which have been delivered to your dealership. NOTIFICATION Car owners whose names and addresses are shown on the OF OWNERS enclosed listing are being notified by First Class Mail. If the owner of any car cannot be contacted or does not make an appointment to have his car corrected, advise your FPSD District Office of the owner's name and address so that we can handle further notification. RECALL Refer to the Recall 89S64 Bulletin dated May 31, 1989 for PROCEDURES technical instructions, parts information, and reporting procedures. If you have any questions concerning this supplement, please contact your Ford Parts and Service Division District Office. Defect Report May 16, 1989 Associate Administrator for Enforcement National Highway Traffic Safety Administration 400 Seventh Street, S.W. Washington, D.C. 20590 Pursuant to Part 573 of Title 49 of the Code of Federal Regulations - Defect and Noncompliance Reports, Ford Motor Company is submitting information concerning a safety-related recall we are initiating. Specific information is as follows: 573/5 (c) (2) 1989 Thunderbird and Cougar vehicles produced at the Lorain, Ohio assembly plant from January 10, 1989 through January 20, 1989. 573.5 (c) (3) Approximately 10,600 units. 573.5 (c) (4) Approximately one percent. 573.5 (c) (5) A small number of the subject vehicles may have been produced with improperly heat treated rear susuension knuckles. Testing has determined that these knuckles could experience high mileage fatigue cracks and eventual fracture. Should a fracture occur, the rear suspension at that wheel would not remain intact and vehicle control could be adversely affected. 573.5 (c) (6) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > Recalls for Rear Knuckle: > 89S64S1 > Sep > 89 > Recall - Rear Suspension Knuckle, Supplement > Page 6277 On January 31, 1989 it was reported that some 1989 Thunderbird and Cougar rear suspension knuckles were exhibiting poor machinability during the manufacturing process. Subsequent investigation found that one lot from the casting supplier had not been properly heat treated. Knuckles produced from this lot were purged from the system; however, 133 suspect knuckles had been installed in the subject vehicles that had been shipped from the plant. Based on vehicle durability testing conducted with knuckles from this lot, Ford engineers predict that the knuckles could experience high mileage fatigue cracks and eventually fracture. Ford is not aware of any field reports concerning this condition. 573.5 (c) (8) Owners of record will be notified of the condition and instructed to return their vehicles for inspection of the heat treat lot code that is stamped on the rear suspension knuckles. Dealers will replace those knuckles found to have the affected lot codes. 573.5 (c) (9) Ford plans to make a public statement concerning the subject matter of this recall. Copies of notification letters to dealer and owners from Ford Parts and Service Division will be forwarded. Supplement Letter Associate Administrator for Enforcement National Highway Traffic Safety Administration 401, Seventh Street, S. W. Washington, D. C. 20590 Dear Sir: Subject: Safety Recall 89S64 - Supplement Enclosed are dealer and owner letters issued by Ford Parts and Service Division announcing the expansion of Ford Safety Recall 89S64. This recall is being expanded to include approximately an additional 7,800 units produced at the Lorain, Ohio assembly plant from January 21, 1989 through February 6, 1989. Specific details regarding this recall were forwarded to you in our letter of May 16, 1989. Owner Letter September, 1989 Dear Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Ford Thunderbirds and Mercury Cougars. Safety Defect A rear suspension part called a rear wheel knuckle may break without warning while the car is being driven. If this should happen to your car, it may become difficult to steer. A crash could occur. Problems Some of the rear wheel knuckles on these cars may not have been properly heat treated during manufacture. Your car may have one or two of these suspect parts installed. Repairs At no cost to you, your dealer will inspect the man- ufacturing codes of the rear wheel knuckles of your car and replace any of them having the suspect date code. How long will The time needed to repair your car is less than four It Take? hours. Call your Call your dealer without delay and ask for a service dealer date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they will be ordered. Such parts would be expected to arrive within a week. If your car needs parts replaced, the dealer will keep your car until parts are received. Your dealer will provide you with a free loaner car (except for fuel) for your use until the service on your car is completed. When you bring your car in, give the dealer the attached form. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > Recalls for Rear Knuckle: > 89S64S1 > Sep > 89 > Recall - Rear Suspension Knuckle, Supplement > Page 6278 If you misplace the form, your dealer will still do the work, free of charge. Changed address If you have, please fill out Section 1 of the enor sold the car? closed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Fordbuilt car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > Recalls for Rear Knuckle: > 89S64 > Jun > 89 > Recall - Rear Suspension Knuckle Replacement Technical Service Bulletin # 89S64 Date: 890601 Recall - Rear Suspension Knuckle Replacement June, 1989 TO: Selected North American Ford and Lincoln-Mercury Product Dealers and Affiliated Ford Motor Companies SUBJECT: Safety Recall 89S64 - 1989 Thunderbird and Cougar, Rear Suspension Knuckles AFFECTED 1989 Thunderbirds and Cougars built from January 10 VEHICLES through January 20, 1989. REASONS FOR IMPROPERLY HEAT TREATED REAR SUSPENSION KNUCKLES. RECALL 133 suspect knuckles were installed on the affected cars during the build period. Improperly heat treated knuckles could fracture at high mileage without warning. Fracture of a knuckle while driving could result in a loss of vehicle control and a crash. IVO PARTS ORDER Dealers are not to order parts for recall until you have FREE LOANER CAR inspected a car and found a suspect coded knuckle. At that time, dealers should: * Submit an IVO order for the parts. * Give the owner the use of a free loaner car until the recall is completed. NOTE: These cars are also affected by Recall 89S63 - Tension Strut Nut Replacement. Complete all required recall service during one visit by the owner. ATTACHMENTS Attachment I Administrative Information Attachment II Labor Allowances - Car Rental (Form 1863) - Parts Ordering Information Attachment III Technical Information Attachment I CARES/OASIS Dealers in Puerto Rico and the U.S. Virgin Islands must use CARES or OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY Affected vehicles on the enclosed list and all other CORRECT eligible vehicles which are brought to your dealership. DEALER-OWNER Immediately contact any owner to whom you have sold an CONTACT involved vehicle but whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT/FORD Advise district office or supervising Ford location if: CONTACT - an owner cannot be contacted. - an owner does not make a service date. Discuss with your Field Service Engineer or supervising Ford location any recall concerns you may have. REPORTING Only the Ford 1864 will be accepted for reimbursement under COMPLETIONS this program. Upon completion of the required service, the AND Form 1864 must be completely filled out and signed by Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > Recalls for Rear Knuckle: > 89S64 > Jun > 89 > Recall - Rear Suspension Knuckle Replacement > Page 6283 REIMBURSEMENT authorized dealer personnel. Dealers must mail the the second copy of the Form 1864 for reimbursement. It is important that claims be filed for all completed units so that you will be reimbursed and our records will show completion. Attachment II SAFETY RECALL 89S64 1989 Thunderbird and Cougar Rear Suspension Knuckles LABOR ALLOWANCES Inspect both sides for stamped 6-59 code 0.3 Hrs. - Insert in Box "A" on Form 1864 Install One Rear Knuckle (Includes Inspection) 2.1 Hrs. - Insert in Box "B" on Form 1864 Install Two Rear Knuckles (Includes Inspection) 3.2 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. FIES 1863 CLAIM FORM (LOANER CAR RENTAL) Prepare Form 1863 per FIES Warranty Claim Preparation Manual. After the basic claim has been filled out, follow the special instructions below: 1. Enter C-99 in the Program Code. 2. Enter 89S64 as the causal part in the Basic Part Number Column. 3. Enter "OB" as the Condition Code. 4. Enter the number of days the vehicle was rented in the Labor Operation Column. If a vehicle was rented for two days, enter the word "Rent" plus the number of days, "2". Example, RENT2 in the Labor Operation Column. 5. Enter the cost of renting the vehicle in the Amount Column. (Example: Rental cost for 2 days x $30.00 per day = $60.00) Enter $60.00 in the Amount Column. NOTE: Try to stay within a guideline of $30.00 per day. The receipt for the rental must be kept in the dealership for one year from the date of company notification of payment. PARTS REQUIREMENTS RECALL 89S64 Removed parts (knuckles and hub nuts) must be tagged and held for Field Service Engineer inspection. The tag must contain the vehicle identification number and Form 1864 number. The Form 1864 must be signed by the Field Service Engineer prior to submission for payment. Parts will not be direct shipped for this recall. Do not order recall parts from FPSD International Distribution Operations (formerly known as Windsor Export Supply). Order all requirements directly from Wixom using the mailing address on page No. 1 of this Bulletin. For more urgent handling, use cable address "RECALLS - FORDEX, WIXOM, MICHIGAN". For locations having telex facilities, our telex Ford private line code is FED and commercial telex code is 669777 answerback Ford FIES WIX. Our telephone number in Wixom, Michigan, is area code (313) 344-5641 and Rapifax number is (313) 344-5647. Please give the part number, description, quantity and recall number when ordering. PART CUSTOMS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > Recalls for Rear Knuckle: > 89S64 > Jun > 89 > Recall - Rear Suspension Knuckle Replacement > Page 6284 NUMBER DESCRIPTION CLASS VALUE E9SZ-5A968-A KNUCKLE ASSY CG $85.80 DRUM BRAKE (RH) E9SZ-5A969-A KNUCKLE ASSY CG $82.00 DRUM BRAKE (LH) E9SZ-5A968-B KNUCKLE ASSY CG $92.00 DISC BRAKE (RH) E9SZ-5A969-B KNUCKLE ASSY CG $94.00 DISC BRAKE (LH) E9SZ-4B477-A RETAINER ASSY CG $ 2.66 (REAR AXLE) (Based on $5.31 pkg/2) REMINDER Order parts only after verifying need by actual vehicle inspection. Attachment III SAFETY RECALL 89S64 1989 Thunderbird and Cougar Rear, Suspension Knuckles TECHNICAL INSTRUCTIONS INSPECTION: 1) Remove both rear wheels. 2) Look for code numbers stamped on upper leg, outboard side of knuckle. 3) 6-59: Knuckles having the numbers 6-59, alone or in combination with other numbers, are suspect and must be replaced. 4) Knuckles with any other combination of numbers are OK and are not to be replaced. 5) Install rear wheels. KNUCKLE INSTALLATION: Follow 1989 Thunderbird/Cougar Shop Manual procedures 14-32-8 through 14-32-12. Owner's Letter June, 1989 Dear Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Ford Thunderbirds and Mercury Cougars. Safety Defect A rear suspension part called a rear wheel knuckle may break without warning while the car is being driven. If this should happen to your car, it may become difficult to steer. A crash could occur. Problems Some of the rear wheel knuckles on these cars may not have been properly heat treated during manufacture. Your car may have one or two of these suspect parts installed. Repairs At no cost to you, your dealer will inspect the man- ufacturing codes of the rear wheel knuckles of your car and replace any of them having the suspect date Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > Recalls for Rear Knuckle: > 89S64 > Jun > 89 > Recall - Rear Suspension Knuckle Replacement > Page 6285 code. How long will The time needed to repair your car is less than four it take? hours. Call your Call your dealer without delay and ask for a service dealer date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they will be ordered. Such parts would be expedited and expected to arrive within approximately a week. If your car needs parts replaced, the dealer will keep your car until parts are received. Your dealer will provide you with a free loaner car (except for fuel) for your use until the service on your car is completed. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Changed address If you have, please fill out Section 1 of the enclosed or sold the car? prepaid postcard and mail it to us. If the dealer does not make the repair promptly and without charge, please fill out Section 3 of the prepaid postcard and mail it to us. You may also send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393. We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Fordbuilt car. For Areas Not Affected by U.S. Law Suggested Owner Letter (Dealership Stationery) Dear Owner: Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Ford Thunderbirds and Mercury Cougars. Safety Defect A rear suspension part called a rear wheel knuckle may break without warning while the car is being driven. If this should happen to your car, it may become difficult to steer. A crash could occur. Problems Some of the rear wheel knuckles on these cars may not have been properly heat treated during manufacture. Your car may have one or two of these suspect parts installed. Repairs At no cost to you, we will inspect the manufacturing codes of the rear wheel knuckles of your car and replace any of them having the suspect date code. How long will The time needed to repair your car is less than four It Take? hours. Call your Call us without delay and ask for a service date. dealer We have the service information needed to repair your car. If we do not have the parts in stock, they will be ordered. Such parts would be expected to arrive within a week. If your car needs parts replaced, we will keep your car until parts are received. We will provide you with a free loaner car (except for fuel) for your use until the service on your car is completed. When you bring your car in, give the attached form to the Service Department. If you misplace the form, we will still do the work, free of charge. Changed address If you have, please fill out Section 1 of the enclosed or sold the car? prepaid postcard and mail it to the addressee. We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Fordbuilt car. Sincerely, Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > Recalls for Rear Knuckle: > NHTSA89V080000 > May > 89 > Recall 89V080000: Rear Suspension Knuckle Fatigue Cracks Rear Knuckle: Recalls Recall 89V080000: Rear Suspension Knuckle Fatigue Cracks IMPROPERLY HEAT TREATED REAR SUSPENSION KNUCKLES COULD EXPERIENCE HIGH MILEAGE FATIGUE CRACKS AND EVENTUAL FRACTURE. THIS COULD RESULT IN REAR SUSPENSION FAILURE AT THE AFFECTED WHEEL WITH AN ADVERSE AFFECT ON CONTROL OF THE CAR, WHICH COULD CAUSE AN ACCIDENT. REPLACE KNUCKLES THAT HAVE THE AFFECTED LOT CODES. SYSTEM: REAR SUSPENSION KNUCKLES. VEHICLE DESCRIPTION: PASSENGER CARS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Knuckle: > 89S64S1 > Sep > 89 > Recall - Rear Suspension Knuckle, Supplement Technical Service Bulletin # 89S64S1 Date: 890901 Recall - Rear Suspension Knuckle, Supplement At Dealers By__________ ___% of Parts Direct Shipped to Dealers At PDC By NOW Date in Owner Letter: Sept., 1989 RECALL NUMBER 89S64 - S1 Date: Sept., 1989 To: All Ford and Lincoln-Mercury Dealers Reference: Safety Recall, 89S64 dated May 31, 1989 Subject: Safety Recall 89S64 Supplement - 1989 Thunderbird and Cougar - Rear Suspension Knuckles The purpose of this supplemental bulletin is to advise you that Recall 89S64 is being expanded to include vehicles produced from 1/21/89 thru 2/6/89. According to our records, the expanded production dates will affect the cars on the enclosed list which have been delivered to your dealership. NOTIFICATION Car owners whose names and addresses are shown on the OF OWNERS enclosed listing are being notified by First Class Mail. If the owner of any car cannot be contacted or does not make an appointment to have his car corrected, advise your FPSD District Office of the owner's name and address so that we can handle further notification. RECALL Refer to the Recall 89S64 Bulletin dated May 31, 1989 for PROCEDURES technical instructions, parts information, and reporting procedures. If you have any questions concerning this supplement, please contact your Ford Parts and Service Division District Office. Defect Report May 16, 1989 Associate Administrator for Enforcement National Highway Traffic Safety Administration 400 Seventh Street, S.W. Washington, D.C. 20590 Pursuant to Part 573 of Title 49 of the Code of Federal Regulations - Defect and Noncompliance Reports, Ford Motor Company is submitting information concerning a safety-related recall we are initiating. Specific information is as follows: 573/5 (c) (2) 1989 Thunderbird and Cougar vehicles produced at the Lorain, Ohio assembly plant from January 10, 1989 through January 20, 1989. 573.5 (c) (3) Approximately 10,600 units. 573.5 (c) (4) Approximately one percent. 573.5 (c) (5) A small number of the subject vehicles may have been produced with improperly heat treated rear susuension knuckles. Testing has determined that these knuckles could experience high mileage fatigue cracks and eventual fracture. Should a fracture occur, the rear suspension at that wheel would not remain intact and vehicle control could be adversely affected. 573.5 (c) (6) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Knuckle: > 89S64S1 > Sep > 89 > Recall - Rear Suspension Knuckle, Supplement > Page 6295 On January 31, 1989 it was reported that some 1989 Thunderbird and Cougar rear suspension knuckles were exhibiting poor machinability during the manufacturing process. Subsequent investigation found that one lot from the casting supplier had not been properly heat treated. Knuckles produced from this lot were purged from the system; however, 133 suspect knuckles had been installed in the subject vehicles that had been shipped from the plant. Based on vehicle durability testing conducted with knuckles from this lot, Ford engineers predict that the knuckles could experience high mileage fatigue cracks and eventually fracture. Ford is not aware of any field reports concerning this condition. 573.5 (c) (8) Owners of record will be notified of the condition and instructed to return their vehicles for inspection of the heat treat lot code that is stamped on the rear suspension knuckles. Dealers will replace those knuckles found to have the affected lot codes. 573.5 (c) (9) Ford plans to make a public statement concerning the subject matter of this recall. Copies of notification letters to dealer and owners from Ford Parts and Service Division will be forwarded. Supplement Letter Associate Administrator for Enforcement National Highway Traffic Safety Administration 401, Seventh Street, S. W. Washington, D. C. 20590 Dear Sir: Subject: Safety Recall 89S64 - Supplement Enclosed are dealer and owner letters issued by Ford Parts and Service Division announcing the expansion of Ford Safety Recall 89S64. This recall is being expanded to include approximately an additional 7,800 units produced at the Lorain, Ohio assembly plant from January 21, 1989 through February 6, 1989. Specific details regarding this recall were forwarded to you in our letter of May 16, 1989. Owner Letter September, 1989 Dear Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Ford Thunderbirds and Mercury Cougars. Safety Defect A rear suspension part called a rear wheel knuckle may break without warning while the car is being driven. If this should happen to your car, it may become difficult to steer. A crash could occur. Problems Some of the rear wheel knuckles on these cars may not have been properly heat treated during manufacture. Your car may have one or two of these suspect parts installed. Repairs At no cost to you, your dealer will inspect the man- ufacturing codes of the rear wheel knuckles of your car and replace any of them having the suspect date code. How long will The time needed to repair your car is less than four It Take? hours. Call your Call your dealer without delay and ask for a service dealer date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they will be ordered. Such parts would be expected to arrive within a week. If your car needs parts replaced, the dealer will keep your car until parts are received. Your dealer will provide you with a free loaner car (except for fuel) for your use until the service on your car is completed. When you bring your car in, give the dealer the attached form. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Knuckle: > 89S64S1 > Sep > 89 > Recall - Rear Suspension Knuckle, Supplement > Page 6296 If you misplace the form, your dealer will still do the work, free of charge. Changed address If you have, please fill out Section 1 of the enor sold the car? closed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Fordbuilt car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Knuckle: > 89S64 > Jun > 89 > Recall - Rear Suspension Knuckle Replacement Technical Service Bulletin # 89S64 Date: 890601 Recall - Rear Suspension Knuckle Replacement June, 1989 TO: Selected North American Ford and Lincoln-Mercury Product Dealers and Affiliated Ford Motor Companies SUBJECT: Safety Recall 89S64 - 1989 Thunderbird and Cougar, Rear Suspension Knuckles AFFECTED 1989 Thunderbirds and Cougars built from January 10 VEHICLES through January 20, 1989. REASONS FOR IMPROPERLY HEAT TREATED REAR SUSPENSION KNUCKLES. RECALL 133 suspect knuckles were installed on the affected cars during the build period. Improperly heat treated knuckles could fracture at high mileage without warning. Fracture of a knuckle while driving could result in a loss of vehicle control and a crash. IVO PARTS ORDER Dealers are not to order parts for recall until you have FREE LOANER CAR inspected a car and found a suspect coded knuckle. At that time, dealers should: * Submit an IVO order for the parts. * Give the owner the use of a free loaner car until the recall is completed. NOTE: These cars are also affected by Recall 89S63 - Tension Strut Nut Replacement. Complete all required recall service during one visit by the owner. ATTACHMENTS Attachment I Administrative Information Attachment II Labor Allowances - Car Rental (Form 1863) - Parts Ordering Information Attachment III Technical Information Attachment I CARES/OASIS Dealers in Puerto Rico and the U.S. Virgin Islands must use CARES or OASIS to determine if a vehicle is eligible for this recall. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY Affected vehicles on the enclosed list and all other CORRECT eligible vehicles which are brought to your dealership. DEALER-OWNER Immediately contact any owner to whom you have sold an CONTACT involved vehicle but whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT/FORD Advise district office or supervising Ford location if: CONTACT - an owner cannot be contacted. - an owner does not make a service date. Discuss with your Field Service Engineer or supervising Ford location any recall concerns you may have. REPORTING Only the Ford 1864 will be accepted for reimbursement under COMPLETIONS this program. Upon completion of the required service, the AND Form 1864 must be completely filled out and signed by Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Knuckle: > 89S64 > Jun > 89 > Recall - Rear Suspension Knuckle Replacement > Page 6301 REIMBURSEMENT authorized dealer personnel. Dealers must mail the the second copy of the Form 1864 for reimbursement. It is important that claims be filed for all completed units so that you will be reimbursed and our records will show completion. Attachment II SAFETY RECALL 89S64 1989 Thunderbird and Cougar Rear Suspension Knuckles LABOR ALLOWANCES Inspect both sides for stamped 6-59 code 0.3 Hrs. - Insert in Box "A" on Form 1864 Install One Rear Knuckle (Includes Inspection) 2.1 Hrs. - Insert in Box "B" on Form 1864 Install Two Rear Knuckles (Includes Inspection) 3.2 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. FIES 1863 CLAIM FORM (LOANER CAR RENTAL) Prepare Form 1863 per FIES Warranty Claim Preparation Manual. After the basic claim has been filled out, follow the special instructions below: 1. Enter C-99 in the Program Code. 2. Enter 89S64 as the causal part in the Basic Part Number Column. 3. Enter "OB" as the Condition Code. 4. Enter the number of days the vehicle was rented in the Labor Operation Column. If a vehicle was rented for two days, enter the word "Rent" plus the number of days, "2". Example, RENT2 in the Labor Operation Column. 5. Enter the cost of renting the vehicle in the Amount Column. (Example: Rental cost for 2 days x $30.00 per day = $60.00) Enter $60.00 in the Amount Column. NOTE: Try to stay within a guideline of $30.00 per day. The receipt for the rental must be kept in the dealership for one year from the date of company notification of payment. PARTS REQUIREMENTS RECALL 89S64 Removed parts (knuckles and hub nuts) must be tagged and held for Field Service Engineer inspection. The tag must contain the vehicle identification number and Form 1864 number. The Form 1864 must be signed by the Field Service Engineer prior to submission for payment. Parts will not be direct shipped for this recall. Do not order recall parts from FPSD International Distribution Operations (formerly known as Windsor Export Supply). Order all requirements directly from Wixom using the mailing address on page No. 1 of this Bulletin. For more urgent handling, use cable address "RECALLS - FORDEX, WIXOM, MICHIGAN". For locations having telex facilities, our telex Ford private line code is FED and commercial telex code is 669777 answerback Ford FIES WIX. Our telephone number in Wixom, Michigan, is area code (313) 344-5641 and Rapifax number is (313) 344-5647. Please give the part number, description, quantity and recall number when ordering. PART CUSTOMS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Knuckle: > 89S64 > Jun > 89 > Recall - Rear Suspension Knuckle Replacement > Page 6302 NUMBER DESCRIPTION CLASS VALUE E9SZ-5A968-A KNUCKLE ASSY CG $85.80 DRUM BRAKE (RH) E9SZ-5A969-A KNUCKLE ASSY CG $82.00 DRUM BRAKE (LH) E9SZ-5A968-B KNUCKLE ASSY CG $92.00 DISC BRAKE (RH) E9SZ-5A969-B KNUCKLE ASSY CG $94.00 DISC BRAKE (LH) E9SZ-4B477-A RETAINER ASSY CG $ 2.66 (REAR AXLE) (Based on $5.31 pkg/2) REMINDER Order parts only after verifying need by actual vehicle inspection. Attachment III SAFETY RECALL 89S64 1989 Thunderbird and Cougar Rear, Suspension Knuckles TECHNICAL INSTRUCTIONS INSPECTION: 1) Remove both rear wheels. 2) Look for code numbers stamped on upper leg, outboard side of knuckle. 3) 6-59: Knuckles having the numbers 6-59, alone or in combination with other numbers, are suspect and must be replaced. 4) Knuckles with any other combination of numbers are OK and are not to be replaced. 5) Install rear wheels. KNUCKLE INSTALLATION: Follow 1989 Thunderbird/Cougar Shop Manual procedures 14-32-8 through 14-32-12. Owner's Letter June, 1989 Dear Owner: This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Ford Thunderbirds and Mercury Cougars. Safety Defect A rear suspension part called a rear wheel knuckle may break without warning while the car is being driven. If this should happen to your car, it may become difficult to steer. A crash could occur. Problems Some of the rear wheel knuckles on these cars may not have been properly heat treated during manufacture. Your car may have one or two of these suspect parts installed. Repairs At no cost to you, your dealer will inspect the man- ufacturing codes of the rear wheel knuckles of your car and replace any of them having the suspect date Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Knuckle: > 89S64 > Jun > 89 > Recall - Rear Suspension Knuckle Replacement > Page 6303 code. How long will The time needed to repair your car is less than four it take? hours. Call your Call your dealer without delay and ask for a service dealer date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they will be ordered. Such parts would be expedited and expected to arrive within approximately a week. If your car needs parts replaced, the dealer will keep your car until parts are received. Your dealer will provide you with a free loaner car (except for fuel) for your use until the service on your car is completed. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Changed address If you have, please fill out Section 1 of the enclosed or sold the car? prepaid postcard and mail it to us. If the dealer does not make the repair promptly and without charge, please fill out Section 3 of the prepaid postcard and mail it to us. You may also send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393. We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Fordbuilt car. For Areas Not Affected by U.S. Law Suggested Owner Letter (Dealership Stationery) Dear Owner: Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Ford Thunderbirds and Mercury Cougars. Safety Defect A rear suspension part called a rear wheel knuckle may break without warning while the car is being driven. If this should happen to your car, it may become difficult to steer. A crash could occur. Problems Some of the rear wheel knuckles on these cars may not have been properly heat treated during manufacture. Your car may have one or two of these suspect parts installed. Repairs At no cost to you, we will inspect the manufacturing codes of the rear wheel knuckles of your car and replace any of them having the suspect date code. How long will The time needed to repair your car is less than four It Take? hours. Call your Call us without delay and ask for a service date. dealer We have the service information needed to repair your car. If we do not have the parts in stock, they will be ordered. Such parts would be expected to arrive within a week. If your car needs parts replaced, we will keep your car until parts are received. We will provide you with a free loaner car (except for fuel) for your use until the service on your car is completed. When you bring your car in, give the attached form to the Service Department. If you misplace the form, we will still do the work, free of charge. Changed address If you have, please fill out Section 1 of the enclosed or sold the car? prepaid postcard and mail it to the addressee. We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Fordbuilt car. Sincerely, Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Knuckle: > NHTSA89V080000 > May > 89 > Recall 89V080000: Rear Suspension Knuckle Fatigue Cracks Rear Knuckle: All Technical Service Bulletins Recall 89V080000: Rear Suspension Knuckle Fatigue Cracks IMPROPERLY HEAT TREATED REAR SUSPENSION KNUCKLES COULD EXPERIENCE HIGH MILEAGE FATIGUE CRACKS AND EVENTUAL FRACTURE. THIS COULD RESULT IN REAR SUSPENSION FAILURE AT THE AFFECTED WHEEL WITH AN ADVERSE AFFECT ON CONTROL OF THE CAR, WHICH COULD CAUSE AN ACCIDENT. REPLACE KNUCKLES THAT HAVE THE AFFECTED LOT CODES. SYSTEM: REAR SUSPENSION KNUCKLES. VEHICLE DESCRIPTION: PASSENGER CARS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Rear Knuckle > Component Information > Technical Service Bulletins > Page 6308 Rear Knuckle: Service and Repair Caution: Do not begin this procedure unless a new hub retainer nut is available. Once removed, this part cannot be reused during assembly. Its torque holding and/or retention capability is greatly diminished during removal. 1. Remove wheelcover/hub cover from wheel and tire assembly, then loosen wheel nuts. 2. Remove and discard hub nut and washer. 3. Raise and support vehicle, then remove wheel and tire assembly. 4. Pull back on parking brake cable release lever and at same time pull on cable. This action will relax cable so it can be removed from brake caliper or backing plate. 5. On models with disc brakes, proceed as follows: a. Remove parking brake cable from caliper. b. Remove upper and lower caliper attaching bolts and remove caliper assembly from rotor. c. Carefully wire caliper to brake junction bracket. 6. On all models, with push on nuts removed, remove brake rotor or drum assembly. 7. Remove three bolts retaining splash shield to knuckle and remove splash shield. 8. Disconnect parking brake cable and disconnect brake line from wheel cylinder. 9. Remove upper control arm nut and bolt. 10. Wire upper control arm to body to prevent damage to CV boots when knuckle and hub assembly is removed. 11. Install hub remover/replacer tool No. T81P-1104-C or equivalent to hub studs. Turn wrench counterclockwise until halfshaft is free in hub. 12. Using a paint marker, mark position of control arm in relation to knuckle with bushings in a relaxed position. When upper control arm bolt is removed from knuckle, lower arm bushings will return to a relaxed position. Failure to mark position will cause bushing wind up upon assembly and incorrect ride height. These conditions can cause misalignment and premature tire wear. 13. Note approximate angle of knuckle in relaxed position by measuring distance from upper bushing to any convenient point on vehicle body. 14. Remove lower control arm to knuckle attaching bolts and nuts. 15. Remove knuckle assembly from halfshaft. 16. Reverse procedure to install. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations Body & Chassis Components Under Center Of Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Control Module > Component Information > Locations > Page 6313 Suspension Control Module: Service and Repair 1. Turn ignition switch to OFF or LOCK position. 2. Working from inside of luggage compartment, remove attaching screws and carefully lower righthand panel located behind rear seat back. 3. Remove screws retaining control module or relay assembly from brackets. 4. Disconnect electrical connectors from control module or relays. 5. Remove control module or relays from mounting brackets. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Main Relay > Component Information > Locations > Hard Ride Relay Suspension Main Relay: Locations Hard Ride Relay Body & Chassis Components Under Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Main Relay > Component Information > Locations > Hard Ride Relay > Page 6318 Suspension Main Relay: Locations Soft Ride Relay Body & Chassis Components Under Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Relays and Modules - Suspension > Suspension Main Relay > Component Information > Locations > Page 6319 Suspension Main Relay: Service and Repair 1. Turn ignition switch to Off or LOCK position. 2. Working from inside luggage compartment, disconnect push pin at left side of package tray. 3. Swing tray downward. 4. Disconnect control module or relay electrical connectors, then remove control module or relays. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Brake Switch, Suspension Control > Component Information > Service and Repair Brake Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from brake sensor switch. 3. Remove sensor switch from brake control valve body. 4. Reverse procedure to install. Torque brake sensor switch to 8---10 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Steering Angle Sensor > Component Information > Service and Repair Steering Angle Sensor: Service and Repair The steering sensor is located at the lower end of the steering column. It may be removed with the steering column either in or out of the vehicle. 1. Disconnect sensor electrical connectors from wiring harness. 2. Disconnect sensor electrical connectors at bracket under instrument panel. 3. Remove speed sensor attaching screws, then remove sensor. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Sensors and Switches - Suspension > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair 1. Remove console top to console base attaching screws, then disconnect top panel from console base. 2. Disconnect fog lamp switch and ride control switch electrical connectors. 3. Remove switch attaching screws under panel. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications Fig. 14 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Spindle > Component Information > Specifications > Page 6333 Spindle: Service and Repair 1. Raise and support vehicle. 2. Remove tire and wheel assembly. 3. Remove brake caliper and rotor. 4. Remove hub and bearing assembly. 5. Remove brake anti-lock sensor and position out of the way. 6. Remove tie rod end cotter pin and loosen castellated nut. Separate tie rod end from spindle using tie rod end remover tool No. 3290-D or equivalent. 7. Remove stabilizer bar link at spindle using joint separator D88L-3006-A or equivalent. 8. Separate lower ball joint from spindle. Loosen nut and rap spindle with hammer. Remove nut. 9. Remove and discard upper spindle to upper control arm bolt and nut. Spread slot slightly and remove spindle from control arm and vehicle. 10. Reverse procedure to install. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications Stabilizer Link: Specifications Tightening Specifications Fig. 14 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link > Component Information > Specifications > Page 6338 Fig. 15 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Brake Switch, Suspension Control > Component Information > Service and Repair Brake Switch: Service and Repair 1. Disconnect battery ground cable. 2. Disconnect electrical connector from brake sensor switch. 3. Remove sensor switch from brake control valve body. 4. Reverse procedure to install. Torque brake sensor switch to 8---10 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Locations Damping Control Actuator: Locations Engine Compartment Component Locations At Top Of Respective Shock Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Service and Repair > Front Damping Control Actuator: Service and Repair Front 1. Position vehicle on level surface, then apply parking brake. 2. Turn ignition switch to Off or LOCK position, then raise hood. 3. Disconnect actuator electrical connectors from wiring harness electrical connectors. 4. Unsnap actuator protective cover. Fig. 9 Front Actuator Connector Removal 5. Remove actuator connector from protective cover by inserting small screwdriver tip between connector and white X-MAS tree track. 6. Depress actuator attaching tabs, then remove actuator. 7. Grasp shock absorber piston rod end with suitable tool, noting position of piston rod flat on thread and actuator mounting bracket. 8. Remove actuator mounting bracket to shock absorber attaching nut. 9. Do not move or raise vehicle after removing bracket attaching nut. If shock absorber must be removed install nut onto shock. 10. Reverse procedure to install, noting the following: a. Ensure flat on actuator mounting bracket aligns with flat on shock absorber piston end. b. Torque actuator mounting bracket attaching nut to 40-48 ft lb. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Damping Control Actuator > Component Information > Service and Repair > Front > Page 6348 Damping Control Actuator: Service and Repair Rear 1. Position vehicle on a level surface. 2. Turn ignition switch to Off or LOCK position. 3. Remove luggage compartment side trim panel. 4. Disconnect actuator electrical connector from harness connector. 5. Depress actuator attaching tabs, then remove actuator. 6. Grasp mounting bracket using a suitable tool. 7. While holding mounting bracket, loosen bracket attaching nut. 8. Remove mounting bracket. CAUTION: Do not attempt to raise vehicle after nut is removed. If shock absorber is to be removed, install mounting bracket retaining nut. 9. Reverse procedure to install, ensuring flat of shock absorber piston rods aligns with mounting bracket. Torque mounting bracket nut to 27-35 ft lb. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Control Solenoid Valve > Component Information > Service and Repair > Front Ride Control Solenoid Valve: Service and Repair Front 1. Place vehicle on a level surface. 2. Apply parking brake. 3. Turn ignition switch to OFF or LOCK position, then raise hood. 4. Disconnect actuator electrical connector from wiring harness electrical connector. 5. Remove actuator protective cover. 6. Remove screws attaching actuator to mounting bracket. 7. Remove actuator. 8. Grasp actuator mounting bracket using a suitable tool. 9. Loosen nut retaining mounting bracket to shock absorber. 10. Remove nut and mounting bracket. NOTE: Do not move or raise vehicle after removing bracket retaining nut. If shock absorber must be removed, install nut onto shock. 11. Reverse procedure to install. a. Ensure flat on actuator mounting bracket aligns with flat on shock absorber piston end. b. Torque actuator mounting bracket attaching nut to 40-48 ft lb. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Ride Control Solenoid Valve > Component Information > Service and Repair > Front > Page 6353 Ride Control Solenoid Valve: Service and Repair Rear 1. Position vehicle on a level surface. 2. Turn ignition switch to Off or LOCK position. 3. Remove luggage compartment side trim panel. 4. Disconnect actuator electrical connector from harness connector. 5. Depress actuator attaching tabs, then remove actuator. 6. Grasp mounting bracket using a suitable tool. 7. While holding mounting bracket, loosen bracket attaching nut. 8. Remove mounting bracket. NOTE: Do not attempt to raise vehicle after nut is removed. If shock absorber is to be removed, install mounting bracket retaining nut. 9. Reverse procedure to install, ensuring flat of shock absorber piston rods aligns with mounting bracket. Torque mounting bracket nut to 27-35 ft lb. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations Suspension Control Module: Locations Body & Chassis Components Under Center Of Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Control Module > Component Information > Locations > Page 6357 Suspension Control Module: Service and Repair 1. Turn ignition switch to OFF or LOCK position. 2. Working from inside of luggage compartment, remove attaching screws and carefully lower righthand panel located behind rear seat back. 3. Remove screws retaining control module or relay assembly from brackets. 4. Disconnect electrical connectors from control module or relays. 5. Remove control module or relays from mounting brackets. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Main Relay > Component Information > Locations > Hard Ride Relay Suspension Main Relay: Locations Hard Ride Relay Body & Chassis Components Under Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Main Relay > Component Information > Locations > Hard Ride Relay > Page 6362 Suspension Main Relay: Locations Soft Ride Relay Body & Chassis Components Under Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Main Relay > Component Information > Locations > Page 6363 Suspension Main Relay: Service and Repair 1. Turn ignition switch to Off or LOCK position. 2. Working from inside luggage compartment, disconnect push pin at left side of package tray. 3. Swing tray downward. 4. Disconnect control module or relay electrical connectors, then remove control module or relays. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Control ( Automatic - Electronic ) > Suspension Mode Switch > Component Information > Service and Repair Suspension Mode Switch: Service and Repair 1. Remove console top to console base attaching screws, then disconnect top panel from console base. 2. Disconnect fog lamp switch and ride control switch electrical connectors. 3. Remove switch attaching screws under panel. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front Suspension Spring ( Coil / Leaf ): Service and Repair Front Upper Mount To Spring Alignment Mark Placement Strut & Coil Spring Replacement The upper shock mount cannot be rotated when the shock and spring are assembled. Mark position of upper mount to coil spring with chalk, paint or grease pencil, prior to disassembly, Fig. 8. If upper mount is not properly positioned during assembly it will not install in vehicle. If installing new coil spring or upper mount transfer reference marks from removed parts to new parts. 1. Remove coil spring and shock strut assembly , Fig. 7, from vehicle as described under STRUT ASSEMBLY. 2. Position shock assembly in Spring Compressor tool No. 086-00029 or equivalent. 3. Compress spring and remove upper mount. 4. Release spring compressor to remove coil spring. 5. Position shock and coil assembly in Spring Compressor tool No. 086-00029 or equivalent and compress spring to install upper mount. 6. Install upper mount aligning reference marks. 7. Install nut and tighten to specification. 8. Release spring compressor, ensuring coil spring is properly seated. 9. Install coil spring and shock strut assembly from vehicle as described under STRUT ASSEMBLY. 10. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6371 Suspension Spring ( Coil / Leaf ): Service and Repair Rear Mounting Spring Cages Exploded View Of Rear Suspension 1. Raise and support vehicle. 2. Remove rear wheel and tire assembly. 3. Remove rear stabilizer bar link nuts at both ends of stabilizer bar. Rotate bar up and out of the way. 4. Disconnect parking brake cable at brake caliper. 5. Install three Spring Cages tool No. 086-00031 or equivalent, to rear springs as follows: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component Information > Service and Repair > Front > Page 6372 a. Install one spring cage without an adjuster link to inboard side or innermost bend of spring, Fig. 17. b. Install two more spring cages, with adjusters, at 120° angles to the previously installed cage. 6. Place a transmission jack or suitable stand under lower rear control arm as far outboard as possible. 7. Support rear knuckle and caliper assembly by wiring upper control arm to body. 8. Remove lower shock absorber mounting bolt and nut. 9. Mark position of toe adjustment cam to subframe for reference. Loosen both inboard pivot bolts on lower control arm. Control arm must not be lowered until pivot bolts are loose. Do not attempt to remove plastic cap on front of pivot nut. 10. Remove two bolts and nuts attaching lower control arm to knuckle, Fig. 18. 11. Lower control arm by lowering jack. Ensure spring cages properly seat on spring as control arm is dropped. 12. Remove jack, pull control arm down fully by hand and remove rear spring with cages in place. 13. Using coil spring compressor tool No. D78P-5310-A or equivalent, compress spring and remove spring cages. 14. Remove upper and lower spring insulators from spring. 15. Reverse procedure to install, compress spring to approximately 10.5 inches overall length prior to installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Recalls for Suspension Strut / Shock Absorber: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification Technical Service Bulletin # 89S63 Date: 890601 Recall - Front Suspension Hardware Modification RECALL NUMBER 89S63 Date: June, 1989 TO: All Ford and Lincoln Mercury Dealers SUBJECT: Safety Recall 89S63 - 1989 Thunderbird and Cougar - Extended Brake Pedal Travel AFFECTED VEHICLES 1989 Thunderbird and Cougar - Built from Job # 1 through March 27, 1989 REASONS FOR RECALL EXCESSIVE BRAKE PEDAL TRAVEL During full-lock, low speed turns (less than 5 MPH) the inboard front brake caliper may contact the stabilizer bar or stabilizer link. This can push the front disc caliper piston back and force brake fluid back into the master cylinder reservoir. This results in increased brake pedal travel during the next brake application. After one brake application, the piston is repositioned and proper pedal travel and brake performance is restored. The sequence could repeat, however, following the next low speed full-lock turn. ATTACHMENTS Attachment I - Administrative Information Attachment II - Labor Allowances - Parts Ordering Information Attachment III - Technical Information Attachment I Administrative Information CARES/OASIS YOU MUST USE CARES OR OASIS TO DETERMINE IF A VEHICLEIS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT CONTACT Advise district office if: - an owner cannot be contacted. - an owner does not make a service date FPSD CONTACT Talk with your FPSD Service Zone Manager about recallconcerns. REIMBURSEMENT FORM 1864 Submit 1864 claims for all completed vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Recalls for Suspension Strut / Shock Absorber: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification > Page 6381 WARRANTY AND POLICY MANUAL See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation. Attachment II Parts & Time Information SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) LABOR ALLOWANCES Inspect for Tension Strut Hex Cap Nut 0.1 Hrs. - Insert in Box "A" on Form 1864 Install two Tension Strut Hex Cap Nuts (Includes inspection) 0.3 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS N806301-S150 HEX CAP NUTS SG (pack of 2) ( tension strut) Attachment III Technical Instructions SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Recalls for Suspension Strut / Shock Absorber: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification > Page 6382 TECHNICAL INSTRUCTIONS The front tension strut-to-lower control arm nuts are to be replaced with special acorn type nuts that serve as steering stops and eliminate the potential for caliper contact. INSPECTION/REPLACEMENT PROCEDURE ^ Put car on hoist. ^ Inspect for acorn type nuts on tension strut-to-lower control arm. If acorn type nuts are in place, claim inspection time on Form 1864 and release car from Recall 89S63. ^ If acorn type are not found follow steps listed below for installation. PASSENGER SIDE ^ Turn front wheels to full left and remove tension strut nut from lower control arm on passenger side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). DRIVERS SIDE ^ Turn front wheels to full right and remove tension strut nut from lower control arm on drivers side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). ^ Lower and remove car from hoist. ^ Complete Form 1864 and release car from recall 89S63. Owner Letter Dear Owner: June, 1989 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Thunderbirds and Cougars. Safety Defect During slow speed extreme turns (less than 5 MPH)the right or left front brake caliper may contact a part of the front suspension. If this happens, extended brake pedal travel could occur during the next brake application. This may result in reduced braking capability and increased stopping distance. A vehicle crash may result. Subsequent brake applications will result in normal braking, until another slow speed extreme turn is made. Repairs At no cost to you, your dealer will modify thefront suspension of your car by installing special nuts to eliminate the contact condition. How long will it take? The time needed to repair your car is less than one hour. Call your dealer Call your dealer without delay and ask for a service date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Recalls for Suspension Strut / Shock Absorber: > 89S63 > Jun > 89 > Recall Front Suspension Hardware Modification > Page 6383 Changed address or sold the car? If you have changed your address or sold the car, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your Owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > Recalls for Suspension Strut / Shock Absorber: > NHTSA89V081000 > May > 89 > Recall 89V081000: Front Strut Nut Replacement Suspension Strut / Shock Absorber: Recalls Recall 89V081000: Front Strut Nut Replacement DUE TO CONTACT BETWEEN THE BRAKE CALIPER OF THE INBOARD FRONT WHEEL AND THE FRONT STABILIZER BAR, THERE MAY BE INCREASED BRAKE PEDAL TRAVEL FOLLOWING LOW SPEED TURNING MANEUVERS. THIS COULD CAUSE A REDUCTION IN BRAKE PERFORMANCE THAT COULD RESULT IN AN ACCIDENT. INSTALL ACORN TYPE FRONT SUSPENSION STRUT NUTS TO ELIMINATE STABILIZER BAR TO BRAKE CALIPER CONTACT. SYSTEM: BRAKES/SUSPENSION. VEHICLE DESCRIPTION: PASSENGER CARS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification Technical Service Bulletin # 89S63 Date: 890601 Recall - Front Suspension Hardware Modification RECALL NUMBER 89S63 Date: June, 1989 TO: All Ford and Lincoln Mercury Dealers SUBJECT: Safety Recall 89S63 - 1989 Thunderbird and Cougar - Extended Brake Pedal Travel AFFECTED VEHICLES 1989 Thunderbird and Cougar - Built from Job # 1 through March 27, 1989 REASONS FOR RECALL EXCESSIVE BRAKE PEDAL TRAVEL During full-lock, low speed turns (less than 5 MPH) the inboard front brake caliper may contact the stabilizer bar or stabilizer link. This can push the front disc caliper piston back and force brake fluid back into the master cylinder reservoir. This results in increased brake pedal travel during the next brake application. After one brake application, the piston is repositioned and proper pedal travel and brake performance is restored. The sequence could repeat, however, following the next low speed full-lock turn. ATTACHMENTS Attachment I - Administrative Information Attachment II - Labor Allowances - Parts Ordering Information Attachment III - Technical Information Attachment I Administrative Information CARES/OASIS YOU MUST USE CARES OR OASIS TO DETERMINE IF A VEHICLEIS ELIGIBLE FOR THIS RECALL. PLEASE NOTE CORRECT ALL VEHICLES IN STOCK BEFORE DELIVERY PROMPTLY CORRECT Affected vehicles on the enclosed list. Other eligible vehicles which are brought to your dealership. DEALER-OWNER CONTACT Immediately contact any owner whose name is not on the list. Give owner a copy of the Owner Letter. DISTRICT CONTACT Advise district office if: - an owner cannot be contacted. - an owner does not make a service date FPSD CONTACT Talk with your FPSD Service Zone Manager about recallconcerns. REIMBURSEMENT FORM 1864 Submit 1864 claims for all completed vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 6393 WARRANTY AND POLICY MANUAL See Section 6.3 pages 5 through 8 of your Warranty and Policy Manual for claims preparation. Attachment II Parts & Time Information SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) LABOR ALLOWANCES Inspect for Tension Strut Hex Cap Nut 0.1 Hrs. - Insert in Box "A" on Form 1864 Install two Tension Strut Hex Cap Nuts (Includes inspection) 0.3 Hrs. - Insert in Box "B" on Form 1864 Administrative Allowance............... 0.1 Hrs. NOTE: Add 0.1 hour Administrative Allowance to the total repair time. PARTS REQUIREMENTS Parts will not be direct shipped for this recall. Order your parts requirements through normal order processing channels. PART NUMBER DESCRIPTION CLASS N806301-S150 HEX CAP NUTS SG (pack of 2) ( tension strut) Attachment III Technical Instructions SAFETY RECALL 89S63 (1989 Thunderbird and Cougar Tension Strut Hex Cap Nut) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 6394 TECHNICAL INSTRUCTIONS The front tension strut-to-lower control arm nuts are to be replaced with special acorn type nuts that serve as steering stops and eliminate the potential for caliper contact. INSPECTION/REPLACEMENT PROCEDURE ^ Put car on hoist. ^ Inspect for acorn type nuts on tension strut-to-lower control arm. If acorn type nuts are in place, claim inspection time on Form 1864 and release car from Recall 89S63. ^ If acorn type are not found follow steps listed below for installation. PASSENGER SIDE ^ Turn front wheels to full left and remove tension strut nut from lower control arm on passenger side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). DRIVERS SIDE ^ Turn front wheels to full right and remove tension strut nut from lower control arm on drivers side. ^ Install and torque new cap nut to 103-118 ft.lbs. (140-160 N-m). ^ Lower and remove car from hoist. ^ Complete Form 1864 and release car from recall 89S63. Owner Letter Dear Owner: June, 1989 This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. Ford Motor Company has determined that a defect which relates to motor vehicle safety exists in certain 1989 Thunderbirds and Cougars. Safety Defect During slow speed extreme turns (less than 5 MPH)the right or left front brake caliper may contact a part of the front suspension. If this happens, extended brake pedal travel could occur during the next brake application. This may result in reduced braking capability and increased stopping distance. A vehicle crash may result. Subsequent brake applications will result in normal braking, until another slow speed extreme turn is made. Repairs At no cost to you, your dealer will modify thefront suspension of your car by installing special nuts to eliminate the contact condition. How long will it take? The time needed to repair your car is less than one hour. Call your dealer Call your dealer without delay and ask for a service date. Your dealer has the service information needed to repair your car. If your dealer does not have the parts in stock, they can be ordered before scheduling your service date. Parts would be expected to arrive within a week. When you bring your car in, give the dealer the attached form. If you misplace the form, your dealer will still do the work, free of charge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > 89S63 > Jun > 89 > Recall - Front Suspension Hardware Modification > Page 6395 Changed address or sold the car? If you have changed your address or sold the car, please fill out Section 1 of the enclosed prepaid postcard and mail it to us. If the dealer doesn't make the repair promptly and without charge, you may either mail Section 3 of the prepaid postcard to us or contact the Ford Parts and Service Division Office whose address is shown in your Owner Guide booklet. You may send a complaint to the Administrator, National Highway Traffic Safety Administration, 400 Seventh Street, SW, Washington, DC 20590 or call the toll free Auto Safety Hotline 800-424-9393 (Washington DC area residents may call 426-0123). We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your Ford-built car. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: > NHTSA89V081000 > May > 89 > Recall 89V081000: Front Strut Nut Replacement Suspension Strut / Shock Absorber: All Technical Service Bulletins Recall 89V081000: Front Strut Nut Replacement DUE TO CONTACT BETWEEN THE BRAKE CALIPER OF THE INBOARD FRONT WHEEL AND THE FRONT STABILIZER BAR, THERE MAY BE INCREASED BRAKE PEDAL TRAVEL FOLLOWING LOW SPEED TURNING MANEUVERS. THIS COULD CAUSE A REDUCTION IN BRAKE PERFORMANCE THAT COULD RESULT IN AN ACCIDENT. INSTALL ACORN TYPE FRONT SUSPENSION STRUT NUTS TO ELIMINATE STABILIZER BAR TO BRAKE CALIPER CONTACT. SYSTEM: BRAKES/SUSPENSION. VEHICLE DESCRIPTION: PASSENGER CARS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber Suspension Strut / Shock Absorber: Specifications Shock Absorber Shock Absorber To Lower Control Arm 110-120 ft.lb Shock Absorber Upper Mount 27-35 ft.lb Shock Absorber Top Stud Nut 16-20 ft.lb Shock Absorber Upper Mount 19-27 ft.lb Shock To Upper Mount 37-45 ft.lb Upper Shock Mount To Body 16-23 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Specifications > Shock Absorber > Page 6402 Fig. 14 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear Suspension Strut / Shock Absorber: Service and Repair Rear Rear Suspension Shock Absorber Replacement These vehicles are equipped with gas pressurized rear shock absorbers which will extend unassisted. Do not apply heat or flame to shock tube during removal. 1. Position vehicle on drive-on hoist or alignment pit, so that rear suspension arms are supported during removal. 2. Remove all upper attaching parts from inside of luggage compartment, Figs. 14 and 15. 3. Remove attaching bolt and at lower arm, then remove shock absorber. 4. Reverse procedure to install. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component Information > Service and Repair > Rear > Page 6405 Suspension Strut / Shock Absorber: Service and Repair Strut Strut & Coil Spring Replacement 1. Remove plastic cover at upper shock mount. 2. Remove automatic ride actuator, if equipped. 3. Remove three upper mounting nuts and collar plate from studs in engine compartment. 4. Raise and support vehicle, then remove tire and wheel assemblies. 5. Remove lower shock mounting bolt and nut, Fig. 7. 6. Remove nut at stabilizer link upper mounting stud. 7. Separate link from spindle using joint separator tool No. D88L-3006-A or equivalent. 8. Support lower control arm assembly with transmission jack. 9. Raise control arm and spindle with jack until stabilizer link can be completely separated from spindle. Position link out of the way. 10. Remove spindle to upper control arm attaching nut and bolt. Discard nut and bolt. 11. Lower jack to separate spindle from upper control arm. Do not allow spindle to hang free, support with wire or other means. 12. Remove support from lower control arm and remove shock and coil spring assembly. 13. Reverse procedure to install. Tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Bearing Adjusting Nut 17-25 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Specifications > Page 6409 Wheel Bearing: Adjustments These models are equipped with sealed bearing units which do not require adjustment or maintenance. If bearing is found to be defective, then hub and bearing must be replaced as an assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Fig. 3 Hub & Wheel Bearing Assembly REPLACE 1. Raise and support front of vehicle, then remove wheel and tire assembly. 2. Remove grease cap from hub. 3. Remove disc brake caliper with brake hose attached. Suspend caliper from suspension with wire. Do not allow caliper to hang from brake hose. 4. Remove brake rotor. 5. Remove hub nut, then remove hub and bearing assembly, Fig. 3. If difficulty is encountered in hub removal, use hub removal tool No. T81P-1104-C or equivalent. 6. Reverse procedure to install. Use a new hub nut and tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6412 Wheel Bearing: Service and Repair Rear NOTE: There are two approved methods for removing the hub from the bearing. Both methods are outlined. Removal 1. Remove knuckle and hub assembly from vehicle as outlined. 2. Place knuckle and hub assembly in a vise. NOTE: On drum brakes, remove shoe and linings, springs, and adjuster from backing plate. Remove four screws that retain the backing plate to the knuckle. Method One A. Position 3-Jaw Puller D88L-1 037-A and Step Plate D8OL-630-5 or equivalent, on the knuckle and press out the hub from the knuckle assembly. Method Two Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6413 A. Position Rear Hub Remover T89P-1 225-AH or equivalent between the knuckle and the backing plate. B. Assemble Hub Remover/Replacer T81 P-il 04-C and Step Plate D8OL-630-5 or equivalent. C. With forcing nut below the crossbar, hold forcing screw and turn forcing nut to remove hub. 3. Remove the backing plate. 4. Remove bearing retainer snap ring. 5. Place knuckle and bearing assembly on a press bed using Hub Support T89P-1 104-A and Bearing Remover T83P-1 1 04-AH2 or equivalent, and press bearing out of knuckle assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6414 Installation 1. Place knuckle assembly on press bed and position bearing in the bearing bore of the knuckle. 2. Using Bearing Installer T86P-1 1 04-A3 or equivalent, press the bearing into the knuckle. 3. Install bearing retainer snap ring. 4. Position the backing plate on the knuckle. Install four retaining bolts and tighten to 61-81 Nm (45-59 lb-ft). 5. Place knuckle assembly on the Hub Support T89P-1 104-A or equivalent and position on press bed plate Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6415 6. Position hub on bearing and using Hub Installer/Bearing Remover T83P-1 104-AH2 or equivalent, press hub into bearing. NOTE: If vehicle is equipped with drum brakes, install shoe linings, springs, and adjuster on backing plate 7. Prior to hub/bearing/knuckle installation replace bearing dust seal on the outboard CV joint with new seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information > Service and Repair > Front > Page 6416 Dust Seal Installation 8. Install new dust seal, ensuring seal flange faces outboard toward bearing. Use Drive Tube T83T-31 32-Al and Bearing Dust Seal Installer T89P-l 249-A or equivalent. 9. Install hub and knuckle assembly. See: Rear Knuckle/Service and Repair Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Wheel Hub: Customer Interest Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 6425 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 6426 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake Wheel Hub: All Technical Service Bulletins Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake > Page 6432 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake > Page 6433 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Page 6443 Wheel Hub: Specifications Rear Axle Hub Nut 250 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Page 6444 Wheel Hub: Service and Repair NOTE: There are two approved methods for removing the hub from the bearing. Both methods are outlined. Removal 1. Remove knuckle and hub assembly from vehicle as outlined. 2. Place knuckle and hub assembly in a vise. NOTE: On drum brakes, remove shoe and linings, springs, and adjuster from backing plate. Remove four screws that retain the backing plate to the knuckle. Method One A. Position 3-Jaw Puller D88L-1 037-A and Step Plate D8OL-630-5 or equivalent, on the knuckle and press out the hub from the knuckle assembly. Method Two Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Page 6445 A. Position Rear Hub Remover T89P-1 225-AH or equivalent between the knuckle and the backing plate. B. Assemble Hub Remover/Replacer T81 P-il 04-C and Step Plate D8OL-630-5 or equivalent. C. With forcing nut below the crossbar, hold forcing screw and turn forcing nut to remove hub. 3. Remove the backing plate. 4. Remove bearing retainer snap ring. 5. Place knuckle and bearing assembly on a press bed using Hub Support T89P-1 104-A and Bearing Remover T83P-1 1 04-AH2 or equivalent, and press bearing out of knuckle assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Page 6446 Installation 1. Place knuckle assembly on press bed and position bearing in the bearing bore of the knuckle. 2. Using Bearing Installer T86P-1 1 04-A3 or equivalent, press the bearing into the knuckle. 3. Install bearing retainer snap ring. 4. Position the backing plate on the knuckle. Install four retaining bolts and tighten to 61-81 Nm (45-59 lb-ft). 5. Place knuckle assembly on the Hub Support T89P-1 104-A or equivalent and position on press bed plate Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Page 6447 6. Position hub on bearing and using Hub Installer/Bearing Remover T83P-1 104-AH2 or equivalent, press hub into bearing. NOTE: If vehicle is equipped with drum brakes, install shoe linings, springs, and adjuster on backing plate 7. Prior to hub/bearing/knuckle installation replace bearing dust seal on the outboard CV joint with new seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Component Information > Technical Service Bulletins > Page 6448 Dust Seal Installation 8. Install new dust seal, ensuring seal flange faces outboard toward bearing. Use Drive Tube T83T-31 32-Al and Bearing Dust Seal Installer T89P-l 249-A or equivalent. 9. Install hub and knuckle assembly. See: Rear Knuckle/Service and Repair Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 9562 > Mar > 95 > Brakes - Roughness During Application Tires: Customer Interest Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 6458 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Tires: Customer Interest Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 6463 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > Customer Interest for Tires: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 6464 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 9562 > Mar > 95 > Brakes - Roughness During Application Tires: All Technical Service Bulletins Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 6470 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Tires: All Technical Service Bulletins Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 6475 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Tires: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 6476 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 89173 > Aug > 89 > Aluminum Wheel - Air Leaks Wheels: Customer Interest Aluminum Wheel - Air Leaks Article No. 89-17-3 WHEEL-ALUMINUM-LEAKS AIR FORD: 1986-90 CROWN VICTORIA, ESCORT 1986-88 EXP 1986-90 MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-90 FESTIVA 1989-90 PROBE LINCOLN-MERCURY: 1986-90 CONTINENTAL, COUGAR, GRAND MARQUIS 1986-87 LYNX 1986-90 MARK VII, SABLE, TOPAZ, TOWN CAR 1987-90 TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO This article is being republished in its entirety to expand the model year coverage to include 1987 through 1990 model year vehicles. ISSUE: Slow air leaks may occur in cast aluminum wheels because of porous wheel castings. ACTION: Use "HOT MELT" sealant (E7AZ-19554-A) and the following diagnostic/service procedure to eliminate the leaks. NOTE: THIS TSB MUST BE PERFORMED PRIOR TO REPLACING THE WHEEL FOR A LEAKING CONDITION. 1. Remove the tire and wheel assembly and inspect the wheel for structural damage. If none exists, go on to Step 2. If the wheel is damaged, replace it. 2. Check the complete wheel for possible air leaks. With the tire mounted on the wheel, locate the air leak using the water bath or equivalent method and mark the location. 3. Dismount the tire and on the tire side of the wheel prepare the surface for sealant. a. Thoroughly clean the leaking area with methylene chloride (e.g., choke cleaner E8AZ-19A501-AA) Or b. Use sandpaper of about 80 grit to thoroughly remove all contamination and score the wheel surface to improve adhesion of sealer. c. Prepare an adequate area around the leak to ensure covering the leak. d. Remove the valve stem if it is close to the repair area. 4. Use a clean rag to remove all cleaner or sanding dust. CAUTION: DO NOT USE AN OXYACETYLENE TORCH TO PERFORM STEP 5. Figure 1 5. Proceed to heat and seal the leaking area. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > Customer Interest: > 89173 > Aug > 89 > Aluminum Wheel - Air Leaks > Page 6485 a. Heat the prepared area of the wheel with an electric heat gun (Rotunda 107-00301 type) or propane torch (not oxyacetylene) until the melt stick (E7AZ-19554-A) flows. b. Apply the hot melt material over the prepared area using a liberal flow and a wiping action to assure coverage of the leaking area. NOTE: THE REPAIR IS MOST EFFECTIVE WHEN THE HEAT IS APPLIED TO THE BRAKE SIDE OF THE WHEEL AND THE SEALER IS MELTED BY THE HEAT IN THE METAL, SEE FIGURE 1. c. Apply only enough heat to melt the sealer and then remove the heat source. 6. Check for air leaks. a. After repairing the leak, allow the wheel to cool until it can be handled safely. b. Reassemble the tire and wheel. c. Inflate the tire to the recommended air pressure as indicated on the tire pressure decal. d. Check that the leak is repaired by using the procedure covered in Step 2. 7. After the repair is completed, balance and reinstall the wheel assembly on the vehicle. PART NUMBER PART NAME CLASS E8AZ-19A501-AA Choke Cleaner B E7AZ-19554-A Melt Stick Sealant BM OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-2-13, dated 1/28/87 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891703A Seal Aluminum Wheel - 0.8 Hr. ONE 891703B Seal Aluminum Wheel - 1.5 Hrs. TWO 891703C Seal Aluminum Wheel - 2.1 Hrs. THREE 891703D Seal Aluminum Wheel - 2.8 Hrs. FOUR DEALER CODING BASIC PART NO. CONDITION CODE 1007 48 OASIS CODES: 3300, 3500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92124 > Jun > 92 > Brakes - Roughness/Runout Check Wheels: All Technical Service Bulletins Brakes - Roughness/Runout Check Article No. 92-12-4 DATE: 06-03-92 ^ BRAKES-ROTOR-REPLACEMENT SERVICE TIPS ^ BRAKES-ROUGHNESS DEVELOPED FROM INCREASE IN ROTOR RUNOUT ^ WHEELS-LUG NUT TIGHTENING PROCEDURE FORD: 1986-92 TAURUS 1989-92 THUNDERBIRD 1992 CROWN VICTORIA LINCOLN-MERCURY: 1986-92 SABLE 1988-92 CONTINENTAL 1989-92 COUGAR 1991-92 TOWN CAR 1992 GRAND MARQUIS ISSUE: Brake roughness may occur after the lug nuts are installed and tightened with an impact wrench. The resulting torque difference from stud to stud can be as high as 60 lb.ft (81 N-m). This torque difference stud to stud may cause an increase in rotor runout by as much as .003"-.005"(.076mm-.127mm). The increase in rotor runout may speed up the development of brake roughness. ACTION: Tighten the wheel lug nuts in the "final' torque in the sequence described in the Service Manual. Use a torque wrench set to 95 +/- 10 lb.ft (129 +/- l4N-m). When performing brake service work that involves replacing or removing the rotor, refer to the following service procedure which minimizes hub/rotor "stacked" runout, a cause of brake roughness and uneven rotor wear. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new/turned rotor installed on the hub) indicates more then .002" (.05mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. HIGH SYSTEM RUNOUT High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT SERVICE TIPS 1. Completely clean the hub area that will contact the new/turned rotor. Remove rust build up. 2. Install the new/turned rotor on the hub and secure it with at least three (3) lug nuts. Tighten the lug nuts to 20 lb.ft (27 N-m) for testing. 3. Using a dial indicator 4201-C or equivalent, determine the total runout of the system. The total system (rotor and hub) runout must not exceed .002" (.05mm). 4. If the runout exceeds .002" (.05mm), proceed as follows: a. Remove the rotor and rotate it clockwise until the next hole lines up with a stud. b. Secure the rotor in the new position, reindexed as described in Step 2. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.05mm) or less total runout. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92124 > Jun > 92 > Brakes - Roughness/Runout Check > Page 6491 5. If .002" (.05mm) or less runout cannot be reached, the hub should be replaced and Steps 2 through 4 repeated when the new hub/rotor is installed. NOTE: IT IS RECOMMENDED THAT NEW BRAKE ROTORS NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUNOUT AND THICKNESS VARIATION SPECIFICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheels: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 90132 > Jun > 90 > Wheels - Loss Of Balance Weights Wheels: All Technical Service Bulletins Wheels - Loss Of Balance Weights Article No. 90-13-2 ^ WHEELS - AVAILABILITY OF NEW BALANCE WEIGHTS ^ WHEELS - LOSS OF BALANCE WEIGHTS AND CORROSION FORD: 1984-86 LTD 1984-88 EXP 1984-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS LINCOLN-MERCURY: 1984-86 CAPRI, MARQUIS 1984-87 LYNX 1984-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE ISSUE: The loss of wheel balance weights and corrosion damage to aluminum and steel wheels may be caused by the use of improper balance weights. As a running change in the 1990 model year, a new series of metric wheel balance weights were introduced across all car lines. These metric wheel balance weights are compatible with previous Ford and Lincoln-Mercury passenger car wheels. The new balance weights come in two series -- one for steel wheels and the other for aluminum wheels. ACTION: If service is required, refer to the following guidelines. Refer to the application blocks on the following page to select the correct balance weights. A Technical Service Bulletin for Light Truck applications will be released in the near future. Until that time, refer to the Rotunda catalog for wheel weight application. METRIC WEIGHTS: The traditional ounce series wheel balance weights were available in .25 ounce increments (.25 oz. = 7 grams). The new metric weights are available in 5 gram increments. This allows for... ^ Tighter spacing of the metric weights ^ Increased accuracy when balancing a tire and wheel assembly ^ Improved overall vehicle ride quality. STEEL WHEEL BALANCE WEIGHTS: Ford has replaced the zinc electroplated coating on the weight's steel clip with a new coating called "Dacromet". This is an improvement because... ^ Zinc electroplated wheel balance weight clips are susceptible to cracking and may allow the balance weight to fall off the wheel. ^ Zinc clips cause cosmetic damage to aluminum wheels as they corrode. ^ "Dacromet" finish provides five times the corrosion resistance of the zinc plate and will not cause the clip to crack. ALUMINUM WHEEL BALANCE WEIGHTS: The new aluminum series wheel balance weights are totally polyester coated (encapsulated) to further improve their corrosion resistance and appearance. MAXIMUM CORROSION PROTECTION: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 90132 > Jun > 90 > Wheels - Loss Of Balance Weights > Page 6500 For maximum corrosion protection and customer satisfaction, it is highly recommended that all dealers begin using... ^ Ford approved polyester coated wheel weights on all aluminum wheels ^ "Dacromet" clip coated weights on steel wheels. Both series of wheel balance weights are available in 5 gram increments. It is recommended that dealers begin converting their current balance equipment to accept the metric series balance weights. GUIDELINES FOR IDENTIFYING BALANCE WEIGHTS: Since Ford passenger car aluminum wheels are not designed to use other manufacturer's balance weights, any mismatch will possibly allow the weight to fall off the wheel resulting in a repeat repair. To ensure retention and improve corrosion resistance, only Ford approved balance weights should be used on Ford wheels. Some guidelines for telling the difference between Ford aluminum wheel weights and GM aluminum wheel weights are ... Figure 1 ^ The GM weight has a larger clip than the Ford weight, Figure 1. Figure 2 ^ When a GM weight is installed on a Ford wheel, the balance weight will not lay flat against the wheel's face, Figure 2. NOTE: REFER TO THE ROTUNDA CATALOG FOR NON-DOMESTIC PASSENGER CAR WHEEL WEIGHTS. Refer to the following wheel weight charts for a description and Rotunda part number. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 90132 > Jun > 90 > Wheels - Loss Of Balance Weights > Page 6501 OASIS CODES: 3300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89173 > Aug > 89 > Aluminum Wheel - Air Leaks Wheels: All Technical Service Bulletins Aluminum Wheel - Air Leaks Article No. 89-17-3 WHEEL-ALUMINUM-LEAKS AIR FORD: 1986-90 CROWN VICTORIA, ESCORT 1986-88 EXP 1986-90 MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-90 FESTIVA 1989-90 PROBE LINCOLN-MERCURY: 1986-90 CONTINENTAL, COUGAR, GRAND MARQUIS 1986-87 LYNX 1986-90 MARK VII, SABLE, TOPAZ, TOWN CAR 1987-90 TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO This article is being republished in its entirety to expand the model year coverage to include 1987 through 1990 model year vehicles. ISSUE: Slow air leaks may occur in cast aluminum wheels because of porous wheel castings. ACTION: Use "HOT MELT" sealant (E7AZ-19554-A) and the following diagnostic/service procedure to eliminate the leaks. NOTE: THIS TSB MUST BE PERFORMED PRIOR TO REPLACING THE WHEEL FOR A LEAKING CONDITION. 1. Remove the tire and wheel assembly and inspect the wheel for structural damage. If none exists, go on to Step 2. If the wheel is damaged, replace it. 2. Check the complete wheel for possible air leaks. With the tire mounted on the wheel, locate the air leak using the water bath or equivalent method and mark the location. 3. Dismount the tire and on the tire side of the wheel prepare the surface for sealant. a. Thoroughly clean the leaking area with methylene chloride (e.g., choke cleaner E8AZ-19A501-AA) Or b. Use sandpaper of about 80 grit to thoroughly remove all contamination and score the wheel surface to improve adhesion of sealer. c. Prepare an adequate area around the leak to ensure covering the leak. d. Remove the valve stem if it is close to the repair area. 4. Use a clean rag to remove all cleaner or sanding dust. CAUTION: DO NOT USE AN OXYACETYLENE TORCH TO PERFORM STEP 5. Figure 1 5. Proceed to heat and seal the leaking area. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89173 > Aug > 89 > Aluminum Wheel - Air Leaks > Page 6506 a. Heat the prepared area of the wheel with an electric heat gun (Rotunda 107-00301 type) or propane torch (not oxyacetylene) until the melt stick (E7AZ-19554-A) flows. b. Apply the hot melt material over the prepared area using a liberal flow and a wiping action to assure coverage of the leaking area. NOTE: THE REPAIR IS MOST EFFECTIVE WHEN THE HEAT IS APPLIED TO THE BRAKE SIDE OF THE WHEEL AND THE SEALER IS MELTED BY THE HEAT IN THE METAL, SEE FIGURE 1. c. Apply only enough heat to melt the sealer and then remove the heat source. 6. Check for air leaks. a. After repairing the leak, allow the wheel to cool until it can be handled safely. b. Reassemble the tire and wheel. c. Inflate the tire to the recommended air pressure as indicated on the tire pressure decal. d. Check that the leak is repaired by using the procedure covered in Step 2. 7. After the repair is completed, balance and reinstall the wheel assembly on the vehicle. PART NUMBER PART NAME CLASS E8AZ-19A501-AA Choke Cleaner B E7AZ-19554-A Melt Stick Sealant BM OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-2-13, dated 1/28/87 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891703A Seal Aluminum Wheel - 0.8 Hr. ONE 891703B Seal Aluminum Wheel - 1.5 Hrs. TWO 891703C Seal Aluminum Wheel - 2.1 Hrs. THREE 891703D Seal Aluminum Wheel - 2.8 Hrs. FOUR DEALER CODING BASIC PART NO. CONDITION CODE 1007 48 OASIS CODES: 3300, 3500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 98-26-2 > Jan > 99 > Fuel - Volatility Related Driveability Concerns Fuel: All Technical Service Bulletins Fuel - Volatility Related Driveability Concerns Article No. 98-26-2 01/04/99 FUEL - INFORMATION ON GASOLINE - TIPS TO RESOLVE VOLATILITY RELATED DRIVEABILITY CONCERNS FORD: 1985-97 THUNDERBIRD 1986-99 MUSTANG, TAURUS 1987-99 ESCORT 1988-94 TEMPO 1989-97 PROBE 1990-99 CROWN VICTORIA 1992-93 FESTIVA 1995-99 CONTOUR LINCOLN-MERCURY: 1985-97 COUGAR 1986-92 MARK VII 1986-99 SABLE 1987-89 TRACER 1988-94 TOPAZ 1988-99 CONTINENTAL 1990-99 GRAND MARQUIS, TOWN CAR 1991-99 TRACER 1993-98 MARK VIII 1995-99 MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1986-97 AEROSTAR 1987-96 BRONCO 1989-97 F SUPER DUTY, F-350 1989-99 F-150, F-250 LD, RANGER 1991-99 EXPLORER 1992-99 ECONOLINE 1993-99 VILLAGER 1995-99 WINDSTAR 1997-99 EXPEDITION, MOUNTAINEER 1998-99 NAVIGATOR 1999 SUPER DUTY F SERIES MEDIUM/HEAVY TRUCK: 1990-97 F-700 This TSB article is being republished in its entirety to expand vehicle model coverage and revise the text. ISSUE Some vehicles using winter blend fuels may exhibit a stall on start up and a no restart, hard start condition or a no start condition in unseasonably hot weather (greater than 27°C/80°F). These concerns may be related to fuel volatility from winter blend fuels during winter-spring and autumn-winter transitions and may result in a fuel pump vapor lock condition. This condition may appear to be a fuel pump failure but may be caused by winter blend fuel. ACTION Refer to the following text for further information. NOTE FUEL TANK ADDITIVES WILL NOT RESOLVE THESE CONCERNS BECAUSE VAPOR FORMS FROM CAVITATION WITHIN THE FUEL PUMP. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 98-26-2 > Jan > 99 > Fuel - Volatility Related Driveability Concerns > Page 6512 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 96107 > May > 96 > Fuel - California Reformulated Gasoline Fuel: All Technical Service Bulletins Fuel - California Reformulated Gasoline Article No. 96-10-7 05/06/96 FUEL - CALIFORNIA REFORMULATED GASOLINE (CARFG) - SERVICE TIP FORD: 1983-86 LTD 1983-88 EXP 1983-96 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1985-94 TEMPO 1986-96 TAURUS 1989-96 PROBE 1995-96 CONTOUR LINCOLN-MERCURY: 1980-83 MARK VI 1983-88 LN7 1983-96 COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1985-94 TOPAZ 1986-96 SABLE 1991-96 TRACER 1993-96 CONTINENTAL, MARK VIII 1995-96 MYSTIQUE LIGHT TRUCK: 1983-96 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1984-90 BRONCO II 1986-96 AEROSTAR 1987-96 F SUPER DUTY 1991-96 EXPLORER 1993-96 VILLAGER 1995-96 WINDSTAR ISSUE: California introduced CaRFG around March 1, 1996 and statewide it must be available at all service stations by June 1, 1996 to help reduce emissions and improve gasoline quality. It will replace the traditional gasoline sold in Northern California and improve the reformulated gasoline that has been sold in Southern California since January 1995. California Air Resources Board (CARB) projects smog forming emissions from motor vehicles to be reduced by about 15 percent. ACTION: The following text is provided to give some answers to some commonly asked questions by our customers. POSITION Ford Motor Company recommends the use of CaRFG as a cost effective means of reducing emissions to provide cleaner air. We have participated in vehicle and laboratory testing of CaRFG to make sure it is acceptable for our customers' use. There are no unusual vehicle performance concerns expected based upon these studies. The use of CaRFG will not affect Ford's new vehicle and/or emissions warranty. WHAT DOES CaRFG CONSIST OF? CaRFG consists of the same basic components as other gasolines, but it reduces pollution because of its cleaner burning components. Features are: ^ reduced aromatic hydrocarbons to form less smog emissions ^ added oxygenates to reduce emissions ^ decreases the amount of fuel evaporating from the vehicle ^ lowered sulfur content to provide more efficient operation of the vehicle's catalytic converter Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 6517 ^ reduced benzene by about one-half IS CaRFG MORE HAZARDOUS THAN CONVENTIONAL GASOLINES? CaRFG is a hazardous substance like conventional gasoline. Precautions should continue to be taken to avoid exposure to vapors or liquid when it is pumped or handled. It should never be siphoned or swallowed. HOW WILL CaRFG AFFECT VEHICLE PERFORMANCE? Properly blended CaRFG should have no adverse effect on vehicle performance or the durability of engine and fuel system components. Its basic properties are not significantly different than other cleaner burning gasolines that have been used in the U.S. for several years. If the vehicle is a certified California calibration 1996 or later model year, it was designed to operate on CaRFG gasoline. The vehicle will operate satisfactorily on gasolines in the other 49 states, but emission control system performance may be affected. Using gasolines other than CaRFG have substantially increased emissions from motor vehicles. WILL THE USE OF CaRFG AFFECT CALIFORNIA VEHICLE WARRANTY? No. The coverage of Ford's new vehicle warranty is not affected. In fact, Ford Owner Guides have consistently approved the use of properly blended reformulated gasolines containing oxygenates. Further information about properly fueling your vehicle is included in the Owner Guide. WILL FUEL ECONOMY BE AFFECTED? A very small reduction in fuel economy of less than one-half mile per gallon is possible if the customer was using gasoline without oxygenates. This is attributed to the lower energy content of oxygenates which have been in all Southern California gasolines since January of 1995 and in some gasolines since the 1970's. Many factors affect fuel economy like driving habits, vehicle maintenance, weather conditions, etc. Fuel economy can vary by more than a mile per gallon from one fill-up to the next with the same gasolines. For further details see TSB Article 95-12-2 for customer expectations regarding fuel economy. ARE SPECIAL ADDITIVES NECESSARY FOR CaRFG? No. It is not necessary to add anything to the vehicle fuel tank after the gasoline is purchased from the service station. California regulations require deposit control additives in CaRFG to minimize port fuel injector and intake valve deposits. WILL OLDER VEHICLES OPERATE SATISFACTORILY WITH THE NEW CaRFG? Older vehicles are expected to operate satisfactorily on CaRFG because vehicles have been operating on gasolines similar to CaRFG for a number of years. However, considerable testing indicates that older, high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasolines. Owners of these older vehicles are encouraged to follow their vehicle manufacturer's recommendations regarding vehicle maintenance. WILL THE SMELL BE DIFFERENT THAN CONVENTIONAL GASOLINE? CaRFG is not expected to smell different than the gasoline most vehicles are currently using. If an unusual odor is noticed, it would probably be from oxygenates. Most service stations use vapor recovery systems to minimize the release of gasoline vapors while refueling. The use of CaRFG should result in little or no "rotten egg" smell from the exhaust because CaRFG has much lower sulfur than conventional gasoline. WAS CaRFG TESTED BEFORE INTRODUCTION? It was tested for over five million miles in more than 800 vehicles under the guidance of CARB including experts representing automobile manufacturers, gasoline suppliers, fleet operations and government. There was no increase in problems identified with the use of CaRFG. DOES CaRFG COST MORE? The price at the pump cannot be accurately predicted, although a modest increase is likely. The price of CaRFG is subject to the competitive forces in the marketplace. Many factors including production costs, supply and demand, weather, crude oil prices, and taxes affect gasoline prices. WHERE CAN I GET MORE INFORMATION ON CaRFG? Additional information within the state of California on CaRFG is available from the California Air Resources Board toll-free at 1-800-922-7349 (within California only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 6518 OTHER APPLICABLE ARTICLES: 95-12-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 623000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 91813 > Apr > 91 > Engine - Rough Idle/Hesitation/Backfire/Stalling Fuel: All Technical Service Bulletins Engine - Rough Idle/Hesitation/Backfire/Stalling Article No. 91-8-13 04/17/91 FUEL - USE OF UNLEADED GASOLINES - TIPS TO AVOID LEAN AIR - FUEL CONDITIONS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY, F47, F53 1991 EXPLORER ISSUE: Rough idle, hesitation, poor throttle response, induction backfire and stalls during cold start/warm up may be caused by the poor volatility of some high octane premium grade unleaded fuels (91 octane or higher (R+M)/2). When compared to regular grade unleaded fuel (87 octane (R+M)/2), high octane premium grade unleaded fuel may cause long crank time. ACTION: Use a regular grade unleaded fuel in all vehicles, except where a premium unleaded fuel is recommended in the Owner Guide. If lean air-fuel type symptoms are experienced, determine the grade and brand of fuel used and offer the following service tips. ^ Advise those using a higher octane grade fuel to switch to a regular grade unleaded fuel. For those using a regular grade fuel, advise them to try another brand. ^ Do not advise using a higher octane unleaded fuel than is recommended for that specific engine. Ford engines are designed to perform best using a high quality regular grade unleaded fuel. ^ Only advise using a higher octane unleaded fuel to avoid potentially damaging spark knock or ping, but do so only after mechanical fixes are ineffective. NOTE: ALL UNLEADED GASOLINES USED SHOULD CONTAIN DETERGENT ADDITIVES THAT ARE ADVERTISED AS HAVING "KEEP CLEAN" OR "CLEAN UP" PERFORMANCE FOR BOTH INTAKE VALVES AND FUEL INJECTORS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 98-26-2 > Jan > 99 > Fuel - Volatility Related Driveability Concerns > Page 6528 FILLING THE TANK TO FULL MAY BE EFFECTIVE. ADVISE CUSTOMER TO USE THE RECOMMENDED OCTANE GRADE PER OWNER MANUAL AND NOT A HIGHER GRADE. Explain to the customer that this concern may be due to a low tank level of winter blend fuel combined with unseasonably warm weather. Advise customer that filling the fuel tank to full may be effective in resolving this concern. Also, advise customer to use the recommended octane grade per their Owner Manual and not a higher grade. BACKGROUND Gasolines are seasonally adjusted, meaning they have higher volatility (vaporize easier) in the winter and lower volatility in the summer. Government mandates to improve air quality have resulted in significant changes to gasolines, such as the mandatory use of oxygenates (ethanol, methyl tertiary butyl ether (MTBE), and others) in the winter or the reduction of Reid Vapor Pressure (RVP) in the summer. The addition of oxygenates (especially ethanol) increases volatility while the reduction of RVP reduces volatility. Gasoline distribution practices often do not allow branded marketers to have much control over their gasoline's volatility other than RVP. Oxygenate (e.g., ethanol, MTBE) use is more dependent on local gasoline markets, rather than specific marketers practice. Therefore, it is difficult to recommend specific brands to avoid volatility related complaints. OTHER APPLICABLE ARTICLES: 91-8-13 SUPERSEDES: 96-5-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES:402000, 404000, 602300, 603300, 607000, 607400, 608000, 608400, 609000, 609400, 610000, 611000, 611500, 612000, 614000, 614500, 623000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 6533 ^ reduced benzene by about one-half IS CaRFG MORE HAZARDOUS THAN CONVENTIONAL GASOLINES? CaRFG is a hazardous substance like conventional gasoline. Precautions should continue to be taken to avoid exposure to vapors or liquid when it is pumped or handled. It should never be siphoned or swallowed. HOW WILL CaRFG AFFECT VEHICLE PERFORMANCE? Properly blended CaRFG should have no adverse effect on vehicle performance or the durability of engine and fuel system components. Its basic properties are not significantly different than other cleaner burning gasolines that have been used in the U.S. for several years. If the vehicle is a certified California calibration 1996 or later model year, it was designed to operate on CaRFG gasoline. The vehicle will operate satisfactorily on gasolines in the other 49 states, but emission control system performance may be affected. Using gasolines other than CaRFG have substantially increased emissions from motor vehicles. WILL THE USE OF CaRFG AFFECT CALIFORNIA VEHICLE WARRANTY? No. The coverage of Ford's new vehicle warranty is not affected. In fact, Ford Owner Guides have consistently approved the use of properly blended reformulated gasolines containing oxygenates. Further information about properly fueling your vehicle is included in the Owner Guide. WILL FUEL ECONOMY BE AFFECTED? A very small reduction in fuel economy of less than one-half mile per gallon is possible if the customer was using gasoline without oxygenates. This is attributed to the lower energy content of oxygenates which have been in all Southern California gasolines since January of 1995 and in some gasolines since the 1970's. Many factors affect fuel economy like driving habits, vehicle maintenance, weather conditions, etc. Fuel economy can vary by more than a mile per gallon from one fill-up to the next with the same gasolines. For further details see TSB Article 95-12-2 for customer expectations regarding fuel economy. ARE SPECIAL ADDITIVES NECESSARY FOR CaRFG? No. It is not necessary to add anything to the vehicle fuel tank after the gasoline is purchased from the service station. California regulations require deposit control additives in CaRFG to minimize port fuel injector and intake valve deposits. WILL OLDER VEHICLES OPERATE SATISFACTORILY WITH THE NEW CaRFG? Older vehicles are expected to operate satisfactorily on CaRFG because vehicles have been operating on gasolines similar to CaRFG for a number of years. However, considerable testing indicates that older, high mileage vehicles are more susceptible to fuel system problems due to age and normal wear and tear regardless of whether they are operated on conventional or CaRFG gasolines. Owners of these older vehicles are encouraged to follow their vehicle manufacturer's recommendations regarding vehicle maintenance. WILL THE SMELL BE DIFFERENT THAN CONVENTIONAL GASOLINE? CaRFG is not expected to smell different than the gasoline most vehicles are currently using. If an unusual odor is noticed, it would probably be from oxygenates. Most service stations use vapor recovery systems to minimize the release of gasoline vapors while refueling. The use of CaRFG should result in little or no "rotten egg" smell from the exhaust because CaRFG has much lower sulfur than conventional gasoline. WAS CaRFG TESTED BEFORE INTRODUCTION? It was tested for over five million miles in more than 800 vehicles under the guidance of CARB including experts representing automobile manufacturers, gasoline suppliers, fleet operations and government. There was no increase in problems identified with the use of CaRFG. DOES CaRFG COST MORE? The price at the pump cannot be accurately predicted, although a modest increase is likely. The price of CaRFG is subject to the competitive forces in the marketplace. Many factors including production costs, supply and demand, weather, crude oil prices, and taxes affect gasoline prices. WHERE CAN I GET MORE INFORMATION ON CaRFG? Additional information within the state of California on CaRFG is available from the California Air Resources Board toll-free at 1-800-922-7349 (within California only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheels: > 96107 > May > 96 > Fuel - California Reformulated Gasoline > Page 6534 OTHER APPLICABLE ARTICLES: 95-12-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 404000, 623000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications Wheel Bearing: Specifications Bearing Adjusting Nut 17-25 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Specifications > Page 6542 Wheel Bearing: Adjustments These models are equipped with sealed bearing units which do not require adjustment or maintenance. If bearing is found to be defective, then hub and bearing must be replaced as an assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front Wheel Bearing: Service and Repair Front Fig. 3 Hub & Wheel Bearing Assembly REPLACE 1. Raise and support front of vehicle, then remove wheel and tire assembly. 2. Remove grease cap from hub. 3. Remove disc brake caliper with brake hose attached. Suspend caliper from suspension with wire. Do not allow caliper to hang from brake hose. 4. Remove brake rotor. 5. Remove hub nut, then remove hub and bearing assembly, Fig. 3. If difficulty is encountered in hub removal, use hub removal tool No. T81P-1104-C or equivalent. 6. Reverse procedure to install. Use a new hub nut and tighten to specifications. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6545 Wheel Bearing: Service and Repair Rear NOTE: There are two approved methods for removing the hub from the bearing. Both methods are outlined. Removal 1. Remove knuckle and hub assembly from vehicle as outlined. 2. Place knuckle and hub assembly in a vise. NOTE: On drum brakes, remove shoe and linings, springs, and adjuster from backing plate. Remove four screws that retain the backing plate to the knuckle. Method One A. Position 3-Jaw Puller D88L-1 037-A and Step Plate D8OL-630-5 or equivalent, on the knuckle and press out the hub from the knuckle assembly. Method Two Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6546 A. Position Rear Hub Remover T89P-1 225-AH or equivalent between the knuckle and the backing plate. B. Assemble Hub Remover/Replacer T81 P-il 04-C and Step Plate D8OL-630-5 or equivalent. C. With forcing nut below the crossbar, hold forcing screw and turn forcing nut to remove hub. 3. Remove the backing plate. 4. Remove bearing retainer snap ring. 5. Place knuckle and bearing assembly on a press bed using Hub Support T89P-1 104-A and Bearing Remover T83P-1 1 04-AH2 or equivalent, and press bearing out of knuckle assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6547 Installation 1. Place knuckle assembly on press bed and position bearing in the bearing bore of the knuckle. 2. Using Bearing Installer T86P-1 1 04-A3 or equivalent, press the bearing into the knuckle. 3. Install bearing retainer snap ring. 4. Position the backing plate on the knuckle. Install four retaining bolts and tighten to 61-81 Nm (45-59 lb-ft). 5. Place knuckle assembly on the Hub Support T89P-1 104-A or equivalent and position on press bed plate Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6548 6. Position hub on bearing and using Hub Installer/Bearing Remover T83P-1 104-AH2 or equivalent, press hub into bearing. NOTE: If vehicle is equipped with drum brakes, install shoe linings, springs, and adjuster on backing plate 7. Prior to hub/bearing/knuckle installation replace bearing dust seal on the outboard CV joint with new seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information > Service and Repair > Front > Page 6549 Dust Seal Installation 8. Install new dust seal, ensuring seal flange faces outboard toward bearing. Use Drive Tube T83T-31 32-Al and Bearing Dust Seal Installer T89P-l 249-A or equivalent. 9. Install hub and knuckle assembly. See: Suspension/Rear Knuckle/Service and Repair Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Wheel Hub: Customer Interest Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 6558 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Customer Interest: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 6559 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake Wheel Hub: All Technical Service Bulletins Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake > Page 6565 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 9243 > Feb > 92 > Brakes Roughness/Pulsation/Steering Wheel Shake > Page 6566 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Hub: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Hub: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 6576 Wheel Hub: Specifications Rear Axle Hub Nut 250 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 6577 Wheel Hub: Service and Repair NOTE: There are two approved methods for removing the hub from the bearing. Both methods are outlined. Removal 1. Remove knuckle and hub assembly from vehicle as outlined. 2. Place knuckle and hub assembly in a vise. NOTE: On drum brakes, remove shoe and linings, springs, and adjuster from backing plate. Remove four screws that retain the backing plate to the knuckle. Method One A. Position 3-Jaw Puller D88L-1 037-A and Step Plate D8OL-630-5 or equivalent, on the knuckle and press out the hub from the knuckle assembly. Method Two Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 6578 A. Position Rear Hub Remover T89P-1 225-AH or equivalent between the knuckle and the backing plate. B. Assemble Hub Remover/Replacer T81 P-il 04-C and Step Plate D8OL-630-5 or equivalent. C. With forcing nut below the crossbar, hold forcing screw and turn forcing nut to remove hub. 3. Remove the backing plate. 4. Remove bearing retainer snap ring. 5. Place knuckle and bearing assembly on a press bed using Hub Support T89P-1 104-A and Bearing Remover T83P-1 1 04-AH2 or equivalent, and press bearing out of knuckle assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 6579 Installation 1. Place knuckle assembly on press bed and position bearing in the bearing bore of the knuckle. 2. Using Bearing Installer T86P-1 1 04-A3 or equivalent, press the bearing into the knuckle. 3. Install bearing retainer snap ring. 4. Position the backing plate on the knuckle. Install four retaining bolts and tighten to 61-81 Nm (45-59 lb-ft). 5. Place knuckle assembly on the Hub Support T89P-1 104-A or equivalent and position on press bed plate Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 6580 6. Position hub on bearing and using Hub Installer/Bearing Remover T83P-1 104-AH2 or equivalent, press hub into bearing. NOTE: If vehicle is equipped with drum brakes, install shoe linings, springs, and adjuster on backing plate 7. Prior to hub/bearing/knuckle installation replace bearing dust seal on the outboard CV joint with new seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Component Information > Technical Service Bulletins > Page 6581 Dust Seal Installation 8. Install new dust seal, ensuring seal flange faces outboard toward bearing. Use Drive Tube T83T-31 32-Al and Bearing Dust Seal Installer T89P-l 249-A or equivalent. 9. Install hub and knuckle assembly. See: Suspension/Rear Knuckle/Service and Repair Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application Wheel Fastener: Customer Interest Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > Customer Interest: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 6590 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 6596 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 6597 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 9562 > Mar > 95 > Brakes - Roughness During Application Wheel Fastener: All Technical Service Bulletins Brakes - Roughness During Application Article No. 95-6-2 03/27/95 BRAKES - ROUGHNESS CONCERN DURING BRAKE APPLICATION FORD: 1982-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1982-86 CAPRI 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE MERKUR: 1985-88 XR4TI 1988-89 SCORPIO ISSUE: Early replacement of the brake components, rotors and pads due to brake roughness concern, is lowering customer's view of quality. The cause of brake roughness is due to small changes in braking torque when the brake is applied. The following are the major reasons for the brake torque variation: ^ Runout of disc rotor ^ Rusted rotor surface ^ Warped rotor due to improper wheel lug nut tightening (torque too high or uneven) ^ Varied rotor thickness around the disk ^ Transferred patches of lining material on the rotor surface ^ Uneven tire wear and balance ACTION: Diagnose brake roughness by referring to the following procedure for service details. SERVICE PROCEDURE/DIAGNOSIS STEPS NOTE: BEGIN WITH STEP 1 AND FINISH WITH STEP 6. 1. Check the Condition of Tires and Their Balance Sometimes the brake roughness concern is not brake roughness at all. In fact, some complaints are due to the out-of-round and out-of-balance tires or broken steel cord (for steel belted radial tires) in the tires. The effects of these problems show up at all conditions of driving, but may seem worse when Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 9562 > Mar > 95 > Brakes - Roughness During Application > Page 6602 braking. That fact can be used to correctly determine that the customer is not experiencing brake-caused roughness. If however, there is brake roughness in addition to tire problems, then both problems must be repaired. If the inspection shows that tires are contributing to roughness (vibration or roughness present in all driving conditions, not just braking) they should first be balanced and rotated using normal maintenance procedures then follow the steps below to correct the brake roughness. 2. Check the Wheel Lug Nut Tightening Torque Uneven and/or out of specification torque on the wheel lug nuts will cause the brake rotors to warp. Up to 0.005 inch rotor runout can occur due to improper lug nut tightening. The first thing to check for is the consistency of torque of the lug nuts on each wheel. If the torque readings are not within 20% of each other, that gives an indication of a cause of the concern of brake roughness. Improper lug nut tightening can have the following order of effects: 1. Rotor runout 2. Rotor thickness variation 3. Brake torque variation 4. Brake roughness Ultimately, the rotor may be damaged and must be resurfaced. Follow the procedure in the Service Manual for resurfacing the rotors. Proper torque must be used when a resurfaced or new rotor is installed. Use of a torque wrench is again stressed, or as an alternative, the Rotunda "ACCUTORQ" 164-R0314 or equivalent must be used. When installing a new rotor, do not machine the rotor on a bench lathe. Any surface contamination can be removed with grease solvents or with very light hand sanding. Refer to # 3, CHECK FOR RUST/CONTAMINATION... 3. Check for Rust/Contamination on Mounting Surfaces Surface rust or contaminations on the wheel-to-rotor and rotor-to-hub flange surfaces should be cleaned with very light hand sanding. Use garnet paper 100A or aluminum oxide 150J grit. DO NOT USE HARSH, ABRASIVE TOOLS. If the cleaning is not done, it will contribute to the runout of the rotor when assembled, which will cause brake roughness later on. Any removal of rust on the rotor braking surfaces using harsh abrasive tools is not approved by Ford. The on-car turning procedure is the only sanctioned method at this time to deal with repairing rusty rotors. Since the thickness of the rotors are manufactured to less than 0.0004 inch tolerance, using hand held tools on the rotor surfaces can not guarantee maintaining the tolerance. Concerns will occur of brake roughness with rotor thickness variation of 0.0008 inch or less on certain very sensitive vehicles. 4. Check for Runout of the Front Rotor on the Car and Front Hub Mount Runout of the rotor mounted on car should not exceed 0.003 inch. With the wheel off, fasten the lug nuts back on to hold the rotor onto the hub. The fastening torque should not exceed 81 N.m (60 lb-ft) and should be even. With the dial indicator attached to the spindle, slowly rotate the rotor to get the total indicated runout. This value should not exceed the Total Indicated Runout (TIR) as specified in the appropriate Service Manual. If it exceeds specification, first index the rotor one (1) wheel stud at a time. If the readings still exceed 0.003 inch, then the hub face runout should be checked. Repeat the runout check procedure on the hub face. If the runout exceeds 0.002 inch, the hub must be replaced, otherwise the rotor must be resurfaced on the vehicle or replaced. 5. Check for Rear Brake Roughness Except for the vehicles with separate drum in disc parking brake (e.g., Crown Victoria, Grand Marquis and Town Car) the rear brake can be actuated by actuating the parking brake. Attempt to slow down the vehicle from 48 km/h (30 mph) with the transmission in neutral using the parking brake. If roughness is present, then the rear brakes need to be serviced. If roughness is not present, then front brakes need servicing. To service the rear brakes follow the procedure above for servicing the front brakes. 6. Check for Proper Caliper Operation Inspect the calipers for leaks and brake fluid contamination. Any leaks from the wheel cylinders and seals must be repaired per the Service Manual. Also, inspect for glazing of the brake pads which may indicate a seized caliper piston, frequent severe or unintentional brake dragging by the customer. Repair as specified in the Service Manual. OTHER APPLICABLE ARTICLES: 92-12-4, 92-19-2, 92-4-3, 93-16-2, 93-26-2, 93-6-3, 94-25-1, 94-25-2, 95-6-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 92124 > Jun > 92 > Brakes Roughness/Runout Check Wheel Fastener: All Technical Service Bulletins Brakes - Roughness/Runout Check Article No. 92-12-4 DATE: 06-03-92 ^ BRAKES-ROTOR-REPLACEMENT SERVICE TIPS ^ BRAKES-ROUGHNESS DEVELOPED FROM INCREASE IN ROTOR RUNOUT ^ WHEELS-LUG NUT TIGHTENING PROCEDURE FORD: 1986-92 TAURUS 1989-92 THUNDERBIRD 1992 CROWN VICTORIA LINCOLN-MERCURY: 1986-92 SABLE 1988-92 CONTINENTAL 1989-92 COUGAR 1991-92 TOWN CAR 1992 GRAND MARQUIS ISSUE: Brake roughness may occur after the lug nuts are installed and tightened with an impact wrench. The resulting torque difference from stud to stud can be as high as 60 lb.ft (81 N-m). This torque difference stud to stud may cause an increase in rotor runout by as much as .003"-.005"(.076mm-.127mm). The increase in rotor runout may speed up the development of brake roughness. ACTION: Tighten the wheel lug nuts in the "final' torque in the sequence described in the Service Manual. Use a torque wrench set to 95 +/- 10 lb.ft (129 +/- l4N-m). When performing brake service work that involves replacing or removing the rotor, refer to the following service procedure which minimizes hub/rotor "stacked" runout, a cause of brake roughness and uneven rotor wear. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new/turned rotor installed on the hub) indicates more then .002" (.05mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. HIGH SYSTEM RUNOUT High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT SERVICE TIPS 1. Completely clean the hub area that will contact the new/turned rotor. Remove rust build up. 2. Install the new/turned rotor on the hub and secure it with at least three (3) lug nuts. Tighten the lug nuts to 20 lb.ft (27 N-m) for testing. 3. Using a dial indicator 4201-C or equivalent, determine the total runout of the system. The total system (rotor and hub) runout must not exceed .002" (.05mm). 4. If the runout exceeds .002" (.05mm), proceed as follows: a. Remove the rotor and rotate it clockwise until the next hole lines up with a stud. b. Secure the rotor in the new position, reindexed as described in Step 2. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.05mm) or less total runout. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Wheel Fastener: > 92124 > Jun > 92 > Brakes Roughness/Runout Check > Page 6607 5. If .002" (.05mm) or less runout cannot be reached, the hub should be replaced and Steps 2 through 4 repeated when the new hub/rotor is installed. NOTE: IT IS RECOMMENDED THAT NEW BRAKE ROTORS NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUNOUT AND THICKNESS VARIATION SPECIFICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure Wheel Fastener: All Technical Service Bulletins Lug Nuts - Proper Installation/Torqueing Procedure Article No. 98-5A-4 ^ BRAKES - PREVENTING BRAKE VIBRATION - SERVICE TIP ^ WHEELS - PROPER LUG TORQUE PROCEDURES - SERVICE TIP FORD: 1972-97 THUNDERBIRD 1976-86 LTD 1976-97 MUSTANG 1981-97 CROWN VICTORIA 1982-88 EXP 1982-98 ESCORT 1984-94 TEMPO 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1979-83 MONARCH, ZEPHYR 1979-97 COUGAR 1980-83 MARK VI 1980-98 CONTINENTAL, TOWN CAR 1981-86 LYNX 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-97 SABLE 1987-89 TRACER 1987-97 GRAND MARQUIS 1991-94 CAPRI 1991-97 TRACER 1993-98 MARK VIII 1995-98 MYSTIQUE LIGHT TRUCK: 1979-96 BRONCO 1979-97 ECONOLINE, F-150-350 SERIES 1984-90 BRONCO II 1984-97 RANGER 1986-97 AEROSTAR 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-98 WINDSTAR 1997 EXPEDITION 1998 NAVIGATOR ISSUE: The use of air impact tools to tighten wheel lug nuts can lead to overtightened and/or unevenly tightened wheel lug nuts. Air impact tools typically used for wheel lug nut removal and installation can generate up to 475 N.m (350 lb-ft) of torque. Overtightened and/or unevenly torqued wheel lug nuts may cause: ^ Brake vibration ^ Distortion of the wheel hub ^ Distortion of the brake rotor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 6613 ^ Brake rotor runout ^ Damage to the wheel ^ Damage to the wheel nuts and studs ACTION: All wheel lug nuts should only be tightened to specification using a torque wrench or by using the Rotunda ACCUTORO 164-R0314 or equivalent on a 1/2" drive air impact tool. The "ACCUTORO" lug nut sockets limit the torque of the air impact tool, preventing overtightening or uneven tightening of the wheel lug nuts. The torque limiting devices (regulators) on air impact tools will not reduce the output torque enough to prevent overtightening of the wheel lug nuts. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 98-5A-4 > Mar > 98 > Lug Nuts - Proper Installation/Torqueing Procedure > Page 6614 NOTE: REFER TO THE APPROPRIATE SERVICE MANUAL OR THE CHART IN FIGURE 1 FOR THE CORRECT WHEEL LUG NUT TORQUE SPECIFICATION. THE CHART IN FIGURE 1 ALSO PROVIDES THE CORRECT "ACCUTORO" LUG NUT SOCKET TO USE. The "ACCUTORO" socket is intended for lug nut installation, not removal. When using the "ACCUTORO" socket, the output torque of the air impact tool must be set to 217-339 N.m (160-250 lb-ft), usually this will be the lowest setting on the air impact tool. The "ACCUTORO" lug nut sockets are available through Rotunda Equipment. The four-piece set (164-R0314) fits most Ford Motor Company cars and light trucks. The tool set consists of four (4) lug nut sockets and a storage case. The set can be ordered by calling Rotunda Equipment at 1-800-ROT-UNDA (768-8632). CAUTION: AIR IMPACT TOOLS SHOULD NOT BE USED TO TIGHTEN WHEEL LUG NUTS UNLESS THE "ACCUTORO" LUG NUT SOCKET OF THE CORRECT SPECIFICATION IS USED. NOTE: DO NOT USE AIR IMPACT TOOLS ON LOCKING WHEEL LUG NUTS. THEY ARE TO BE HAND-TORQUED ONLY. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-17-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 303000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 92124 > Jun > 92 > Brakes Roughness/Runout Check Wheel Fastener: All Technical Service Bulletins Brakes - Roughness/Runout Check Article No. 92-12-4 DATE: 06-03-92 ^ BRAKES-ROTOR-REPLACEMENT SERVICE TIPS ^ BRAKES-ROUGHNESS DEVELOPED FROM INCREASE IN ROTOR RUNOUT ^ WHEELS-LUG NUT TIGHTENING PROCEDURE FORD: 1986-92 TAURUS 1989-92 THUNDERBIRD 1992 CROWN VICTORIA LINCOLN-MERCURY: 1986-92 SABLE 1988-92 CONTINENTAL 1989-92 COUGAR 1991-92 TOWN CAR 1992 GRAND MARQUIS ISSUE: Brake roughness may occur after the lug nuts are installed and tightened with an impact wrench. The resulting torque difference from stud to stud can be as high as 60 lb.ft (81 N-m). This torque difference stud to stud may cause an increase in rotor runout by as much as .003"-.005"(.076mm-.127mm). The increase in rotor runout may speed up the development of brake roughness. ACTION: Tighten the wheel lug nuts in the "final' torque in the sequence described in the Service Manual. Use a torque wrench set to 95 +/- 10 lb.ft (129 +/- l4N-m). When performing brake service work that involves replacing or removing the rotor, refer to the following service procedure which minimizes hub/rotor "stacked" runout, a cause of brake roughness and uneven rotor wear. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new/turned rotor installed on the hub) indicates more then .002" (.05mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. HIGH SYSTEM RUNOUT High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not properly positioned during assembly. ROTOR REPLACEMENT SERVICE TIPS 1. Completely clean the hub area that will contact the new/turned rotor. Remove rust build up. 2. Install the new/turned rotor on the hub and secure it with at least three (3) lug nuts. Tighten the lug nuts to 20 lb.ft (27 N-m) for testing. 3. Using a dial indicator 4201-C or equivalent, determine the total runout of the system. The total system (rotor and hub) runout must not exceed .002" (.05mm). 4. If the runout exceeds .002" (.05mm), proceed as follows: a. Remove the rotor and rotate it clockwise until the next hole lines up with a stud. b. Secure the rotor in the new position, reindexed as described in Step 2. c. Repeat the checking and rotation (reindexing process) until the system measures .002" (.05mm) or less total runout. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Technical Service Bulletins > All Other Service Bulletins for Wheel Fastener: > 92124 > Jun > 92 > Brakes Roughness/Runout Check > Page 6619 5. If .002" (.05mm) or less runout cannot be reached, the hub should be replaced and Steps 2 through 4 repeated when the new hub/rotor is installed. NOTE: IT IS RECOMMENDED THAT NEW BRAKE ROTORS NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUNOUT AND THICKNESS VARIATION SPECIFICATIONS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 301000, 306000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence Wheel Fastener: Specifications Wheel Tightening Sequence Lug Nut Torque Patterns IMPORTANT Check all parts, including rims, lug studs, lug nuts, and mating surfaces of hubs and tire rims for rust, damage, or dirt. Clean mating surfaces with a wire brush to remove any foreign material. Replace any damaged parts as needed. Careless installation of tire/rim assemblies in a vehicle is a major cause of tire installation problems. Proper installation, including fastener torque, is essential to economical, safe and trouble free service. Use only the proper sizes and types of fasteners for safe and proper service. Tighten the fasteners a quarter turn at a time using the tightening sequence diagram as a guide. This is very important to prevent misalignment of the wheel. Continue tightening the fasteners in sequence until the fasteners are tightened to the proper torque (See WHEEL FASTENER TORQUE). CAUTION: Improper torque or tightening sequence can cause distortion, fatigue cracks, or alignment problems. After driving the vehicle for a short distance, recheck the wheel fastener torque. Parts will usually seat naturally, reducing the torque on the fasteners. Retorque all fasteners to the proper torque. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information > Specifications > Wheel Tightening Sequence > Page 6622 Wheel Fastener: Specifications Wheel Lug Nuts 85-105 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Accumulator HVAC > Component Information > Service and Repair Accumulator HVAC: Service and Repair The suction accumulator/drier should be replaced when: 1. Unit is restricted, plugged or perforated. 2. System has been left open for 1-2 months. 3. There is evidence of moisture in system such as internal corrosion of metal lines or dark, thick refrigerant oil. 4. There are more than 5 ounces of refrigerant oil in suction accumulator/drier indicating bleed hole is clogged. Do not replace suction accumulator/drier each time the following condition exists: 1. There is a loss of refrigerant charge. 2. A component such as a condenser, evaporator or compressor is replaced. 3. A dent is found in outer shell of suction accumulator/drier. Fig. 6 Accumulator/dryer 1. Discharge refrigerant from system. 2. On vehicles equipped with 4-140 engine, remove speed control servo, if equipped. 3. On all vehicles, disconnect suction hose at compressor and cap both hose and compressor. 4. Disconnect accumulator inlet tube from evaporator core outlet, Fig. 6. 5. Disconnect wire harness connector from pressure switch on top of accumulator. 6. Remove accumulator to accumulator bracket attaching screw and remove accumulator. 7. Reverse procedure to install. Use new O-ring lubricated with refrigerant oil. 8. Leak test, evacuate and charge system. Check system for proper operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Locations Air Door Actuator / Motor: Locations Behind RH Side Of I/P, On Heater Plenum Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Servo Motor Replace Air Door Actuator / Motor: Service and Repair Servo Motor Replace Fig. 16 Servo motor assembly removal 1. Disconnect battery ground cable. 2. Disconnect glove compartment door stop and let door hang by hinges. 3. Remove vacuum hose from servo motor, Fig. 16. 4. Remove two screws from servo motor assembly mounting bracket and position servo for access to vacuum diverter valve. 5. Remove retaining push nut and unplug multiple vacuum connector from vacuum diverter valve. 6. Remove servo motor protective arm cover. 7. Remove push nut retaining servo motor overtravel spring and link to blend door crank arm, and remove servo assembly from vehicle. 8. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC > Component Information > Service and Repair > Servo Motor Replace > Page 6633 Air Door Actuator / Motor: Service and Repair Vacuum Control Motors FLOOR DEFROST DOOR 1. Remove instrument panel as described under, ``Evaporator Case, Replace.'' 2. Remove two vacuum motor-to-mounting bracket retaining nuts. 3. Disconnect vacuum motor vacuum hoses, then disengage motor arm from the floor defrost door crank arm and remove motor. 4. Reverse procedure to install. PANEL DEFROST DOOR 1. Disconnect battery ground cable. 2. Remove instrument panel. 3. Remove spring nut retaining panel defrost door vacuum motor arm to the door shaft. 4. Remove two nuts retaining vacuum motor to mounting bracket. 5. Remove the vacuum motor from mounting bracket, then disconnect vacuum hose. 6. Reverse procedure to install. 1. Working between dash panel and outside-recirculate air inlet duct, remove two vacuum motor-to-mounting bracket retaining screws. 2. Disconnect the vacuum motor, vacuum hose. 3. Disengage vacuum motor from door link, then remove vacuum motor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Cable: > 89155 > Jul > 89 > Heater System Slow Warm Up/Insufficient Heat Air Door Cable: Customer Interest Heater System - Slow Warm Up/Insufficient Heat A/C-HEATER SYSTEM-SLOW WARM-UP OR INSUFFICIENT HEAT Article No. 89-15-5 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The A/C-Heater system may be slow to warm up after the vehicle is started or it won't provide enough heat after the car has been running for a reasonable length of time. This condition is usually caused by the temperature control cable being out of adjustment. ACTION: If service is required, check the A/C-Heater system and adjust the temperature control cable by using the following service procedure. 1. Check the radiator coolant level. Add coolant (50% anti-freeze, 50% water) if required. Figure 1 2. Check and adjust the temperature control cable as follows: a. Check for any interference that may prevent the control cable and self-adjusting clip from moving through its complete range of travel. b. Move the temperature control lever to the "Full Cool" setting. c. Hold the temperature blend door crank arm firmly in position. d. Grasp the cable end and self-adjusting clip with pliers, as shown in Figure 1. e. Pull the cable wire through the clip until there is a space of approximately 3/4 inch (18 mm) between the clip and the cable end. f. Move the temperature control lever to the "Full Warm" setting to position the self-adjusting clip. g. Move the temperature control lever from the "Full Cool" to the "Full Warm" setting to be sure that the temperature blend door is firmly seating at both ends of its travel range. h. Make any necessary final adjustments. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Customer Interest for Air Door Cable: > 89155 > Jul > 89 > Heater System Slow Warm Up/Insufficient Heat > Page 6642 Figure 2 3. Check for gaps in the evaporator case seam when adjusting the temperature control cable. a. Examine the area directly under the temperature blend door crank arm as shown in Figure 2. b. Seal any gaps as necessary with caulking cord rope sealer (D6AZ-19560-A), or equivalent. 4. Check to see that the heater core cover is properly positioned over the two locating pins on the evaporator case. If it is not, perform the following steps. a. Loosen the four heater core cover screws. b. Position the cover as it should be placed. c. Retighten the screws. PART NUMBER PART NAME CLASS D6AZ-19560-A Caulking Cord Rope Sealer AG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891505A Adjust Control Cable 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 19988 07 OASIS CODES: 2600, 2620 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Cable: > 89155 > Jul > 89 > Heater System - Slow Warm Up/Insufficient Heat Air Door Cable: All Technical Service Bulletins Heater System - Slow Warm Up/Insufficient Heat A/C-HEATER SYSTEM-SLOW WARM-UP OR INSUFFICIENT HEAT Article No. 89-15-5 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The A/C-Heater system may be slow to warm up after the vehicle is started or it won't provide enough heat after the car has been running for a reasonable length of time. This condition is usually caused by the temperature control cable being out of adjustment. ACTION: If service is required, check the A/C-Heater system and adjust the temperature control cable by using the following service procedure. 1. Check the radiator coolant level. Add coolant (50% anti-freeze, 50% water) if required. Figure 1 2. Check and adjust the temperature control cable as follows: a. Check for any interference that may prevent the control cable and self-adjusting clip from moving through its complete range of travel. b. Move the temperature control lever to the "Full Cool" setting. c. Hold the temperature blend door crank arm firmly in position. d. Grasp the cable end and self-adjusting clip with pliers, as shown in Figure 1. e. Pull the cable wire through the clip until there is a space of approximately 3/4 inch (18 mm) between the clip and the cable end. f. Move the temperature control lever to the "Full Warm" setting to position the self-adjusting clip. g. Move the temperature control lever from the "Full Cool" to the "Full Warm" setting to be sure that the temperature blend door is firmly seating at both ends of its travel range. h. Make any necessary final adjustments. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Air Door Cable: > 89155 > Jul > 89 > Heater System - Slow Warm Up/Insufficient Heat > Page 6648 Figure 2 3. Check for gaps in the evaporator case seam when adjusting the temperature control cable. a. Examine the area directly under the temperature blend door crank arm as shown in Figure 2. b. Seal any gaps as necessary with caulking cord rope sealer (D6AZ-19560-A), or equivalent. 4. Check to see that the heater core cover is properly positioned over the two locating pins on the evaporator case. If it is not, perform the following steps. a. Loosen the four heater core cover screws. b. Position the cover as it should be placed. c. Retighten the screws. PART NUMBER PART NAME CLASS D6AZ-19560-A Caulking Cord Rope Sealer AG OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891505A Adjust Control Cable 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 19988 07 OASIS CODES: 2600, 2620 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Cable, HVAC > Component Information > Technical Service Bulletins > Page 6649 Air Door Cable: Adjustments Function and/or temperature control cables self-adjust when levers are moved to extreme right of WARM and/or DEFROST slot in face of control assembly. On models equipped with a control knob, the cables self-adjust when the knob is rapidly rotated clockwise toward the WARM position. Some function and temperature control levers move from top to bottom. The control cable wire should be pre-set to prevent kinking before attempting self-adjusting procedure. Cable pre-set may be performed in vehicle or before installing a replacement cable assembly. Proceed as follows to pre-set cable before installing assembly: Fig. 35 Control cable adjust 1. On control cables with wire loop end, insert a small screwdriver into crank arm end of the control wire loop, Fig. 40. 2. On control cables with solid end, grasp adjusting clip and control cable with pliers. 3. For either type cable, slide self-adjusting clip one inch away from control wire loop, then install cable assembly. 4. Position self-adjusting clip by moving control lever to extreme right of WARM and/or DEFROST slot, or rapidly rotating control knob to WARM position. 5. Ensure proper control operation. To pre-set cable after installation, move control lever to COOL and/or OFF position, or rotate control knob to COOL position and proceed as follows: 1. Firmly secure crank arm. 2. On control cables with wire loop end, proceed as follows: a. Insert a small screwdriver into crank arm end of the control wire loop. b. Pull control wire through self-adjusting clip until there is a one inch gap between loop and clip. 3. On control cables with solid end, proceed as follows: a. Grasp control cable with pliers. b. Pull control wire through self-adjusting clip until there is a one and one half inch gap between loop and clip. 4. For either type cable, position control lever to extreme right of WARM and/or DEFROST slot, or rapidly rotating control knob to WARM position. 5. Ensure proper control operation and full door travel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 97-25-5 > Dec > 97 > Blower Motor - Chirping/Squeaking Blower Motor: Customer Interest Blower Motor - Chirping/Squeaking Article No. 97-25-5 12/08/97 ^ BLOWER MOTOR - "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS ^ NOISE - "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS FORD: 1984-94 TEMPO 1986-97 TAURUS 1989-97 THUNDERBIRD 1991-97 ESCORT 1994-97 MUSTANG 1995-97 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1986-97 CONTINENTAL, SABLE 1989-97 COUGAR 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, F-150, F-250 LD This TSB article is being republished in its entirety to correct the supersede article reference. ISSUE: Some vehicles may exhibit a "squeaking" or "chirping" from the blower motor at low blower motor speeds. This may be caused by uneven brush friction on the commutator surface of the motor. ACTION: Replace the blower motor with a revised blower motor which has improved brush-to-commutator friction. Refer to the appropriate model/year Service Manual for removal and installation procedures. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Customer Interest for Blower Motor: > 97-25-5 > Dec > 97 > Blower Motor - Chirping/Squeaking > Page 6658 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-23-4, 97-6-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-97 Model Year Vehicles And 1991 Continental, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 972505A Replace Blower Motor - All Refer to Vehicles SLTS Manual DEALER CODING CONDITION BASIC PART NO. CODE 19805 14 OASIS CODES: 208000, 208300, 208999, 702000, 702300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 97-25-5 > Dec > 97 > Blower Motor - Chirping/Squeaking Blower Motor: All Technical Service Bulletins Blower Motor - Chirping/Squeaking Article No. 97-25-5 12/08/97 ^ BLOWER MOTOR - "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS ^ NOISE - "CHIRPING" OR "SQUEAKING" FROM BLOWER MOTOR AT LOW SPEEDS FORD: 1984-94 TEMPO 1986-97 TAURUS 1989-97 THUNDERBIRD 1991-97 ESCORT 1994-97 MUSTANG 1995-97 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1986-97 CONTINENTAL, SABLE 1989-97 COUGAR 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE LIGHT TRUCK: 1992-97 AEROSTAR 1993-97 VILLAGER 1995-97 WINDSTAR 1997 EXPEDITION, F-150, F-250 LD This TSB article is being republished in its entirety to correct the supersede article reference. ISSUE: Some vehicles may exhibit a "squeaking" or "chirping" from the blower motor at low blower motor speeds. This may be caused by uneven brush friction on the commutator surface of the motor. ACTION: Replace the blower motor with a revised blower motor which has improved brush-to-commutator friction. Refer to the appropriate model/year Service Manual for removal and installation procedures. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Blower Motor: > 97-25-5 > Dec > 97 > Blower Motor - Chirping/Squeaking > Page 6664 Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-23-4, 97-6-10 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-97 Model Year Vehicles And 1991 Continental, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 972505A Replace Blower Motor - All Refer to Vehicles SLTS Manual DEALER CODING CONDITION BASIC PART NO. CODE 19805 14 OASIS CODES: 208000, 208300, 208999, 702000, 702300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 6665 Blower Motor: Locations Behind RH Side Of I/P, In Heater Plenum Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Technical Service Bulletins > Page 6666 Blower Motor: Service and Repair Fig. 36 Blower motor & wheel assembly removal 1. Remove glove compartment liner. 2. Remove four blower motor mounting plate screws. 3. Remove blower motor and wheel assembly from blower housing, Fig. 36. 4. Remove blower wheel from motor shaft. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Locations Blower Motor Resistor: Locations I/P Components Behind RH Side Of I/P, In Heater Plenum Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Locations Blower Motor Switch: Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Technical Service Bulletins > A/C Clutch - Slips At High Ambient Temperature Compressor Clutch: Technical Service Bulletins A/C Clutch - Slips At High Ambient Temperature Article No. 92-20-5 09/23/92 AIR CONDITIONING - FX-15 - COMPRESSOR AIR GAP SPECIFICATION - REVISION FORD: 1988-93 TAURUS 1989-93 THUNDERBIRD 1991-93 CROWN VICTORIA 1992-93 ESCORT, TEMPO LINCOLN-MERCURY: 1988-93 SABLE 1989-93 COUGAR 1991-93 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1992-93 TOPAZ, TRACER LIGHT TRUCK: 1989 ECONOLINE 1989-90 BRONCO II 1989-93 BRONCO, F-150-350 SERIES, F-47, RANGER 1990-93 AEROSTAR, EXPLORER ISSUE: The air conditioner clutch may "slip" during high ambient temperature conditions. This is normally caused by improper air gap adjustment between the clutch plate and hub assembly. ACTION: The air gap specifications between the clutch plate, hub assembly and the clutch pulley has been revised. When service is required the air gap must be set between 0.35 and 0.85 mm instead of the current Service Manual specification of 0.45 and 0.85 mm. NOTE: WHEN ADJUSTMENT IS REQUIRED, USE THE SPACERS INCLUDED IN THE SPACER KIT LISTED IN THE PARTS BLOCK. OPTIMUM ADJUSTMENT IS TOWARD THE LOWER LIMIT OF THE SPECIFICATION RANGE IN THE INTEREST OF DURABILITY. Part Number/Name Chart OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Clutch Air Gap A/C Data Table Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component Information > Specifications > Clutch Air Gap > Page 6680 Air Conditioning Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > FS-6, Nippon 6P148, 6E171, 10P15, FX-15 Compressor Clutch Coil: Service and Repair FS-6, Nippon 6P148, 6E171, 10P15, FX-15 CLUTCH FIELD COIL REMOVAL 1. Remove clutch hub and pulley. 2. Remove snap ring retaining clutch field coil on front of compressor. 3. Remove field coil. INSTALLATION 1. Position clutch field coil to compressor, engaging locator pin on compressor head with hole in clutch field coil. 2. Install snap ring to retain clutch field coil on compressor with bevel side out. 3. Install pulley and hub on compressor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component Information > Service and Repair > FS-6, Nippon 6P148, 6E171, 10P15, FX-15 > Page 6685 Compressor Clutch Coil: Service and Repair HR-980 (Clutch Hub, Pulley & Field Coil Replace) Removal Fig. 1 Clutch assembly exploded view 1. Hold clutch hub with suitable spanner wrench and remove retaining nut, Fig. 1. 2. Remove clutch hub using tool No. T80L19703-B or equivalent, then withdraw shims, noting thickness for assembly. 3. Remove clutch pulley retaining nut using spanner wrench T83P-19623-A or equivalent. 4. Remove pulley and bearing assembly and field coil from compressor, using suitable puller if necessary. 5. If pulley bearing is to be replaced, proceed as follows: a. Support pulley with large opening of tool No. T80L-19703-E or equivalent, then drive bearing from pulley using suitable spacer. b. Place pulley friction face over small opening in support tool. c. Position new bearing in bore and seat bearing using suitable driver. d. Stake bearing to pulley in three equally spaced positions, taking care not to damage bearing. Do not stake bearing in locations used to stake the removed bearing. Installation 1. Thoroughly clean front of compressor. 2. Mount clutch field coil on compressor with electrical connector on top and slots in coil engaging housing lugs. 3. Align pulley bearing with boss on compressor head, then slide pulley and bearing assembly onto compressor. The bearing should be a slip fit on compressor head when properly aligned. However, if difficulty is encountered when installing bearing and pulley assembly, lightly tap assembly using driver T80L-19703-J or equivalent and a light hammer. 4. Apply suitable thread locking compound to threads of pulley retaining nut. Install nut and torque to 56-70 ft. lbs. using a suitable spanner wrench. 5. Mount clutch hub shims and clutch on compressor, ensuring drive key is properly aligned with keyway, then press hub into position using tool No. T80L-19703-F or equivalent. Do not attempt to drive clutch hub onto shaft, as compressor will be damaged. 6. Install hub retaining nut and torque to 10-14 ft. lbs. 7. Check air gap between hub and pulley mating surface at three equally spaced positions and record the readings. 8. Rotate pulley one-half turn and repeat step 7. 9. If smallest measured air gap is not within specifications, replace hub shims as needed to obtain specified clearance. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Technical Service Bulletins > A/C - FX 15 Compressor Clutch Shaft and Hub Assembly Compressor Clutch Hub: Technical Service Bulletins A/C - FX 15 Compressor Clutch Shaft and Hub Assembly Article No. 92-5-8 February 26, 1992 AIR CONDITIONING - FX-15 COMPRESSOR - CLUTCH SHAFT AND HUB ASSEMBLY DESIGN CHANGE INFORMATION FORD: 1988-92 TAURUS 1989-92 THUNDERBIRD 1991-92 CROWN VICTORIA 1992 ESCORT, TEMPO LINCOLN-MERCURY: 1988-92 SABLE 1989-92 COUGAR 1991-92 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1992 TOPAZ LIGHT TRUCK: 1989 ECONOLINE 1989-92 BRONCO, F-150-350 SERIES, F-47, RANGER 1990-92 AEROSTAR 1991-92 EXPLORER ISSUE: Effective with Job # 1, 1992, the FX-15 compressor shaft and hub assemblies have 21 splines instead of 16, as in prior years. This design change was made to increase shaft strength. The 16 tooth spline compressor is no longer in production. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Technical Service Bulletins > A/C - FX 15 Compressor Clutch Shaft and Hub Assembly > Page 6690 ACTION: If it becomes necessary to replace an FX-15 Compressor, use the following guidelines for replacement. Refer to Figure 1. 16 TOOTH SPLINE COMPRESSOR AND CLUTCH ASSEMBLY If a 16 tooth spline compressor and clutch assembly are not available, replace both assemblies with 21 tooth spline compressor and clutch hub assembly. 16 TOOTH SPLINE CLUTCH HUB ASSEMBLY Use a 16 tooth spline clutch hub assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Technical Service Bulletins > A/C - FX 15 Compressor Clutch Shaft and Hub Assembly > Page 6691 16 TOOTH SPLINE COMPRESSOR If a 16 tooth spline compressor is not available, replace it with a 21 tooth spline compressor. It will also be necessary to replace the clutch hub assembly with a 21 tooth spline clutch hub. If the clutch pulley has grooves worn into the friction surface, it should be replaced. 21 TOOTH SPLINE COMPRESSOR AND/OR CLUTCH HUB ASSEMBLY Job # 1, 1992 and beyond ... Replace with 21 tooth spline components. Clutch hub assembly and compressor are ordered separately. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Technical Service Bulletins > A/C - FX 15 Compressor Clutch Shaft and Hub Assembly > Page 6692 Compressor Clutch Hub: Technical Service Bulletins A/C Clutch - Slips At High Ambient Temperature Article No. 92-20-5 09/23/92 AIR CONDITIONING - FX-15 - COMPRESSOR AIR GAP SPECIFICATION - REVISION FORD: 1988-93 TAURUS 1989-93 THUNDERBIRD 1991-93 CROWN VICTORIA 1992-93 ESCORT, TEMPO LINCOLN-MERCURY: 1988-93 SABLE 1989-93 COUGAR 1991-93 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1992-93 TOPAZ, TRACER LIGHT TRUCK: 1989 ECONOLINE 1989-90 BRONCO II 1989-93 BRONCO, F-150-350 SERIES, F-47, RANGER 1990-93 AEROSTAR, EXPLORER ISSUE: The air conditioner clutch may "slip" during high ambient temperature conditions. This is normally caused by improper air gap adjustment between the clutch plate and hub assembly. ACTION: The air gap specifications between the clutch plate, hub assembly and the clutch pulley has been revised. When service is required the air gap must be set between 0.35 and 0.85 mm instead of the current Service Manual specification of 0.45 and 0.85 mm. NOTE: WHEN ADJUSTMENT IS REQUIRED, USE THE SPACERS INCLUDED IN THE SPACER KIT LISTED IN THE PARTS BLOCK. OPTIMUM ADJUSTMENT IS TOWARD THE LOWER LIMIT OF THE SPECIFICATION RANGE IN THE INTEREST OF DURABILITY. Part Number/Name Chart OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 Compressor Clutch Hub: Service and Repair FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 Removal 1. Remove clutch hub retaining nut using spanner wrench T81P-19623-MH or equivalent. On 10P15A compressors, use strap wrench D85L-6000-A or equivalent. It is necessary to connect field coil to a 12V source to energize the coil engaging the clutch. Fig. 1 Clutch hub removal Fig. 1a Hub Driven Plate Remover Tool. FX-15 2. Remove clutch hub and shims from compressor shaft with tool T80L-19703-B or equivalent, Fig. 1. Holding tool with 1 inch wrench, tighten bolt with 1/2 inch wrench. Use hub driven plate remover T88C-19703-BH or equivalent, Fig. 1a, when removing hub plate of 10P15A compressors Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 6695 Fig. 2 Disassembled view of clutch assembly. FS-6 Fig. 3 Disassembled view of clutch assembly. 6P148 3. Remove clutch pulley retaining snap ring, Figs. 2 and 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 6696 Fig. 4 Clutch pulley removal 4. Remove pulley and bearing assembly from compressor. If pulley and bearing assembly cannot be removed by hand, use a suitable puller, Fig. 5. Installation Clutch Pulley Installation 1. Clean pulley bearing surface of compressor. 2. Install pulley and bearing on compressor. Bearing should be a slip fit onto compressor head. If difficulty is encountered installing pulley, gently tap pulley on compressor using tool T80L-19703-J or equivalent, Fig. 5. Be sure pulley bearing is aligned with compressor head. 3. Install pulley retaining snap ring with bevel side out. Fig. 6 Clutch hub installation 4. Install clutch hub on compressor shaft using new shims between clutch hub and end of shaft. Be sure shaft key is aligned with keyway in clutch hub. Do not attempt to drive hub on compressor shaft as damage to compressor will result. Use tool T80L-19703-F or equivalent if hub will not easily slide on compressor shaft, Fig. 6. 5. Install hub retaining nut on compressor shaft and torque to 10-14 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 6697 Fig. 7 Checking clutch air gap 6. Check clutch air gap between hub and pulley mating surface in three locations equally spaced, Fig. 7. Then rotate pulley one-half turn and check air gap again. The smallest air gap must be within specification. Add or remove shims until desired limit is attained. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Hub > Component Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 6698 Compressor Clutch Hub: Service and Repair HR-980 Removal Fig. 1 Clutch assembly exploded view 1. Hold clutch hub with suitable spanner wrench and remove retaining nut, Fig. 1. 2. Remove clutch hub using tool No. T80L19703-B or equivalent, then withdraw shims, noting thickness for assembly. 3. Remove clutch pulley retaining nut using spanner wrench T83P-19623-A or equivalent. 4. Remove pulley and bearing assembly and field coil from compressor, using suitable puller if necessary. 5. If pulley bearing is to be replaced, proceed as follows: a. Support pulley with large opening of tool No. T80L-19703-E or equivalent, then drive bearing from pulley using suitable spacer. b. Place pulley friction face over small opening in support tool. c. Position new bearing in bore and seat bearing using suitable driver. d. Stake bearing to pulley in three equally spaced positions, taking care not to damage bearing. Do not stake bearing in locations used to stake the removed bearing. Installation 1. Thoroughly clean front of compressor. 2. Mount clutch field coil on compressor with electrical connector on top and slots in coil engaging housing lugs. 3. Align pulley bearing with boss on compressor head, then slide pulley and bearing assembly onto compressor. The bearing should be a slip fit on compressor head when properly aligned. However, if difficulty is encountered when installing bearing and pulley assembly, lightly tap assembly using driver T80L-19703-J or equivalent and a light hammer. 4. Apply suitable thread locking compound to threads of pulley retaining nut. Install nut and torque to 56-70 ft. lbs. using a suitable spanner wrench. 5. Mount clutch hub shims and clutch on compressor, ensuring drive key is properly aligned with keyway, then press hub into position using tool No. T80L-19703-F or equivalent. Do not attempt to drive clutch hub onto shaft, as compressor will be damaged. 6. Install hub retaining nut and torque to 10-14 ft. lbs. 7. Check air gap between hub and pulley mating surface at three equally spaced positions and record the readings. 8. Rotate pulley one-half turn and repeat step 7. 9. If smallest measured air gap is not within specifications, replace hub shims as needed to obtain specified clearance. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 Compressor Pulley: Service and Repair FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 Removal 1. Remove clutch hub retaining nut using spanner wrench T81P-19623-MH or equivalent. On 10P15A compressors, use strap wrench D85L-6000-A or equivalent. It is necessary to connect field coil to a 12V source to energize the coil engaging the clutch. Fig. 1 Clutch hub removal Fig. 1a Hub Driven Plate Remover Tool. FX-15 2. Remove clutch hub and shims from compressor shaft with tool T80L-19703-B or equivalent, Fig. 1. Holding tool with 1 inch wrench, tighten bolt with 1/2 inch wrench. Use hub driven plate remover T88C-19703-BH or equivalent, Fig. 1a, when removing hub plate of 10P15A compressors Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 6703 Fig. 2 Disassembled view of clutch assembly. FS-6 Fig. 3 Disassembled view of clutch assembly. 6P148 3. Remove clutch pulley retaining snap ring, Figs. 2 and 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 6704 Fig. 4 Clutch pulley removal 4. Remove pulley and bearing assembly from compressor. If pulley and bearing assembly cannot be removed by hand, use a suitable puller, Fig. 5. Installation Clutch Pulley Installation 1. Clean pulley bearing surface of compressor. 2. Install pulley and bearing on compressor. Bearing should be a slip fit onto compressor head. If difficulty is encountered installing pulley, gently tap pulley on compressor using tool T80L-19703-J or equivalent, Fig. 5. Be sure pulley bearing is aligned with compressor head. 3. Install pulley retaining snap ring with bevel side out. Fig. 6 Clutch hub installation 4. Install clutch hub on compressor shaft using new shims between clutch hub and end of shaft. Be sure shaft key is aligned with keyway in clutch hub. Do not attempt to drive hub on compressor shaft as damage to compressor will result. Use tool T80L-19703-F or equivalent if hub will not easily slide on compressor shaft, Fig. 6. 5. Install hub retaining nut on compressor shaft and torque to 10-14 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 6705 Fig. 7 Checking clutch air gap 6. Check clutch air gap between hub and pulley mating surface in three locations equally spaced, Fig. 7. Then rotate pulley one-half turn and check air gap again. The smallest air gap must be within specification. Add or remove shims until desired limit is attained. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Pulley > Component Information > Service and Repair > FS-6, Nippon, 6P148, 6E171, 10P15, FX-15 > Page 6706 Compressor Pulley: Service and Repair HR-980 (Clutch Hub, Pulley & Field Coil Replace) Removal Fig. 1 Clutch assembly exploded view 1. Hold clutch hub with suitable spanner wrench and remove retaining nut, Fig. 1. 2. Remove clutch hub using tool No. T80L19703-B or equivalent, then withdraw shims, noting thickness for assembly. 3. Remove clutch pulley retaining nut using spanner wrench T83P-19623-A or equivalent. 4. Remove pulley and bearing assembly and field coil from compressor, using suitable puller if necessary. 5. If pulley bearing is to be replaced, proceed as follows: a. Support pulley with large opening of tool No. T80L-19703-E or equivalent, then drive bearing from pulley using suitable spacer. b. Place pulley friction face over small opening in support tool. c. Position new bearing in bore and seat bearing using suitable driver. d. Stake bearing to pulley in three equally spaced positions, taking care not to damage bearing. Do not stake bearing in locations used to stake the removed bearing. Installation 1. Thoroughly clean front of compressor. 2. Mount clutch field coil on compressor with electrical connector on top and slots in coil engaging housing lugs. 3. Align pulley bearing with boss on compressor head, then slide pulley and bearing assembly onto compressor. The bearing should be a slip fit on compressor head when properly aligned. However, if difficulty is encountered when installing bearing and pulley assembly, lightly tap assembly using driver T80L-19703-J or equivalent and a light hammer. 4. Apply suitable thread locking compound to threads of pulley retaining nut. Install nut and torque to 56-70 ft. lbs. using a suitable spanner wrench. 5. Mount clutch hub shims and clutch on compressor, ensuring drive key is properly aligned with keyway, then press hub into position using tool No. T80L-19703-F or equivalent. Do not attempt to drive clutch hub onto shaft, as compressor will be damaged. 6. Install hub retaining nut and torque to 10-14 ft. lbs. 7. Check air gap between hub and pulley mating surface at three equally spaced positions and record the readings. 8. Rotate pulley one-half turn and repeat step 7. 9. If smallest measured air gap is not within specifications, replace hub shims as needed to obtain specified clearance. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Compressor Shaft Seal: > 89222 > Nov > 89 > A/C Compressor Shaft Seal - Leaks Compressor Shaft Seal: Customer Interest A/C Compressor Shaft Seal - Leaks AIR CONDITIONING - FX-15 COMPRESSOR SHAFT SEAL LEAKS NEW SHAFT SEAL KIT AND COMPRESSOR SERVICE Article No. 89-22-2 FORD: 1988-90 TAURUS 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1988-90 SABLE 1989-90 COUGAR LIGHT TRUCK: 1989-90 BRONCO, BRONCO II 1989 ECONOLINE 1989-90 F SUPER DUTY, F-150, F-250, F-350, RANGER 1990 AEROSTAR This TSB article is being republished in its entirety to expand model year and vehicle line coverage as follows: ^ 1988-1990 Taurus/Sable - 3.0L built after 4/01/89 ^ 1989-1990 Thunderbird/Cougar - All ^ 1989 Econolines - All engines built before 1/10/89 ^ 1989-1990 Ranger/Bronco II - 2.3L & 4.0L ^ 1989-1990 F-Series/Bronco - All gasoline engines ^ 1990 Aerostar - 4.0L ^ 1989-1990 F-Super Duty - All In addition, it is not necessary to replace the FX-15 compressor for a shaft seal leak or when clutch components require replacement. ISSUE: Air conditioning refrigerant and oil that leaks from the A/C compressor may be caused by a cracked or split compressor shaft seal. A service A/C compressor shaft seal kit is available for service. ACTION: Install a new compressor shaft seal. Refer to the following procedure for service details. NOTE: DO NOT REPLACE THE FX-15 COMPRESSOR WHEN ONLY A SHAFT SEAL LEAK HAS BEEN DIAGNOSED OR WHEN CLUTCH COMPONENTS REQUIRE REPLACEMENT. REMOVAL 1. Discharge the refrigerant from the A/C system. 2. Remove the A/C compressor from the vehicle. Figure 1 3. Remove the clutch hub retaining bolt from the compressor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Compressor Shaft Seal: > 89222 > Nov > 89 > A/C Compressor Shaft Seal - Leaks > Page 6715 4. Install an 8 mm bolt into the shaft hole of the hub to force the hub from the shaft, Figure 1. Figure 2 5. Remove the shaft seal felt from the nose of the A/C compressor using Rotunda Tool T71P-19703-C, Figure 2. 6. Clean the seal cavity with low pressure compressed air and a lint-free cloth. Figure 3 7. Insert the tip of snap ring remover T89P-19623-DH into one of the eyes of the shaft seal retaining snap ring located inside the compressor nose, Figure 3. 8. Position the tool tip and snap ring eye as shown in Figure 3. 9. Pull the snap ring remover up quickly while keeping the tool against the side of the compressor nose housing, Figure 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Compressor Shaft Seal: > 89222 > Nov > 89 > A/C Compressor Shaft Seal - Leaks > Page 6716 Figure 4 10. Position the shaft seal remover tool T89P-19623-BH over the compressor shaft and push the tool into the nose of the compressor and down against the shaft seal, Figure 4. 11. Engage the end of the tool with the internal diameter of the shaft seal and turn the tool handle clockwise to expand the tool tip inside the seal inner radius. 12. Pull the shaft seal from the A/C compressor. Figure 5 INSTALLATION 1. Make sure the shaft seal protector tool that is included in the seal kit is not damaged, Figure 5. 2. Lubricate the tool with clean refrigerant oil. Figure 6 3. Clean the inside of the compressor nose and shaft with a clean lint-free cloth. 4. Coat the shaft seal with clean refrigerant oil. 5. Position the seal over the shaft protector tool. Make sure the lip portion of the seal is pointed toward the large diameter end of the tool, Figure 6. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Compressor Shaft Seal: > 89222 > Nov > 89 > A/C Compressor Shaft Seal - Leaks > Page 6717 Figure 7 6. Place the shaft seal protector tool over the end of the compressor shaft, Figure 7. Figure 8 7. Using the shaft seal installer tool T89P-19623-AH, slowly push the seal down the shaft protector tool onto the A/C compressor shaft until the seal is seated, Figure 8. 8. Remove the shaft seal installer tool and the shaft seal protector tool from the compressor shaft. 9. Position the seal retaining snap ring into the compressor nose opening. 10. Push and seat the snap ring against the seal with the snap ring remover tool, T89P-19623-DH. 11. Leak test the compressor. Refer to the 1988 Taurus/Sable Shop Manual, Section 36 for service details. 12. Install a new shaft seal felt in the nose of the compressor. 13. Re-install the clutch hub onto the A/C compressor shaft. 14. Re-install the A/C compressor into the vehicle. 15. Recharge the A/C system with refrigerant. PART NUMBER PART NAME CLASS E9SZ-19D665-A A/C Shaft Seal Kit B OTHER APPLICABLE ARTICLES: none SUPERSEDES: 88-7-5, 89-2-3, date 3/30/88, 1/25/89 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892202A Install New Seal Kit - 1.7 Hrs. Aerostar 892202A Install New Seal Kit - 2.0 Hrs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > Customer Interest for Compressor Shaft Seal: > 89222 > Nov > 89 > A/C Compressor Shaft Seal - Leaks > Page 6718 Econoline 4.9L, 5.0L, 5.8L 892202A Install New Seal Kit - 2.3 Hrs. Econoline 7.3L Diesel 892202A Install New Seal Kit - 2.1 Hrs. Econoline 7.5L 892202A Install New Seal Kit - 1.9 Hrs. F-Series, Bronco 4.9L, 5.0L, 5.8L 892202A Install New Seal Kit - 2.1 Hrs. F-Series, F-Super Duty 7.3L Diesel 892202A Install New Seal Kit - 2.2 Hrs. F-Series, F-Super Duty 7.5L 892202A Install New Seal Kit - 2.6 Hrs. Ranger 2.9L 892202A Install New Seal Kit - 2.0 Hrs. Ranger 4.0L 892202A Install New Seal Kit - 3.1 Hrs. Taurus, Sable, 892202A Install New Seal Kit - 1.6 Hrs. Thunderbird, Cougar DEALER CODING BASIC PART NO. CONDITION CODE 19703 48 OASIS CODES: 2610, 2611, 2612 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Shaft Seal: > 89222 > Nov > 89 > A/C Compressor Shaft Seal - Leaks Compressor Shaft Seal: All Technical Service Bulletins A/C Compressor Shaft Seal - Leaks AIR CONDITIONING - FX-15 COMPRESSOR SHAFT SEAL LEAKS NEW SHAFT SEAL KIT AND COMPRESSOR SERVICE Article No. 89-22-2 FORD: 1988-90 TAURUS 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1988-90 SABLE 1989-90 COUGAR LIGHT TRUCK: 1989-90 BRONCO, BRONCO II 1989 ECONOLINE 1989-90 F SUPER DUTY, F-150, F-250, F-350, RANGER 1990 AEROSTAR This TSB article is being republished in its entirety to expand model year and vehicle line coverage as follows: ^ 1988-1990 Taurus/Sable - 3.0L built after 4/01/89 ^ 1989-1990 Thunderbird/Cougar - All ^ 1989 Econolines - All engines built before 1/10/89 ^ 1989-1990 Ranger/Bronco II - 2.3L & 4.0L ^ 1989-1990 F-Series/Bronco - All gasoline engines ^ 1990 Aerostar - 4.0L ^ 1989-1990 F-Super Duty - All In addition, it is not necessary to replace the FX-15 compressor for a shaft seal leak or when clutch components require replacement. ISSUE: Air conditioning refrigerant and oil that leaks from the A/C compressor may be caused by a cracked or split compressor shaft seal. A service A/C compressor shaft seal kit is available for service. ACTION: Install a new compressor shaft seal. Refer to the following procedure for service details. NOTE: DO NOT REPLACE THE FX-15 COMPRESSOR WHEN ONLY A SHAFT SEAL LEAK HAS BEEN DIAGNOSED OR WHEN CLUTCH COMPONENTS REQUIRE REPLACEMENT. REMOVAL 1. Discharge the refrigerant from the A/C system. 2. Remove the A/C compressor from the vehicle. Figure 1 3. Remove the clutch hub retaining bolt from the compressor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Shaft Seal: > 89222 > Nov > 89 > A/C Compressor Shaft Seal - Leaks > Page 6724 4. Install an 8 mm bolt into the shaft hole of the hub to force the hub from the shaft, Figure 1. Figure 2 5. Remove the shaft seal felt from the nose of the A/C compressor using Rotunda Tool T71P-19703-C, Figure 2. 6. Clean the seal cavity with low pressure compressed air and a lint-free cloth. Figure 3 7. Insert the tip of snap ring remover T89P-19623-DH into one of the eyes of the shaft seal retaining snap ring located inside the compressor nose, Figure 3. 8. Position the tool tip and snap ring eye as shown in Figure 3. 9. Pull the snap ring remover up quickly while keeping the tool against the side of the compressor nose housing, Figure 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Shaft Seal: > 89222 > Nov > 89 > A/C Compressor Shaft Seal - Leaks > Page 6725 Figure 4 10. Position the shaft seal remover tool T89P-19623-BH over the compressor shaft and push the tool into the nose of the compressor and down against the shaft seal, Figure 4. 11. Engage the end of the tool with the internal diameter of the shaft seal and turn the tool handle clockwise to expand the tool tip inside the seal inner radius. 12. Pull the shaft seal from the A/C compressor. Figure 5 INSTALLATION 1. Make sure the shaft seal protector tool that is included in the seal kit is not damaged, Figure 5. 2. Lubricate the tool with clean refrigerant oil. Figure 6 3. Clean the inside of the compressor nose and shaft with a clean lint-free cloth. 4. Coat the shaft seal with clean refrigerant oil. 5. Position the seal over the shaft protector tool. Make sure the lip portion of the seal is pointed toward the large diameter end of the tool, Figure 6. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Shaft Seal: > 89222 > Nov > 89 > A/C Compressor Shaft Seal - Leaks > Page 6726 Figure 7 6. Place the shaft seal protector tool over the end of the compressor shaft, Figure 7. Figure 8 7. Using the shaft seal installer tool T89P-19623-AH, slowly push the seal down the shaft protector tool onto the A/C compressor shaft until the seal is seated, Figure 8. 8. Remove the shaft seal installer tool and the shaft seal protector tool from the compressor shaft. 9. Position the seal retaining snap ring into the compressor nose opening. 10. Push and seat the snap ring against the seal with the snap ring remover tool, T89P-19623-DH. 11. Leak test the compressor. Refer to the 1988 Taurus/Sable Shop Manual, Section 36 for service details. 12. Install a new shaft seal felt in the nose of the compressor. 13. Re-install the clutch hub onto the A/C compressor shaft. 14. Re-install the A/C compressor into the vehicle. 15. Recharge the A/C system with refrigerant. PART NUMBER PART NAME CLASS E9SZ-19D665-A A/C Shaft Seal Kit B OTHER APPLICABLE ARTICLES: none SUPERSEDES: 88-7-5, 89-2-3, date 3/30/88, 1/25/89 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892202A Install New Seal Kit - 1.7 Hrs. Aerostar 892202A Install New Seal Kit - 2.0 Hrs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Compressor Shaft Seal: > 89222 > Nov > 89 > A/C Compressor Shaft Seal - Leaks > Page 6727 Econoline 4.9L, 5.0L, 5.8L 892202A Install New Seal Kit - 2.3 Hrs. Econoline 7.3L Diesel 892202A Install New Seal Kit - 2.1 Hrs. Econoline 7.5L 892202A Install New Seal Kit - 1.9 Hrs. F-Series, Bronco 4.9L, 5.0L, 5.8L 892202A Install New Seal Kit - 2.1 Hrs. F-Series, F-Super Duty 7.3L Diesel 892202A Install New Seal Kit - 2.2 Hrs. F-Series, F-Super Duty 7.5L 892202A Install New Seal Kit - 2.6 Hrs. Ranger 2.9L 892202A Install New Seal Kit - 2.0 Hrs. Ranger 4.0L 892202A Install New Seal Kit - 3.1 Hrs. Taurus, Sable, 892202A Install New Seal Kit - 1.6 Hrs. Thunderbird, Cougar DEALER CODING BASIC PART NO. CONDITION CODE 19703 48 OASIS CODES: 2610, 2611, 2612 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > With HR-980 Compressor Compressor Shaft Seal: Service and Repair With HR-980 Compressor Removal Fig. 2 Compressor shaft seal assembly exploded view 1. Discharge A/C system and remove compressor from vehicle. 2. Mount compressor in holding fixture T57L-500-B or equivalent. 3. remove clutch hub, pulley and field coil as outlined, then pry drive key from compressor shaft, taking care not to damage shaft. 4. Pry dust shield from compressor, Fig. 2, taking care not to damage housing. 5. Remove ceramic seat retaining ring, then clean area surrounding compressor seal to prevent dirt from entering compressor. 6. Insert tool No. T71P-19703-M or equivalent into recess of ceramic seat, tighten tool outer sleeve to expand tool into seat, then pull seat from compressor using a twisting motion. 7. Remove ceramic seat O-ring from compressor neck. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > With HR-980 Compressor > Page 6730 Fig. 3 Compressor seal replacement tool 8. Insert tool No. T71P-19703-G or equivalent into compressor neck. Rotate tool clockwise while pressing against seal to engage tangs on tool, Fig. 3, then pull seal from compressor. Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > With HR-980 Compressor > Page 6731 Fig. 4 Seal seat O-ring installation 1. Inspect compressor shaft and seal seat areas, and clean or repair as necessary. 2. Coat new O-ring seal with clean refrigerant oil. Refer to Fig. 4 and install O-ring as follows: a. Position O-ring guide over compressor shaft and insert O-ring into installation tool. b. Install O-ring and sleeve assembly over guide. c. Slide installer over guide and into sleeve, bottoming installer against guide. d. Lift up on O-ring sleeve to allow O-ring to slip into installed position, then remove sleeve, installer and guide. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > With HR-980 Compressor > Page 6732 Fig. 3 Compressor seal replacement tool 3. Coat new shaft seal with clean refrigerant oil and mount seal on tool No. T71P-19703-G or equivalent, Fig. 3. 4. Place suitable seal protector over compressor shaft, then press seal into compressor with twisting motion until seal engages flats on compressor shaft and is fully seated. 5. Press down and rotate seal installer to disengage tangs, then remove installer. 6. Coat ceramic seat with clean refrigerant oil and grip seat with tool No. T71P-19703-M or equivalent. 7. Install ceramic seat with clockwise rotation, taking care not to damage or dislodge O-ring. 8. Remove ceramic seat installer and protective sleeve. 9. Install snap ring with flat side toward ceramic seat and ensure snap ring is fully seated in groove. Do not tap against snap ring to seat ring in groove, as ceramic seat may be damaged. 10. Install dust shield in compressor neck. 11. Install clutch drive key and clutch components previously removed. 12. Reinstall compressor. Ensure system is properly charged with refrigerant oil, evacuate and recharge system, then check for leaks. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > With HR-980 Compressor > Page 6733 Compressor Shaft Seal: Service and Repair With FX-15 Compressor Removal Except for manifold hose O-rings and front shaft seal this compressor is not serviceable and must be replaced as an assembly. 1. Drain oil from compressor through manifold openings. 2. Clamp compressor in suitable vise, then remove clutch assembly. 3. Remove snap ring using suitable tool and clutch field coil from front of compressor. 4. Remove felt and retainer from front of compressor. 5. Place shaft seal remover tool T89P-19623-BH or equivalent over compressor shaft and push tool into nose of compressor and down against shaft seal, Fig. 23. Engage end of tool with internal diameter of shaft seal and turn handle clockwise to expand tool tip inside seal inner radius, then remove seal. Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Shaft Seal > Component Information > Service and Repair > With HR-980 Compressor > Page 6734 Fig. 24 Shaft seal removal. FX-15 1. Ensure shaft protector tool T89P-19623-CH is free of burrs and, then lubricate tool with clean refrigerant oil. 2. Lubricate shaft seal in clean refrigerant oil and place seal over shaft protector, Fig. 24. Ensure lip portion of seal is pointed toward compressor. Using shaft seal installer tool T89P-19623-AH or equivalent, Fig. 25, slowly push seal down shaft protector until seated, Fig. 25. 3. Remove replacer tool and shaft protector tool, then install snap ring. After ensuring no internal leaks are present, install felt in nose and replace hub on compressor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Diode HVAC > Component Information > Locations Compressor Clutch Diode HVAC: Locations Taped To Engine Harness, Near Clutch Coil Connector Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Engine Compartment Component Locations On Relay Bracket Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description Compressor Clutch Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6743 X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6744 Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6745 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6746 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6747 Compressor Clutch Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6748 X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 - CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6749 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6750 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6751 Fig. 23 Integrated Controller Pinpoint Tests X13 & X14 (Part 4 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6752 Fig. 23 Integrated Controller Pinpoint Tests X15 (Part 5 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6753 Fig. 23 Integrated Controller Pinpoint Test X16 & X17 (Part 6 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6754 Fig. 23 Integrated Controller Pinpoint Tests X18, X19, X20 & X21 (Part 7 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6755 Fig. 23 Integrated Controller Pinpoint Test X22 (Part 8 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6756 Fig. 23 Integrated Controller Pinpoint Tests X23 & X25 (Part 9 Of 26) Fig. 23 Integrated Controller Pinpoint Tests X26, X27 & X30 (Part 10 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6757 Fig. 23 Integrated Controller Pinpoint Tests X31 & X32 (Part 11 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6758 Fig. 23 Integrated Controller Pinpoint Tests X33 & X35 (Part 12 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6759 Fig. 23 Integrated Controller Pinpoint Tests X36 & X37 (Part 13 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6760 Fig. 23 Integrated Controller Pinpoint Tests X40, X41, X42 & X43 (Part 14 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6761 Fig. 23 Integrated Controller Pinpoint Tests X44, X45 & X46 (Part 15 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6762 Fig. 23 Integrated Controller Pinpoint Tests X50, X51 & X52 (Part 16 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6763 Fig. 23 Integrated Controller Pinpoint Tests X53, X54 & X55 (Part 17 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6764 Fig. 23 Integrated Controller Pinpoint Tests X56, X57 & X58 (Part 18 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6765 Fig. 23 Integrated Controller Pinpoint Tests X59, X60 & X80 (Part 19 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6766 Fig. 23 Integrated Controller Pinpoint Tests X81, X82 & X83 (Part 20 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6767 Fig. 23 Integrated Controller Pinpoint Tests X84, X90 & X91 (Part 21 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6768 Fig. 23 Integrated Controller Pinpoint Tests X92, X93 & X94 (Part 22 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6769 Fig. 23 Integrated Controller Pinpoint Tests X95 & X96 (Part 23 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6770 Fig. 23 Integrated Controller Pinpoint Tests X100 & X101 (Part 24 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6771 Fig. 23 Integrated Controller Pinpoint Tests X102 & X103 (Part 25 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 6772 Fig. 23 Integrated Controller Pinpoint Test X104 (Part 26 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures Condenser HVAC: Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Air Conditioning - Approved Flushing Procedures > Page 6777 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 6778 Condenser HVAC: Service and Repair 1. Discharge refrigerant from system at service access gauge port valve located on the suction line. 2. Remove battery from vehicle. Fig. 2 Spring lock coupling disconnect & connect 3. Disconnect the two refrigerant lines on right side of radiator, Fig. 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Technical Service Bulletins > Page 6779 Fig. 3 Condenser assembly removal 4. Remove four bolts attaching condenser to radiator support, then the condenser, Fig. 3. 5. Reverse procedure to install. Use new O-rings lubricated with refrigerant oil. Add one ounce of refrigerant oil to new condenser. 6. Evacuate, charge and leak test system. Check system for proper operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Locations Control Assembly: Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Control Module HVAC > Component Information > Service and Repair Control Module HVAC: Service and Repair Fig. 10 Control panel removal 1. Disconnect battery ground cable. 2. Position removal tool T87P-19061 into retaining clip access holes, Fig. 10, then disengage clips by applying pressure away from control panel. Fig. 11 Control panel assembly 3. Pull control assembly away from instrument panel, then disconnect electrical connectors, vacuum harness and temperature control cable from the assembly, Fig. 11. 4. Remove control assembly from instrument panel. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings A/C Coupler O-ring: Technical Service Bulletins A/C - New Refrigerant O-Rings Article No. 91-22-5 10/30/91 AIR CONDITIONING - NEW REFRIGERANT FITTING "O" RINGS (GREEN COLOR) AVAILABLE TO PROVIDE IMPROVED SEALING AND DURABILITY FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-92 TAURUS LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1991-92 TRACER LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-92 AEROSTAR 1988-92 F SUPER DUTY 1989-92 F-47 1991-92 EXPLORER ISSUE: New refrigerant 0-rings (GREEN COLOR) are available for use in the Ford Spring Lock Coupling (SLC) and threaded (Tube-0) connections. The new GREEN COLORED 0-ring material provides improved sealing and longer seal life. Use of any other 0-ring for Ford refrigerant fittings is not recommended and may result in premature leakage at the fitting. ACTION: If a refrigerant system repair is made which requires an A/C fitting to be disconnected, replace the existing 0-rings with the new GREEN COLORED type. Refer to the following 0-ring Usage Chart for identifying the correct 0-ring. O-RING USAGE CHART (SLC) (SLC) (TUBE-0) (TUBE-0) MOTORCRAFT SERVICE MOTORCRAFT SERVICE SIZE PART NO. PART NO. PART NO. PART NO. 3/8" YF-1753 391302-S100 YF-1753 391302-S100 1/2" YF-1754 391303-S100 YF-1754 391303-S100 5/8" YF-1755 391304-S100 YF-1756 391306-S100 3/4" YF-1752 3913O5-S100 YF-1757 391307-S100 PART NUMBER PART NAME CLASS 391302-S100 3/8" 0-ring (SLC & TUBE-0, S Pkg./6) 391303-S100 1/2" 0-ring (SLC & TUBE-0, S Pkg./6) 391304-S100 5/8" 0-ring (SLC, Pkg./6) S 391306-S100 5/8" 0-ring (TUBE-0, Pkg./6) S 391305-S100 3/4" 0-ring (SLC, Pkg./6) S 391307-S100 3/4" 0-ring (TUBE-0, Pkg./4) S OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-14-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings > Page 6791 A/C Coupler O-ring: Technical Service Bulletins Air Conditioning - O Ring Removal Service Tip Article No. 95-2-2 01/30/95 AIR CONDITIONING - O-RING REMOVAL FROM SPRING LOCK COUPLER - SERVICE TIP FORD: 1981-95 MUSTANG 1982-83 FAIRMONT 1982-88 EXP 1982-95 CROWN VICTORIA, ESCORT, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-95 TAURUS 1989-95 PROBE 1995 CONTOUR LINCOLN-MERCURY: 1982-83 LN7, ZEPHYR 1982-87 LYNX 1982-95 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1991-95 TRACER 1993-94 CAPRI 1993-95 MARK VIII 1995 MYSTIQUE LIGHT TRUCK: 1982-95 BRONCO, F SUPER DUTY, F-150-350 SERIES, RANGER 1983-90 BRONCO II 1986-95 AEROSTAR 1988-95 ECONOLINE 1991-95 EXPLORER 1995 WINDSTAR This TSB is being republished in its entirety to include the latest level tools and procedures available. ISSUE: Some technicians may use small screwdrivers to remove 0-rings from spring lock coupling fittings. This practice can and has resulted in scratches across the 0-ring grooves in the fittings. Loss of refrigerant charge in the system may result. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings > Page 6792 ACTION: It is recommended that a plastic toothpick, or equivalent tool, be used to remove 0-rings. Refer to Figure 1. Do not use the metal O-Ring Tool (T71P-19703-C). Only plastic O-Ring Tool (F5VH-17B017-AA) is approved for O-ring removal. OTHER APPLICABLE ARTICLES: 91-22-5, 93-6-5 SUPERSEDES: 93-15-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings > Page 6793 A/C Coupler O-ring: Technical Service Bulletins A/C Coupling - Cleaning Procedures Article No. 93-6-5 03/17/93 ^ AIR CONDITIONING - AVAILABILITY OF NEW GREEN O-RING SERVICE KIT TO PROVIDE IMPROVED SEALING AND DURABILITY ^ AIR CONDITIONING - SPRING LOCK COUPLING REFRIGERANT FITTINGS - CLEANING PROCEDURE FORD: 1981-91 MUSTANG 1982-88 EXP 1982-91 CROWN VICTORIA, ESCORT, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS LINCOLN-MERCURY: 1981-86 CAPRI 1982-83 MARK VI 1982-87 LYNX 1982-91 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1983-86 MARQUIS 1984-91 MARK VII, TOPAZ 1986-91 SABLE 1991 TRACER LIGHT TRUCK: 1982-91 BRONCO, F-150-350 SERIES 1983-90 BRONCO II 1983-91 RANGER 1986-91 AEROSTAR 1988-91 ECONOLINE 1991 EXPLORER ISSUE: A procedure has been developed for cleaning Spring Lock Coupling (SLC) refrigerant fittings during air conditioning system repairs. This procedure and replacement of black O-rings with the improved green O-rings will reduce the potential of refrigerant leaks. ACTION: When servicing the air conditioning system on the subject vehicles, or if a refrigerant leak is suspected at any of the SLC connections, disconnect all SLC connections and replace all black O-rings with new green O-rings which are made of an improved material. Use the following service procedure to clean the coupling before installing new green O-rings. Refer to the Parts Block in this article for correct parts usage. CLEANING PROCEDURE 1. Remove all refrigerant from the vehicle A/C system using an U.L. approved Refrigerant/Recovery device prior to disconnecting the refrigerant couplings. Refer to the appropriate model year Service Manual for a detailed A/C discharging procedure. 2. Disconnect the SLC coupling. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler O-ring > Component Information > Technical Service Bulletins > A/C - New Refrigerant O-Rings > Page 6794 3. Remove the black O-rings. Be careful not to scratch the O-ring grooves. CAUTION: A SCRATCH CAN CAUSE FUTURE REFRIGERANT LEAKS. 4. Remove any surface residue from the inside of the female SLC and the grooves of the male SLC by polishing with 400 grit emery cloth or equivalent. Polish the female surface by using a twisting motion, Figure 1, so that any scratches made will not cross the O-ring sealing surface. 5. Perform additional polishing of the surface using 600 grit emery cloth or equivalent. 6. Remove all residue from polishing operations from both fittings by wiping with a lint-free rag. 7. Install new green O-rings. If the O-rings are not prelubricated, lube with YN-9 A/C compressor oil (F73Z-19577-A) before installing them. 8. Lubricate the inside of the female portion of the SLC with YN-9 compressor oil (F73Z-19577-A) and apply additional oil to the O-rings. 9. Reconnect the fitting. 10. Recharge the A/C system. Refer to the appropriate model year Service Manual for specific detailed instructions. OTHER APPLICABLE ARTICLES: 91-22-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler Spring > Component Information > Technical Service Bulletins > A/C Coupling - Cleaning Procedures A/C Coupler Spring: Technical Service Bulletins A/C Coupling - Cleaning Procedures Article No. 93-6-5 03/17/93 ^ AIR CONDITIONING - AVAILABILITY OF NEW GREEN O-RING SERVICE KIT TO PROVIDE IMPROVED SEALING AND DURABILITY ^ AIR CONDITIONING - SPRING LOCK COUPLING REFRIGERANT FITTINGS - CLEANING PROCEDURE FORD: 1981-91 MUSTANG 1982-88 EXP 1982-91 CROWN VICTORIA, ESCORT, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS LINCOLN-MERCURY: 1981-86 CAPRI 1982-83 MARK VI 1982-87 LYNX 1982-91 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1983-86 MARQUIS 1984-91 MARK VII, TOPAZ 1986-91 SABLE 1991 TRACER LIGHT TRUCK: 1982-91 BRONCO, F-150-350 SERIES 1983-90 BRONCO II 1983-91 RANGER 1986-91 AEROSTAR 1988-91 ECONOLINE 1991 EXPLORER ISSUE: A procedure has been developed for cleaning Spring Lock Coupling (SLC) refrigerant fittings during air conditioning system repairs. This procedure and replacement of black O-rings with the improved green O-rings will reduce the potential of refrigerant leaks. ACTION: When servicing the air conditioning system on the subject vehicles, or if a refrigerant leak is suspected at any of the SLC connections, disconnect all SLC connections and replace all black O-rings with new green O-rings which are made of an improved material. Use the following service procedure to clean the coupling before installing new green O-rings. Refer to the Parts Block in this article for correct parts usage. CLEANING PROCEDURE 1. Remove all refrigerant from the vehicle A/C system using an U.L. approved Refrigerant/Recovery device prior to disconnecting the refrigerant couplings. Refer to the appropriate model year Service Manual for a detailed A/C discharging procedure. 2. Disconnect the SLC coupling. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Coupler HVAC > A/C Coupler Spring > Component Information > Technical Service Bulletins > A/C Coupling - Cleaning Procedures > Page 6799 3. Remove the black O-rings. Be careful not to scratch the O-ring grooves. CAUTION: A SCRATCH CAN CAUSE FUTURE REFRIGERANT LEAKS. 4. Remove any surface residue from the inside of the female SLC and the grooves of the male SLC by polishing with 400 grit emery cloth or equivalent. Polish the female surface by using a twisting motion, Figure 1, so that any scratches made will not cross the O-ring sealing surface. 5. Perform additional polishing of the surface using 600 grit emery cloth or equivalent. 6. Remove all residue from polishing operations from both fittings by wiping with a lint-free rag. 7. Install new green O-rings. If the O-rings are not prelubricated, lube with YN-9 A/C compressor oil (F73Z-19577-A) before installing them. 8. Lubricate the inside of the female portion of the SLC with YN-9 compressor oil (F73Z-19577-A) and apply additional oil to the O-rings. 9. Reconnect the fitting. 10. Recharge the A/C system. Refer to the appropriate model year Service Manual for specific detailed instructions. OTHER APPLICABLE ARTICLES: 91-22-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor Evaporator Case: Customer Interest Air Conditioning - Water Drips On Floor Article No. 95-23-3 11/20/95 AIR CONDITIONING - WATER DRIPS ON FLOOR FROM EVAPORATOR WHEN BLOWER IS ON HIGH IN MAX A/C OR NORMAL A/C MODE FORD: 1989-95 THUNDERBIRD LINCOLN-MERCURY: 1989-95 COUGAR LIGHT TRUCK: 1995-96 EXPLORER, RANGER ISSUE: Water from condensation building on the evaporator core may drip onto the floor when the A/C blower is on HIGH and the A/C mode control is in MAX A/C or Normal A/C position. This may be caused by the evaporator core seals being misaligned. ACTION: For Ranger/Explorer, stretch and reposition the evaporator core seal. Refer to the Ranger/Explorer Service Procedure. For Thunderbird/Cougar, refer to the Thunderbird/Cougar Service Procedure. SERVICE PROCEDURE RANGER/EXPLORER 1. Check the evaporator drain tube for blockage. If blockage is present, clear the tube and recheck. 2. Remove the evaporator/blower case from the engine compartment following the procedures outlined in Section 12 of the 1995 Ranger/Explorer Service Manual. 3. Remove the service cover on the evaporator case. 4. Remove the evaporator core. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6808 5. Inspect the foam evaporator strip seals for proper positioning (Figure 1). 6. The seals are positioned on the blower wheel area as marked. There should be no gaps at either end of the seals. Witness marks should be present along the entire length of the seals. If no marks are present then the seals need to be repositioned to provide a better seal. Wipe out any excess moisture and reinstall evaporator core and case assembly. 7. Verify the repair. DIAGNOSTIC TIPS THUNDERBIRD/COUGAR The first thing to do when repairing a water leak is to determine the root cause of the leak. Ford has noted a number of different locations where water leak issues can arise on the Thunderbird/Cougar. Refer to the following list when addressing a water leak concern. Water may come from the outside of the vehicle as well as the evaporator case. Always check the evaporator drain for blockage prior to performing any of these steps. The following is a list of areas where a water leak is possible: 1. Water dripping from the floor ducts when the A/C is operating on vehicles built Job 1, 1989 through 10/15/93 are most likely exhibiting a Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6809 condensate carryover from the evaporator core. Refer to TSB 94-2-12 for Service Procedures on this concern. 2. Water dripping onto the floor in vehicles built after 10/15/93 or in vehicles built prior to that date which have been serviced following TSB 94-2-12 may have condensate leaking from one (1) of the following places (refer to Figure 2): a. The evaporator tube seal. Condensate forms on the liquid line inside the evaporator case. When the blower motor is operated on HIGH, condensate is blown against the inside of the seal and eventually leaks from the case. Condensate droplets will fall on the passenger side, just above the carpeting on the sound absorber. In very high humidity, this leak may appear within 10-15 minutes of A/C system start-up. A leaking seal can be observed in the vehicle with the use of an inspection mirror. Leakage from this area and area b described next, may be significant enough to saturate the carpeting over a long period of time. b. Case seam near evaporator tube seal. There is a seam between the upper and lower case halves adjacent to the recirc door linkage. This seam may not be adequately welded during assembly. When this occurs, condensate may leak from the case in this area. The seam is not visible when the evaporator is assembled in the vehicle. It is difficult to determine between leaks from this source, or source a, above. Generally, Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6810 leaks from this source may wet the recirc door vacuum motor, while leaks from source a, above, fall directly onto the sound absorber. c. Heater core cover seal. This foam seal may become saturated with condensate and drip on the passenger 5 feet. The source of this condensate leakage is visible through the glove compartment opening. Condensate leaking from this area may fall near the floor ducts, giving the mistaken impression that condensate is dripping from that duct. The volume of condensate from this location is usually low, typically about one (1) drop every several minutes. 3. Water accumulating on the floor can come from these other sources not related to evaporator core condensate. a. Water may enter the vehicle around the evaporator drain seal from the outside due to the lower evaporator case-to-dash mounting stud not being properly torqued. b. Water may leak into the passenger side kick panel on 1994 and 1995 models built through 8/10/94 due to insufficient body sealing in the right A-pillar/cowl area. If the kick panel area does not drain this water due to rustproofing or debris, the water can potentially build up and reach the carpet, or the water may find a path to flow onto the carpet when making its way down from the cowl area. This leak source is very rare and is outlined in TSB 94-22-5 for other wiring corrosion concerns. SERVICE PROCEDURE THUNDERBIRD/COUGAR 1. Diagnosis # 1. Condensate carryover. Follow the Service Procedures listed in TSB 94-2-12. 2. Diagnosis # 2a and 2b. Evaporator tube seal or case seam near evaporator tube seal. Repair as follows: a. Remove the evaporator case from the vehicle as outlined in the appropriate Service Manual, Section 12. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6811 b. Remove the evaporator tube seal from the case (Figure 3). c. Cut away the portion of the liquid line clip that extends outside of the case. d. Apply a generous bead of RTV sealant to the inside of the case as shown in Figure 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6812 e. Apply a generous bead of RTV to the evaporator tube seal as shown in Figure 4. f. Reinstall the evaporator tube seal being careful to ensure the RTV seals around the entire perimeter of the seal. g. Apply a bead of RTV around the perimeter of the seal where it meets the case. h. Allow the RTV to fully cure before reinstalling the case. Take care not to disturb the seal during installation of the case. 3. Diagnosis # 2c. Heater core cover seal. a. Remove the heater core cover and seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6813 b. Cut the seal as shown in Figure 6. This prevents the seal from extending beyond the cover and interfering with the RTV. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6814 c. Apply a bead of RTV to the heater core cover along the inside face as indicated in Figure 5. d. Reinstall heater core cover seal and heater core cover. e. Apply a bead of RTV between the heater core cover and the case. 4. Diagnosis # 3a. Loose lower mounting stud. a. Tighten nut as required. 5. Diagnosis # 3b. Water in passenger side kick panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6815 a. Follow the Service Procedures listed in TSB 94-22-5. OTHER APPLICABLE ARTICLES: 94-2-12, 94-22-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Base Warranty Coverage For All Others OPERATION DESCRIPTION TIME 952303A Stretch And Reposition 2.5 Hrs. Evaporator Core Seals - 1995-96 Ranger/Explorer 952303B Condensate Carryover - Refer 1989-95 To TSB Thunderbird/Cougar 94-2-12 952303C Evaporator Tube Seal And 2.7 Hrs. Leaky Seam Repair - 1989-95 Thunderbird/Cougar 952303D Heater Core Cover Seal 2.2 Hrs. Repair - 1989-95 Thunderbird/Cougar 952303E Lower Mounting Stud 0.2 Hr. Retighten - 1989-95 Thunderbird/Cougar 952303F Water In Passenger Side Refer Kick Panel Repair - To TSB 1989-95 Thunderbird/Cougar 94-22-5 DEALER CODING CONDITION BASIC PART NO. CODE 19850 36 OASIS CODES: 110000, 208000, 208300, 208400, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts Evaporator Case: Customer Interest A/C - Water Leaks From the Floor Ducts Article No. 94-2-12 01/26/94 AIR CONDITIONING - WATER DRIPS FROM THE FLOOR DUCTS WHEN A/C IS OPERATING VEHICLES BUILT FROM JOB-1 1989 THROUGH 10/15/93 FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR ISSUE: Condensation may drip from the floor duct when the A/C is operating. This occurs because the location of the evaporator core inside the housing allows high velocity air to carry water droplets from the core face beyond the sump area in the housing. ACTION: Replace the evaporator core and housing assembly with a new assembly which has a relocated evaporator core that allows the condensate to drain into the sump area of the housing rather than into the passenger compartment. Refer to the following procedure for service details. NOTE: USE PROCEDURE # 1 FOR 1994 MODELS ONLY AND USE PROCEDURE # 2 FOR 1989-93 MODELS. CAUTION: OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS WHILE PERFORMING THE FOLLOWING SERVICE PROCEDURE. PROCEDURE # 1 - 1994 MODELS BUILT BEFORE 10/15/93 ONLY NOTE: THIS VEHICLE USES THE NON-CHLOROFLUOROCARBON (NON-CFC) BASED REFRIGERANT R-134a. R-134a A/C SYSTEMS REQUIRE THE USE OF SPECIAL SERVICING EQUIPMENT DESIGNED SPECIALLY FOR SERVICING R-134a A/C SYSTEMS CAUTION: DO NOT USE R-12 SPECIAL TOOLS AND EQUIPMENT WHEN SERVICING AN R-134a SYSTEM. DOING SO MAY CAUSE DAMAGE TO THE A/C SYSTEM. REFER TO THE ROTUNDA CATALOG FOR MORE INFORMATION ON R-134a SPECIAL SERVICING EQUIPMENT. 1. Record radio stations. 2. Disconnect battery ground cable. Disconnect positive battery and wait one (1) minute for the air bag diagnostic monitor to deplete the air bag back-up power supply. Refer to Service Manual Section 01-20B. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6820 3. Loosen main wiring connector bolt in engine compartment at LH side of dash panel and separate connectors, Figure 1. 4. Remove the radio antenna through the right front wheel well. Disengage the antenna wire grommet from the sheet metal and push the antenna lead-in cable through the sheet metal into vehicle interior. 5. Remove the screws retaining the RH and LH scuff plates (do not remove the scuff plates from the vehicle). Lift scuff plates and remove door opening weatherstrips from body flanges. 6. Remove both RH and LH windshield side garnish moldings. 7. Remove both RH and LH cowl side trim panels. 8. Remove instrument panel steering column cover: a. remove the three (3) screws along the bottom b. pull on cover to unsnap the three (3) clips across the top. 9. Remove one (1) screw and A/C evaporator register duct from under the steering column tube. 10. Disconnect the electrical connectors at the base of the steering column. 11. Remove the pinch bolt attaching the steering column tube to steering column lower yoke and slightly spread the joint with a screwdriver. 12. Disconnect the multi-function switch connector located under the column assembly. 13. Disconnect the ignition switch connector. 14. While supporting the steering column tube, remove the four (4) steering column tube retaining nuts. 15. Lower steering column and remove shift interlock cable retaining screws and shift actuator cable fitting. Disconnect the electrical connector from shift interlock solenoid. 16. Remove steering column from the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6821 17. Disconnect stop lamp switch, Figure 2. 18. Pull back the floor carpet as required on the RH and LH sides of the vehicle and disconnect the window regulator safety switch connector and the Powertrain Control Module connector. 19. Remove glove compartment: a. Open glove compartment to the stop. b. Unsnap the hydraulic lift from the right side of the glove compartment. c. Remove the three (3) screws at the bottom retaining the glove compartment door hinge and glove compartment to the instrument panel. d. Remove glove compartment from the instrument panel. 20. Reach through the glove compartment opening and disconnect the electrical and vacuum connectors from the heater-A/C evaporator housing. 21. Disconnect the connectors behind the RH kick panel, Figure 3. 22. Disconnect the two (2) speed control amplifier connectors. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6822 23. Remove floor console panel. Refer to the 1994 Thunderbird/Cougar Service Manual, Section 01-12-4 and 01-12-5. NOTE: PROTECT THE INSTRUMENT PANEL SURFACE DURING THE FOLLOWING PROCEDURE. 24. Remove two (2) nuts and one (1) bolt from the instrument panel-to-console mount, Figure 4. 25. Remove two (2) nuts retaining the LH side of instrument panel to cowl side, Figure 4. 26. Remove the nut attaching the RH side of instrument panel to cowl side, Figure 4. NOTE: THE FOLLOWING THREE STEPS REQUIRE TWO TECHNICIANS. 27. Remove 6 bolts from the top of the instrument panel, Figure 4. 28. Carefully pull the instrument panel away from windshield glass, checking for and disconnecting any remaining wiring connectors. 29. Remove the instrument panel from the vehicle. 30. Recover the R-134a refrigerant from the A/C system at the service access gauge port valve, following the proper recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 31. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 32. Place a drain pan or suitable container under heater hose connections at the cowl panel. 33. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 34. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 35. Remove the suction accumulator drier from its bracket then remove the bracket. 36. Remove the three (3) retaining nuts attaching the evaporator housing to the cowl panel (under the hood). 37. Remove one (1) screw at the base of the evaporator housing and one (1) screw at the evaporator housing-to-cowl panel bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6823 38. Remove the evaporator housing from the vehicle. 39. Transfer the parts from the removed evaporator assembly to the new service evaporator assembly, based on the type of system in the vehicle. See illustrations. 40. Install the evaporator case and instrument panel in the vehicle by reversing the removal procedure. 41. Refill coolant and check for leaks. 42. Recharge the A/C system and check the operation of the system. 43. Reset radio stations recorded in step # 1. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. PROCEDURE # 2 - 1989-93 MODELS NOTE: AUTOMATIC TEMPERATURE CONTROL - EQUIPPED UNITS BUILT BEFORE 7/1/92 WILL REQUIRE A NEW ASPIRATOR ASSEMBLY (F4SZ-19E628-A) ALONG WITH THE NEW EVAPORATOR CASE ASSEMBLY. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6824 CAUTION: OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS WHILE PERFORMING THE FOLLOWING SERVICE PROCEDURE. 1. Record radio stations. 2. Disconnect battery ground cable. 3. Remove steering column lower trim cover. (Remove three (3) screws at bottom, one (1) screw LH side and pull to disengage five (5) snap-in retainers across top). 4. Remove steering column lower opening reinforcement. Six (6) screws retain reinforcement to instrument panel. 5. Remove steering column upper and lower shrouds. 6. Disconnect wiring from steering column. 7. Remove shift interlock switch, if equipped. 8. Disconnect steering column lower universal joint. 9. Support steering column and remove four (4) nuts retaining column to support. Remove column from vehicle. 10. Remove one (1) nut retaining LH side of instrument panel to parking brake bracket. 11. Remove RH and LH side cowl trim panels. 12. Disconnect electrical connections at RH cowl side. 13. Remove two (2) instrument panel-to-floor tunnel nuts. 14. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor. 15. Disconnect wiring, heater and A/C vacuum lines and control cables through glove compartment opening. 16. Remove two (2) screws at RH side retaining instrument panel to cowl side. 17. Remove two (2) screws at LH side retaining instrument panel to cowl side. 18. Remove RH and LH finish panel by pulling up to disengage snap-in retainers, three (3) on RH side and four (4) on LH side. 19. Remove RH and LH roof rail trim panels. 20. Remove four (4) screws retaining instrument panel to cowl top. 21. Gently pull instrument panel away from RH side of cowl panel. 22. Place a drain pan or suitable container under heater hose connections at the cowl panel. 23. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the proper recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 24. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 25. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 26. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 27. Working under the hood, remove three (3) nuts retaining the evaporator case to the cowl panel. 28. Inside the passenger compartment, remove the screw attaching the evaporator case support bracket to the cowl top panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6825 29. Remove one (1) nut retaining the bracket below the evaporator case to the cowl panel. 30. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 31. Transfer the following parts from the removed evaporator assembly to the new service evaporator assembly, based on the type of system in the vehicle. NOTE: IF THE UNIT IS EQUIPPED WITH ATC AND WAS BUILT PRIOR TO 7/1/92, YOU WILL HAVE TO USE A NEW ASPIRATOR (F4SZ-19E628-A) THAT IS DESIGNED FOR THE NEW SERVICE CASE AND ELIMINATE THE OLD ASPIRATOR. CHANGE OVER TO THE NEW ASPIRATOR AS FOLLOWS: ^ TRANSFER THE GASKET FROM THE EXISTING ASPIRATOR ASSEMBLY PLATE TO THE BACK OF THE BLOWER SPEED CONTROLLER SO YOU WILL SEAL THE MATING SURFACE OF THE CONTROLLER TO THE CASE. INSTALL THE BLOWER SPEED CONTROLLER TO THE CASE WITHOUT THE OLD ASPIRATOR, MAKING CERTAIN THAT THE GASKET SEALS PROPERLY. ^ DISCARD THE EXISTING ASPIRATOR ASSEMBLY AND INSTALL THE NEW ASPIRATOR (F4SZ-19E628-A) IN THE UPPER CASE HALF, IN THE EXISTING HOLE NEXT TO THE MUFFLER ASSEMBLY, USING A SCREW (# 10-12X .75 HEX WASHER HEAD SELF-TAPPING); OBTAIN LOCALLY. ^ USING THE OLD ASPIRATOR CONNECTING TUBE, CUT IT TO SIZE (SHORTEN) AND INSTALL IT BETWEEN THE NEW ASPIRATOR AND THE MUFFLER. 32. Cut off the end of the drain tube located on the bottom of the evaporator case under the heater core area. Cut Off The End Of The Drain Tube, Do Not Drill. CAUTION: DO NOT DRILL OUT THE HOLE BECAUSE THE HEATER CORE COULD BE DAMAGED, FIGURE 5. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6826 Connect A Hose To The Drain Tube. 33. Connect a 1/2" (12.7 mm) outside diameter hose (E8UZ-19K592-A) to the drain tube using a small hose clamp (376240-S100), Figure 6. 34. Install the evaporator case in the vehicle by reversing the removal procedure. a. Drill a hole in the cowl panel to accommodate the new drain tube. See Figure 2 for location. The hole should be about 2" (50.8 mm) below the regular evaporator case drain tube. b. After the new drain tube is through the hole and in permanent position, seal around the tube with body sealer (F1AZ-19562-A). 35. Recharge the A/C system and check the operation of the system. 36. Reset radio stations recorded in step # 1. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. NOTE: IF EVAPORATOR CORE AND HOUSING ASSEMBLY IS REPLACED PER THIS TSB ARTICLE, IT WILL NOT BE NECESSARY TO PERFORM TSB 94-2-9. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 92-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Models; Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 940212A Remove And Replace 4.5 Hrs. Evaporator Case DEALER CODING BASIC PART NO. CONDITION CODE 19850 08 OASIS CODES: 208000, 208300, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 9429 > Jan > 94 > Air Conditioning - Poor Performance Evaporator Case: Customer Interest Air Conditioning - Poor Performance Article No. 94-2-9 01/26/94 AIR CONDITIONING - HIGH DISCHARGE TEMPERATURES - POOR A/C PERFORMANCE VEHICLES BUILT FROM JOB 1 1989 TO 11/30/92 FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR ISSUE: Poor A/C performance, high discharge temperatures, may be the result of incorrect welding of the temperature blend door. If this occurs, air flow from the evaporator will be allowed to leak through the heater core and poor A/C performance will result. ACTION: If the A/C system seems to be operating, but is not cooling the car properly, the temperature blend door frame could be incorrectly positioned. Follow the attached service procedure to position the blend door properly. NOTE: DO NOT PERFORM THIS PROCEDURE IF TSB 94-2-12 HAS BEEN PERFORMED. FOLLOW NORMAL DIAGNOSTICS FOR POOR A/C PERFORMANCE. Verify the condition by performing the following diagnosis: 1. Run the A/C with the control set at MAX A/C and the blower on high for 5 minutes. Record the discharge air temperature at the center instrument panel register. 2. Clamp off the heater core hoses and continue to operate the system at MAX A/C with high blower for 10 minutes to cool the heater core. 3. Continue to operate the system on MAX A/C and high blower and record the discharge air temperature at the center instrument panel register. If there is a decrease in temperature of 5~F. (3~ C.) from the original temperature check made in Step 1, there is a good chance of an incorrectly welded door frame. INCORRECTLY WELDED DOOR FRAME SERVICE PROCEDURE Correct the condition by performing the following repair: 1. Remove the evaporator case from the vehicle. Refer to the 1993 Thunderbird/Cougar Service Manual, page 12-03-23, for the removal procedure. 2. Remove the heater core from the evaporator case. The temperature blend door can now be visually checked for incorrect welding. 3. The door frame may be held away from a firm seat on the evaporator case by two or three of the plastic weld stakes (along the side closest to the evaporator core). If not secured, it will be loose at the corner closest to the heater core cover. 4. Remove the weld stakes so that the door frame fits flush with the evaporator case. This can be done using a utility knife or a saw blade. NOTE: BE SURE TO REMOVE ALL DEBRIS FROM THE CASE, AFTER THIS PROCESS, TO PREVENT VIBRATION NOISES FROM OCCURRING DURING SYSTEM OPERATION. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 9429 > Jan > 94 > Air Conditioning - Poor Performance > Page 6831 5. Hold the blend door frame firmly down against the evaporator case and drill two 5/32" (4 mm) holes as shown in Figure 1. Holding the door frame firmly in position, install a 5/32" X 3/8" (4 mm X 9.5 mm) pop rivet in each hole. CAUTION: DO NOT USE SCREWS. THE SHARP POINT TENDS TO CATCH ON THE DOOR. BE SURE TO USE 5/32", X 3/8" (4 mm X 9.5 mm) RIVETS. IF A LONGER RIVET IS USED, IT MAY INTERFERE WITH THE BLEND DOOR TRAVEL AND CAUSE FURTHER PROBLEMS. 6. Run a bead of caulking cord along the underside of the door frame on the side nearest the evaporator core, from one corner to the other. a. Be sure to fill the corners. b. Use calking cord, Part No. (D6AZ-19560-A), (ESB-M4G32-A) or equivalent. NOTE: IT IS VERY IMPORTANT TO GET A GOOD SEAL BETWEEN THE DOOR FRAME AND THE EVAPORATOR CASE, TO PREVENT AIR LEAKAGE THROUGH THE HEATER CORE. NOTE: DO NOT USE SILICONE OR OTHER TYPES OF SEALANT THAT HAVE STRONG ODORS. THESE ODORS MAY ENTER THE PASSENGER COMPARTMENT DURING SYSTEM OPERATION. PART NUMBER PART NAME CLASS D6AZ-19560-A Rope Caulk (Pk./8) AG OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/93 Model Vehicles, Basic Warranty Coverage For All Other Model Vehicles OPERATION DESCRIPTION TIME 940209A Repair Blend Door Seal - 4.1 Hrs. ATC 940209B Repair Blend Door Seal - 4.2 Hrs. Manual DEALER CODING BASIC PART NO. CONDITION CODE 19D842 61 OASIS CODES: 208000, 208200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 92128 > Jun > 92 > A/C - Condensation Enters Passenger Compartment Evaporator Case: Customer Interest A/C - Condensation Enters Passenger Compartment Article No. 92-12-8 DATE: 06-03-92 AIR CONDITIONING-CONDENSATION (WATER DROPLETS) ENTERS INTO PASSENGER COMPARTMENT THROUGH FLOOR DUCTS FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR This TSB article is being republished in its entirety to extend the model year application through the 1993 model year. ISSUE: Water droplets in the air conditioning system may become airborne. Condensation forms into droplets which would follow the airstream as it flows through the system and out through the floor ducts into the passenger compartment. This occurs because there is a build-up of localized high velocity air in the evaporator case which moves water droplets toward the floor ducts. ACTION: Rework the evaporator case and install a baffle to prevent the build-up of high velocity air. Refer to the following procedure for modification and service details. BAFFLE INSTALLATION 1. Using aluminum plate stock about 1/16" (1.6) thick, make the baffle shown in Figure 1. a. The bend between the 5 1/4" (133mm) and the 1" (25.4mm) sides of the baffle is about 90 degree b. The two 3/16" (4.8mm) diameter holes in the 1" (25.4mm) side of the baffle are provided for attaching the part to the evaporator case. 2. Squeeze the sides of the glove compartment assembly toward the center of the compartment to gain access to the evaporator case. This will free the attaching tabs at the upper rear corners of the assembly and allow it to be hung free. 3. Working through the glove compartment opening, cut a 1/16" (1.6mm) wide by 2 1/2" long slot in the evaporator case. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 92128 > Jun > 92 > A/C - Condensation Enters Passenger Compartment > Page 6836 a. The size and location of the slot are shown in Figure 2. b. The centerline of the slot is located 1 3/4" (44.5mm) back from the edge of the case and 1/4" (6.4mm) below the underside of the flange in the case. c. Cut the slot into the case using a die grinder/cutting wheel or a series of drilled holes. CAUTION: WHEN SLIDING THE BAFFLE INTO THE SLOT, BE SURE THAT ITS ATTACHING FLANGE FACES TOWARD THE PASSENGER SIDE OF THE VEHICLE, FIGURE 2. IF THE FLANGE FACES TOWARD THE DRIVER'S SIDE, THE ATTACHING SCREWS COULD PUNCTURE THE EVAPORATOR CORE. 4. Install the two #10-12 X 1/2" self-tapping screws through the baffle and into the mating 3/16" (4.8mm) diameter holes which are to be made in the evaporator case using the baffle holes as a template. 5. Check the installation for vibration noise. a. Turn the blower speed selector knob to its high position. b. Operate the system in the MAX A/C, NORM A/C, and VENT function selections, c. If the vibration noise is detected in any of the three (3) functional selections, remove the baffle and bend it slightly to change the 90~angle at the bend. Make this change as the baffle is again being installed. 6. Check for any air leaks which may be caused by reworking the evaporator case. If any air leaks are located, seal them with black rope sealant (D6AZ-19560-A). WARNING: DO NOT USE A SILICONE SEALER BECAUSE IT COULD CAUSE EYE AND SKIN IRRITATION. 7. if sealing material is installed, check again for vibration noise. Refer to Step 5. 8. Install the glove compartment. 9. Test drive the vehicle. Include several right and hard left turns in the test to force any condensate, which may have accumulated in the case, to flow out through the floor ducts. NOTE: IF STEP 9 IS NOT TAKEN, SUBSEQUENT PASSING OF WATER DROPLETS FROM THE FLOOR DUCTS COULD BE A MISLEADING SIGN THAT ADDITION OF THE BAFFLE WAS AN INEFFECTIVE REPAIR. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 92128 > Jun > 92 > A/C - Condensation Enters Passenger Compartment > Page 6837 FOLLOW-UP REWORK OF THE EVAPORATOR CASE If the aluminum baffle, installed previously, does not stop the flow of airborne water droplets through the floor ducts, it will be necessary to remove the evaporator case from the vehicle and perform the following additional changes. NOTE: THE CUSTOMER SHOULD BE INFORMED BEFOREHAND THAT THERE WILL BE A NOTICEABLE DIFFERENCE IN THE TEMPERATURE OF THE AIR BEING DISCHARGED THROUGH THE INSTRUMENT PANEL REGISTERS LOCATED ON THE DRIVER'S SIDE OF THE VEHICLE VERSUS THOSE LOCATED ON THE PASSENGER'S SIDE. THIS TEMPERATURE DIFFERENCE COULD BE AS HIGH AS 20~ F. 1. Remove three (3) screws and pull the air inlet duct away from the evaporator case. 2. With a small saw, cut the top of the evaporator case between the dotted lines, Figure 2. 3. Remove the evaporator core from the case. 4. Cut the temperature door frame off as shown in Figure 3. NOTE: THIS CAN BE DONE BY USING A CUTOFF WHEEL OR HACKSAW BLADE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Customer Interest: > 92128 > Jun > 92 > A/C - Condensation Enters Passenger Compartment > Page 6838 5. Install two (2) pieces of 3/4"(19.05mm) x 3/4"(19.05mm) x 3"(76.2mm) stiff foam rubber (locally procured) inside the case in the locations shown in Figure 4. The purpose of these pieces is to shift the evaporator core as far as possible toward the passenger side of the vehicle. 6. Obtain a service cover (E9SZ-19B735-A) and hold it tightly against the case. Drill five (5) 3/16" (4.763mm) diameter attaching holes for the cover. 7. Install the evaporator core in the case. 8. Install the service cover using the five attaching screws provided in the service cover kit (E9SZ-19B735-A). Be sure to seal all holes in the case. Use caulking cord rope sealer (D6AZ19560-A). 9. Drill three (3) 1/4" (6.35mm) drain holes at the bottom edge of the small vertical wall in the evaporator case as shown in Figure 4. These holes will allow any water accumulation to drain back into the heater core area. CAUTION: DRILL THROUGH THE WALL, BUT DO NOT DRILL THROUGH THE BOTTOM OF THE EVAPORATOR CASE. 10. Install the evaporator case. 11. Test drive the vehicle. Include several right and hard left turns in the test to force any condensate which may have accumulated in the case to flow out through the floor ducts. PART NUMBER PART NAME CLASS D6AZ-19560-A Caulking Rope AG E9SZ- 19B735-A Service Cover Kit C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 92-3-1 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1992 And 1993 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 921208A Evaporator Case Rework 1.0 Hr. 921208B Evaporator Case Follow-up 4.5 Hrs. Rework (includes Evacuate, Recharge And Freon R-12 Recovery) DEALER CODING BASIC PART NO. CONDITION CODE 19850 08 OASIS CODES: 208000, 208300, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor Evaporator Case: All Technical Service Bulletins Air Conditioning - Water Drips On Floor Article No. 95-23-3 11/20/95 AIR CONDITIONING - WATER DRIPS ON FLOOR FROM EVAPORATOR WHEN BLOWER IS ON HIGH IN MAX A/C OR NORMAL A/C MODE FORD: 1989-95 THUNDERBIRD LINCOLN-MERCURY: 1989-95 COUGAR LIGHT TRUCK: 1995-96 EXPLORER, RANGER ISSUE: Water from condensation building on the evaporator core may drip onto the floor when the A/C blower is on HIGH and the A/C mode control is in MAX A/C or Normal A/C position. This may be caused by the evaporator core seals being misaligned. ACTION: For Ranger/Explorer, stretch and reposition the evaporator core seal. Refer to the Ranger/Explorer Service Procedure. For Thunderbird/Cougar, refer to the Thunderbird/Cougar Service Procedure. SERVICE PROCEDURE RANGER/EXPLORER 1. Check the evaporator drain tube for blockage. If blockage is present, clear the tube and recheck. 2. Remove the evaporator/blower case from the engine compartment following the procedures outlined in Section 12 of the 1995 Ranger/Explorer Service Manual. 3. Remove the service cover on the evaporator case. 4. Remove the evaporator core. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6844 5. Inspect the foam evaporator strip seals for proper positioning (Figure 1). 6. The seals are positioned on the blower wheel area as marked. There should be no gaps at either end of the seals. Witness marks should be present along the entire length of the seals. If no marks are present then the seals need to be repositioned to provide a better seal. Wipe out any excess moisture and reinstall evaporator core and case assembly. 7. Verify the repair. DIAGNOSTIC TIPS THUNDERBIRD/COUGAR The first thing to do when repairing a water leak is to determine the root cause of the leak. Ford has noted a number of different locations where water leak issues can arise on the Thunderbird/Cougar. Refer to the following list when addressing a water leak concern. Water may come from the outside of the vehicle as well as the evaporator case. Always check the evaporator drain for blockage prior to performing any of these steps. The following is a list of areas where a water leak is possible: 1. Water dripping from the floor ducts when the A/C is operating on vehicles built Job 1, 1989 through 10/15/93 are most likely exhibiting a Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6845 condensate carryover from the evaporator core. Refer to TSB 94-2-12 for Service Procedures on this concern. 2. Water dripping onto the floor in vehicles built after 10/15/93 or in vehicles built prior to that date which have been serviced following TSB 94-2-12 may have condensate leaking from one (1) of the following places (refer to Figure 2): a. The evaporator tube seal. Condensate forms on the liquid line inside the evaporator case. When the blower motor is operated on HIGH, condensate is blown against the inside of the seal and eventually leaks from the case. Condensate droplets will fall on the passenger side, just above the carpeting on the sound absorber. In very high humidity, this leak may appear within 10-15 minutes of A/C system start-up. A leaking seal can be observed in the vehicle with the use of an inspection mirror. Leakage from this area and area b described next, may be significant enough to saturate the carpeting over a long period of time. b. Case seam near evaporator tube seal. There is a seam between the upper and lower case halves adjacent to the recirc door linkage. This seam may not be adequately welded during assembly. When this occurs, condensate may leak from the case in this area. The seam is not visible when the evaporator is assembled in the vehicle. It is difficult to determine between leaks from this source, or source a, above. Generally, Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6846 leaks from this source may wet the recirc door vacuum motor, while leaks from source a, above, fall directly onto the sound absorber. c. Heater core cover seal. This foam seal may become saturated with condensate and drip on the passenger 5 feet. The source of this condensate leakage is visible through the glove compartment opening. Condensate leaking from this area may fall near the floor ducts, giving the mistaken impression that condensate is dripping from that duct. The volume of condensate from this location is usually low, typically about one (1) drop every several minutes. 3. Water accumulating on the floor can come from these other sources not related to evaporator core condensate. a. Water may enter the vehicle around the evaporator drain seal from the outside due to the lower evaporator case-to-dash mounting stud not being properly torqued. b. Water may leak into the passenger side kick panel on 1994 and 1995 models built through 8/10/94 due to insufficient body sealing in the right A-pillar/cowl area. If the kick panel area does not drain this water due to rustproofing or debris, the water can potentially build up and reach the carpet, or the water may find a path to flow onto the carpet when making its way down from the cowl area. This leak source is very rare and is outlined in TSB 94-22-5 for other wiring corrosion concerns. SERVICE PROCEDURE THUNDERBIRD/COUGAR 1. Diagnosis # 1. Condensate carryover. Follow the Service Procedures listed in TSB 94-2-12. 2. Diagnosis # 2a and 2b. Evaporator tube seal or case seam near evaporator tube seal. Repair as follows: a. Remove the evaporator case from the vehicle as outlined in the appropriate Service Manual, Section 12. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6847 b. Remove the evaporator tube seal from the case (Figure 3). c. Cut away the portion of the liquid line clip that extends outside of the case. d. Apply a generous bead of RTV sealant to the inside of the case as shown in Figure 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6848 e. Apply a generous bead of RTV to the evaporator tube seal as shown in Figure 4. f. Reinstall the evaporator tube seal being careful to ensure the RTV seals around the entire perimeter of the seal. g. Apply a bead of RTV around the perimeter of the seal where it meets the case. h. Allow the RTV to fully cure before reinstalling the case. Take care not to disturb the seal during installation of the case. 3. Diagnosis # 2c. Heater core cover seal. a. Remove the heater core cover and seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6849 b. Cut the seal as shown in Figure 6. This prevents the seal from extending beyond the cover and interfering with the RTV. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6850 c. Apply a bead of RTV to the heater core cover along the inside face as indicated in Figure 5. d. Reinstall heater core cover seal and heater core cover. e. Apply a bead of RTV between the heater core cover and the case. 4. Diagnosis # 3a. Loose lower mounting stud. a. Tighten nut as required. 5. Diagnosis # 3b. Water in passenger side kick panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6851 a. Follow the Service Procedures listed in TSB 94-22-5. OTHER APPLICABLE ARTICLES: 94-2-12, 94-22-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Base Warranty Coverage For All Others OPERATION DESCRIPTION TIME 952303A Stretch And Reposition 2.5 Hrs. Evaporator Core Seals - 1995-96 Ranger/Explorer 952303B Condensate Carryover - Refer 1989-95 To TSB Thunderbird/Cougar 94-2-12 952303C Evaporator Tube Seal And 2.7 Hrs. Leaky Seam Repair - 1989-95 Thunderbird/Cougar 952303D Heater Core Cover Seal 2.2 Hrs. Repair - 1989-95 Thunderbird/Cougar 952303E Lower Mounting Stud 0.2 Hr. Retighten - 1989-95 Thunderbird/Cougar 952303F Water In Passenger Side Refer Kick Panel Repair - To TSB 1989-95 Thunderbird/Cougar 94-22-5 DEALER CODING CONDITION BASIC PART NO. CODE 19850 36 OASIS CODES: 110000, 208000, 208300, 208400, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94114 > Jun > 94 > A/C - Evaporator Core and Case Assembly Application Evaporator Case: All Technical Service Bulletins A/C - Evaporator Core and Case Assembly Application Article No. 94-11-4 06/01/94 AIR CONDITIONING - EVAPORATOR CORE AND CASE ASSEMBLY APPLICATION FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR 1993-94 MARK VIII ISSUE: A service replacement A/C evaporator core/case usage chart is available. ACTION: Refer to the usage chart for correct evaporator core/case application. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts Evaporator Case: All Technical Service Bulletins A/C - Water Leaks From the Floor Ducts Article No. 94-2-12 01/26/94 AIR CONDITIONING - WATER DRIPS FROM THE FLOOR DUCTS WHEN A/C IS OPERATING VEHICLES BUILT FROM JOB-1 1989 THROUGH 10/15/93 FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR ISSUE: Condensation may drip from the floor duct when the A/C is operating. This occurs because the location of the evaporator core inside the housing allows high velocity air to carry water droplets from the core face beyond the sump area in the housing. ACTION: Replace the evaporator core and housing assembly with a new assembly which has a relocated evaporator core that allows the condensate to drain into the sump area of the housing rather than into the passenger compartment. Refer to the following procedure for service details. NOTE: USE PROCEDURE # 1 FOR 1994 MODELS ONLY AND USE PROCEDURE # 2 FOR 1989-93 MODELS. CAUTION: OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS WHILE PERFORMING THE FOLLOWING SERVICE PROCEDURE. PROCEDURE # 1 - 1994 MODELS BUILT BEFORE 10/15/93 ONLY NOTE: THIS VEHICLE USES THE NON-CHLOROFLUOROCARBON (NON-CFC) BASED REFRIGERANT R-134a. R-134a A/C SYSTEMS REQUIRE THE USE OF SPECIAL SERVICING EQUIPMENT DESIGNED SPECIALLY FOR SERVICING R-134a A/C SYSTEMS CAUTION: DO NOT USE R-12 SPECIAL TOOLS AND EQUIPMENT WHEN SERVICING AN R-134a SYSTEM. DOING SO MAY CAUSE DAMAGE TO THE A/C SYSTEM. REFER TO THE ROTUNDA CATALOG FOR MORE INFORMATION ON R-134a SPECIAL SERVICING EQUIPMENT. 1. Record radio stations. 2. Disconnect battery ground cable. Disconnect positive battery and wait one (1) minute for the air bag diagnostic monitor to deplete the air bag back-up power supply. Refer to Service Manual Section 01-20B. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6860 3. Loosen main wiring connector bolt in engine compartment at LH side of dash panel and separate connectors, Figure 1. 4. Remove the radio antenna through the right front wheel well. Disengage the antenna wire grommet from the sheet metal and push the antenna lead-in cable through the sheet metal into vehicle interior. 5. Remove the screws retaining the RH and LH scuff plates (do not remove the scuff plates from the vehicle). Lift scuff plates and remove door opening weatherstrips from body flanges. 6. Remove both RH and LH windshield side garnish moldings. 7. Remove both RH and LH cowl side trim panels. 8. Remove instrument panel steering column cover: a. remove the three (3) screws along the bottom b. pull on cover to unsnap the three (3) clips across the top. 9. Remove one (1) screw and A/C evaporator register duct from under the steering column tube. 10. Disconnect the electrical connectors at the base of the steering column. 11. Remove the pinch bolt attaching the steering column tube to steering column lower yoke and slightly spread the joint with a screwdriver. 12. Disconnect the multi-function switch connector located under the column assembly. 13. Disconnect the ignition switch connector. 14. While supporting the steering column tube, remove the four (4) steering column tube retaining nuts. 15. Lower steering column and remove shift interlock cable retaining screws and shift actuator cable fitting. Disconnect the electrical connector from shift interlock solenoid. 16. Remove steering column from the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6861 17. Disconnect stop lamp switch, Figure 2. 18. Pull back the floor carpet as required on the RH and LH sides of the vehicle and disconnect the window regulator safety switch connector and the Powertrain Control Module connector. 19. Remove glove compartment: a. Open glove compartment to the stop. b. Unsnap the hydraulic lift from the right side of the glove compartment. c. Remove the three (3) screws at the bottom retaining the glove compartment door hinge and glove compartment to the instrument panel. d. Remove glove compartment from the instrument panel. 20. Reach through the glove compartment opening and disconnect the electrical and vacuum connectors from the heater-A/C evaporator housing. 21. Disconnect the connectors behind the RH kick panel, Figure 3. 22. Disconnect the two (2) speed control amplifier connectors. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6862 23. Remove floor console panel. Refer to the 1994 Thunderbird/Cougar Service Manual, Section 01-12-4 and 01-12-5. NOTE: PROTECT THE INSTRUMENT PANEL SURFACE DURING THE FOLLOWING PROCEDURE. 24. Remove two (2) nuts and one (1) bolt from the instrument panel-to-console mount, Figure 4. 25. Remove two (2) nuts retaining the LH side of instrument panel to cowl side, Figure 4. 26. Remove the nut attaching the RH side of instrument panel to cowl side, Figure 4. NOTE: THE FOLLOWING THREE STEPS REQUIRE TWO TECHNICIANS. 27. Remove 6 bolts from the top of the instrument panel, Figure 4. 28. Carefully pull the instrument panel away from windshield glass, checking for and disconnecting any remaining wiring connectors. 29. Remove the instrument panel from the vehicle. 30. Recover the R-134a refrigerant from the A/C system at the service access gauge port valve, following the proper recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 31. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 32. Place a drain pan or suitable container under heater hose connections at the cowl panel. 33. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 34. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 35. Remove the suction accumulator drier from its bracket then remove the bracket. 36. Remove the three (3) retaining nuts attaching the evaporator housing to the cowl panel (under the hood). 37. Remove one (1) screw at the base of the evaporator housing and one (1) screw at the evaporator housing-to-cowl panel bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6863 38. Remove the evaporator housing from the vehicle. 39. Transfer the parts from the removed evaporator assembly to the new service evaporator assembly, based on the type of system in the vehicle. See illustrations. 40. Install the evaporator case and instrument panel in the vehicle by reversing the removal procedure. 41. Refill coolant and check for leaks. 42. Recharge the A/C system and check the operation of the system. 43. Reset radio stations recorded in step # 1. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. PROCEDURE # 2 - 1989-93 MODELS NOTE: AUTOMATIC TEMPERATURE CONTROL - EQUIPPED UNITS BUILT BEFORE 7/1/92 WILL REQUIRE A NEW ASPIRATOR ASSEMBLY (F4SZ-19E628-A) ALONG WITH THE NEW EVAPORATOR CASE ASSEMBLY. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6864 CAUTION: OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS WHILE PERFORMING THE FOLLOWING SERVICE PROCEDURE. 1. Record radio stations. 2. Disconnect battery ground cable. 3. Remove steering column lower trim cover. (Remove three (3) screws at bottom, one (1) screw LH side and pull to disengage five (5) snap-in retainers across top). 4. Remove steering column lower opening reinforcement. Six (6) screws retain reinforcement to instrument panel. 5. Remove steering column upper and lower shrouds. 6. Disconnect wiring from steering column. 7. Remove shift interlock switch, if equipped. 8. Disconnect steering column lower universal joint. 9. Support steering column and remove four (4) nuts retaining column to support. Remove column from vehicle. 10. Remove one (1) nut retaining LH side of instrument panel to parking brake bracket. 11. Remove RH and LH side cowl trim panels. 12. Disconnect electrical connections at RH cowl side. 13. Remove two (2) instrument panel-to-floor tunnel nuts. 14. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor. 15. Disconnect wiring, heater and A/C vacuum lines and control cables through glove compartment opening. 16. Remove two (2) screws at RH side retaining instrument panel to cowl side. 17. Remove two (2) screws at LH side retaining instrument panel to cowl side. 18. Remove RH and LH finish panel by pulling up to disengage snap-in retainers, three (3) on RH side and four (4) on LH side. 19. Remove RH and LH roof rail trim panels. 20. Remove four (4) screws retaining instrument panel to cowl top. 21. Gently pull instrument panel away from RH side of cowl panel. 22. Place a drain pan or suitable container under heater hose connections at the cowl panel. 23. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the proper recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 24. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 25. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 26. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 27. Working under the hood, remove three (3) nuts retaining the evaporator case to the cowl panel. 28. Inside the passenger compartment, remove the screw attaching the evaporator case support bracket to the cowl top panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6865 29. Remove one (1) nut retaining the bracket below the evaporator case to the cowl panel. 30. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 31. Transfer the following parts from the removed evaporator assembly to the new service evaporator assembly, based on the type of system in the vehicle. NOTE: IF THE UNIT IS EQUIPPED WITH ATC AND WAS BUILT PRIOR TO 7/1/92, YOU WILL HAVE TO USE A NEW ASPIRATOR (F4SZ-19E628-A) THAT IS DESIGNED FOR THE NEW SERVICE CASE AND ELIMINATE THE OLD ASPIRATOR. CHANGE OVER TO THE NEW ASPIRATOR AS FOLLOWS: ^ TRANSFER THE GASKET FROM THE EXISTING ASPIRATOR ASSEMBLY PLATE TO THE BACK OF THE BLOWER SPEED CONTROLLER SO YOU WILL SEAL THE MATING SURFACE OF THE CONTROLLER TO THE CASE. INSTALL THE BLOWER SPEED CONTROLLER TO THE CASE WITHOUT THE OLD ASPIRATOR, MAKING CERTAIN THAT THE GASKET SEALS PROPERLY. ^ DISCARD THE EXISTING ASPIRATOR ASSEMBLY AND INSTALL THE NEW ASPIRATOR (F4SZ-19E628-A) IN THE UPPER CASE HALF, IN THE EXISTING HOLE NEXT TO THE MUFFLER ASSEMBLY, USING A SCREW (# 10-12X .75 HEX WASHER HEAD SELF-TAPPING); OBTAIN LOCALLY. ^ USING THE OLD ASPIRATOR CONNECTING TUBE, CUT IT TO SIZE (SHORTEN) AND INSTALL IT BETWEEN THE NEW ASPIRATOR AND THE MUFFLER. 32. Cut off the end of the drain tube located on the bottom of the evaporator case under the heater core area. Cut Off The End Of The Drain Tube, Do Not Drill. CAUTION: DO NOT DRILL OUT THE HOLE BECAUSE THE HEATER CORE COULD BE DAMAGED, FIGURE 5. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6866 Connect A Hose To The Drain Tube. 33. Connect a 1/2" (12.7 mm) outside diameter hose (E8UZ-19K592-A) to the drain tube using a small hose clamp (376240-S100), Figure 6. 34. Install the evaporator case in the vehicle by reversing the removal procedure. a. Drill a hole in the cowl panel to accommodate the new drain tube. See Figure 2 for location. The hole should be about 2" (50.8 mm) below the regular evaporator case drain tube. b. After the new drain tube is through the hole and in permanent position, seal around the tube with body sealer (F1AZ-19562-A). 35. Recharge the A/C system and check the operation of the system. 36. Reset radio stations recorded in step # 1. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. NOTE: IF EVAPORATOR CORE AND HOUSING ASSEMBLY IS REPLACED PER THIS TSB ARTICLE, IT WILL NOT BE NECESSARY TO PERFORM TSB 94-2-9. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 92-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Models; Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 940212A Remove And Replace 4.5 Hrs. Evaporator Case DEALER CODING BASIC PART NO. CONDITION CODE 19850 08 OASIS CODES: 208000, 208300, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9429 > Jan > 94 > Air Conditioning - Poor Performance Evaporator Case: All Technical Service Bulletins Air Conditioning - Poor Performance Article No. 94-2-9 01/26/94 AIR CONDITIONING - HIGH DISCHARGE TEMPERATURES - POOR A/C PERFORMANCE VEHICLES BUILT FROM JOB 1 1989 TO 11/30/92 FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR ISSUE: Poor A/C performance, high discharge temperatures, may be the result of incorrect welding of the temperature blend door. If this occurs, air flow from the evaporator will be allowed to leak through the heater core and poor A/C performance will result. ACTION: If the A/C system seems to be operating, but is not cooling the car properly, the temperature blend door frame could be incorrectly positioned. Follow the attached service procedure to position the blend door properly. NOTE: DO NOT PERFORM THIS PROCEDURE IF TSB 94-2-12 HAS BEEN PERFORMED. FOLLOW NORMAL DIAGNOSTICS FOR POOR A/C PERFORMANCE. Verify the condition by performing the following diagnosis: 1. Run the A/C with the control set at MAX A/C and the blower on high for 5 minutes. Record the discharge air temperature at the center instrument panel register. 2. Clamp off the heater core hoses and continue to operate the system at MAX A/C with high blower for 10 minutes to cool the heater core. 3. Continue to operate the system on MAX A/C and high blower and record the discharge air temperature at the center instrument panel register. If there is a decrease in temperature of 5~F. (3~ C.) from the original temperature check made in Step 1, there is a good chance of an incorrectly welded door frame. INCORRECTLY WELDED DOOR FRAME SERVICE PROCEDURE Correct the condition by performing the following repair: 1. Remove the evaporator case from the vehicle. Refer to the 1993 Thunderbird/Cougar Service Manual, page 12-03-23, for the removal procedure. 2. Remove the heater core from the evaporator case. The temperature blend door can now be visually checked for incorrect welding. 3. The door frame may be held away from a firm seat on the evaporator case by two or three of the plastic weld stakes (along the side closest to the evaporator core). If not secured, it will be loose at the corner closest to the heater core cover. 4. Remove the weld stakes so that the door frame fits flush with the evaporator case. This can be done using a utility knife or a saw blade. NOTE: BE SURE TO REMOVE ALL DEBRIS FROM THE CASE, AFTER THIS PROCESS, TO PREVENT VIBRATION NOISES FROM OCCURRING DURING SYSTEM OPERATION. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9429 > Jan > 94 > Air Conditioning - Poor Performance > Page 6871 5. Hold the blend door frame firmly down against the evaporator case and drill two 5/32" (4 mm) holes as shown in Figure 1. Holding the door frame firmly in position, install a 5/32" X 3/8" (4 mm X 9.5 mm) pop rivet in each hole. CAUTION: DO NOT USE SCREWS. THE SHARP POINT TENDS TO CATCH ON THE DOOR. BE SURE TO USE 5/32", X 3/8" (4 mm X 9.5 mm) RIVETS. IF A LONGER RIVET IS USED, IT MAY INTERFERE WITH THE BLEND DOOR TRAVEL AND CAUSE FURTHER PROBLEMS. 6. Run a bead of caulking cord along the underside of the door frame on the side nearest the evaporator core, from one corner to the other. a. Be sure to fill the corners. b. Use calking cord, Part No. (D6AZ-19560-A), (ESB-M4G32-A) or equivalent. NOTE: IT IS VERY IMPORTANT TO GET A GOOD SEAL BETWEEN THE DOOR FRAME AND THE EVAPORATOR CASE, TO PREVENT AIR LEAKAGE THROUGH THE HEATER CORE. NOTE: DO NOT USE SILICONE OR OTHER TYPES OF SEALANT THAT HAVE STRONG ODORS. THESE ODORS MAY ENTER THE PASSENGER COMPARTMENT DURING SYSTEM OPERATION. PART NUMBER PART NAME CLASS D6AZ-19560-A Rope Caulk (Pk./8) AG OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/93 Model Vehicles, Basic Warranty Coverage For All Other Model Vehicles OPERATION DESCRIPTION TIME 940209A Repair Blend Door Seal - 4.1 Hrs. ATC 940209B Repair Blend Door Seal - 4.2 Hrs. Manual DEALER CODING BASIC PART NO. CONDITION CODE 19D842 61 OASIS CODES: 208000, 208200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92128 > Jun > 92 > A/C - Condensation Enters Passenger Compartment Evaporator Case: All Technical Service Bulletins A/C - Condensation Enters Passenger Compartment Article No. 92-12-8 DATE: 06-03-92 AIR CONDITIONING-CONDENSATION (WATER DROPLETS) ENTERS INTO PASSENGER COMPARTMENT THROUGH FLOOR DUCTS FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR This TSB article is being republished in its entirety to extend the model year application through the 1993 model year. ISSUE: Water droplets in the air conditioning system may become airborne. Condensation forms into droplets which would follow the airstream as it flows through the system and out through the floor ducts into the passenger compartment. This occurs because there is a build-up of localized high velocity air in the evaporator case which moves water droplets toward the floor ducts. ACTION: Rework the evaporator case and install a baffle to prevent the build-up of high velocity air. Refer to the following procedure for modification and service details. BAFFLE INSTALLATION 1. Using aluminum plate stock about 1/16" (1.6) thick, make the baffle shown in Figure 1. a. The bend between the 5 1/4" (133mm) and the 1" (25.4mm) sides of the baffle is about 90 degree b. The two 3/16" (4.8mm) diameter holes in the 1" (25.4mm) side of the baffle are provided for attaching the part to the evaporator case. 2. Squeeze the sides of the glove compartment assembly toward the center of the compartment to gain access to the evaporator case. This will free the attaching tabs at the upper rear corners of the assembly and allow it to be hung free. 3. Working through the glove compartment opening, cut a 1/16" (1.6mm) wide by 2 1/2" long slot in the evaporator case. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92128 > Jun > 92 > A/C - Condensation Enters Passenger Compartment > Page 6876 a. The size and location of the slot are shown in Figure 2. b. The centerline of the slot is located 1 3/4" (44.5mm) back from the edge of the case and 1/4" (6.4mm) below the underside of the flange in the case. c. Cut the slot into the case using a die grinder/cutting wheel or a series of drilled holes. CAUTION: WHEN SLIDING THE BAFFLE INTO THE SLOT, BE SURE THAT ITS ATTACHING FLANGE FACES TOWARD THE PASSENGER SIDE OF THE VEHICLE, FIGURE 2. IF THE FLANGE FACES TOWARD THE DRIVER'S SIDE, THE ATTACHING SCREWS COULD PUNCTURE THE EVAPORATOR CORE. 4. Install the two #10-12 X 1/2" self-tapping screws through the baffle and into the mating 3/16" (4.8mm) diameter holes which are to be made in the evaporator case using the baffle holes as a template. 5. Check the installation for vibration noise. a. Turn the blower speed selector knob to its high position. b. Operate the system in the MAX A/C, NORM A/C, and VENT function selections, c. If the vibration noise is detected in any of the three (3) functional selections, remove the baffle and bend it slightly to change the 90~angle at the bend. Make this change as the baffle is again being installed. 6. Check for any air leaks which may be caused by reworking the evaporator case. If any air leaks are located, seal them with black rope sealant (D6AZ-19560-A). WARNING: DO NOT USE A SILICONE SEALER BECAUSE IT COULD CAUSE EYE AND SKIN IRRITATION. 7. if sealing material is installed, check again for vibration noise. Refer to Step 5. 8. Install the glove compartment. 9. Test drive the vehicle. Include several right and hard left turns in the test to force any condensate, which may have accumulated in the case, to flow out through the floor ducts. NOTE: IF STEP 9 IS NOT TAKEN, SUBSEQUENT PASSING OF WATER DROPLETS FROM THE FLOOR DUCTS COULD BE A MISLEADING SIGN THAT ADDITION OF THE BAFFLE WAS AN INEFFECTIVE REPAIR. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92128 > Jun > 92 > A/C - Condensation Enters Passenger Compartment > Page 6877 FOLLOW-UP REWORK OF THE EVAPORATOR CASE If the aluminum baffle, installed previously, does not stop the flow of airborne water droplets through the floor ducts, it will be necessary to remove the evaporator case from the vehicle and perform the following additional changes. NOTE: THE CUSTOMER SHOULD BE INFORMED BEFOREHAND THAT THERE WILL BE A NOTICEABLE DIFFERENCE IN THE TEMPERATURE OF THE AIR BEING DISCHARGED THROUGH THE INSTRUMENT PANEL REGISTERS LOCATED ON THE DRIVER'S SIDE OF THE VEHICLE VERSUS THOSE LOCATED ON THE PASSENGER'S SIDE. THIS TEMPERATURE DIFFERENCE COULD BE AS HIGH AS 20~ F. 1. Remove three (3) screws and pull the air inlet duct away from the evaporator case. 2. With a small saw, cut the top of the evaporator case between the dotted lines, Figure 2. 3. Remove the evaporator core from the case. 4. Cut the temperature door frame off as shown in Figure 3. NOTE: THIS CAN BE DONE BY USING A CUTOFF WHEEL OR HACKSAW BLADE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92128 > Jun > 92 > A/C - Condensation Enters Passenger Compartment > Page 6878 5. Install two (2) pieces of 3/4"(19.05mm) x 3/4"(19.05mm) x 3"(76.2mm) stiff foam rubber (locally procured) inside the case in the locations shown in Figure 4. The purpose of these pieces is to shift the evaporator core as far as possible toward the passenger side of the vehicle. 6. Obtain a service cover (E9SZ-19B735-A) and hold it tightly against the case. Drill five (5) 3/16" (4.763mm) diameter attaching holes for the cover. 7. Install the evaporator core in the case. 8. Install the service cover using the five attaching screws provided in the service cover kit (E9SZ-19B735-A). Be sure to seal all holes in the case. Use caulking cord rope sealer (D6AZ19560-A). 9. Drill three (3) 1/4" (6.35mm) drain holes at the bottom edge of the small vertical wall in the evaporator case as shown in Figure 4. These holes will allow any water accumulation to drain back into the heater core area. CAUTION: DRILL THROUGH THE WALL, BUT DO NOT DRILL THROUGH THE BOTTOM OF THE EVAPORATOR CASE. 10. Install the evaporator case. 11. Test drive the vehicle. Include several right and hard left turns in the test to force any condensate which may have accumulated in the case to flow out through the floor ducts. PART NUMBER PART NAME CLASS D6AZ-19560-A Caulking Rope AG E9SZ- 19B735-A Service Cover Kit C OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 92-3-1 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1992 And 1993 Models, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 921208A Evaporator Case Rework 1.0 Hr. 921208B Evaporator Case Follow-up 4.5 Hrs. Rework (includes Evacuate, Recharge And Freon R-12 Recovery) DEALER CODING BASIC PART NO. CONDITION CODE 19850 08 OASIS CODES: 208000, 208300, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 891713 > Aug > 89 > A/C - Service Replacement Kits Evaporator Case: All Technical Service Bulletins A/C - Service Replacement Kits AIR CONDITIONING - SERVICE REPLACEMENT KITS Article No. 89-17-13 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Service replacement kits for evaporator cores and evaporator cases, including case covers, are now available. An evaporator core cover must be used to seal the opening made in the top of the case when a core is replaced. ACTION: If service is required, refer to the 1989 Thunderbird/Cougar Shop Manual, Section 36-45. Also use the following supplemental service procedure. NOTE: WHENEVER THE EVAPORATOR CORE IS REPLACED, THE A/C ACCUMULATOR MUST ALSO BE REPLACED. Figure 1 1. Remove the evaporator assembly from the vehicle. 2. Cut the top out of the evaporator case. Use a small saw to cut between the dotted lines as shown in Figure 1. If a new evaporator case and cover kit is being installed, cut the top out of the new evaporator case by using the same method. 3. Remove the old evaporator core from the case. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 891713 > Aug > 89 > A/C - Service Replacement Kits > Page 6883 Figure 2 4. Remove all burrs from the sawed edges of the evaporator case. 5. Position the new cover on the case. 6. Hold the cover in place and drill five 3/16" (7.938 mm) diameter holes for the attaching screws. 7. Install the new evaporator core in the evaporator case. If a new evaporator case and cover kit is being installed, transfer all hardware (evaporator core, heater core, vacuum motors, etc.) from the old evaporator case to the new case. 8. Run a bead of caulking cord rope sealer (D6AZ-19560-A), or equivalent, around the sawed edges of the evaporator case for a tight seal between the cover and the case. 9. Install the service cover on the evaporator case as shown in Figure 2. 10. Tighten the five attaching screws. 11. Install the evaporator case in the vehicle. PART NUMBER PART NAME CLASS E9SZ-19860-B Evaporator Core And Cover Kit B E9SZ-19850-B Evaporator Case And Cover Kit C E9SZ-19B735-A Evaporator Cover B D6AZ-19560-A Caulking Cord Rope Sealer - AG Pkg. of 8 E9SZ-19C836-A Accumulator - 3.8L Base C E9SZ-19C836-B Accumulator - 3.8L C Supercharged OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610, 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Case: > 97811 > Apr > 97 > Rear Axle - Whining/Howling Noise Pinion Gear: All Technical Service Bulletins Rear Axle - Whining/Howling Noise Article No. 97-8-11 04/14/97 ^ NOISE - "WHINING/HOWLING" FROM REAR AXLE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION ^ REAR AXLE - "WHINING/HOWLING" NOISE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION FORD: 1989-96 THUNDERBIRD LINCOLN-MERCURY: 1989-96 COUGAR ISSUE: Some vehicles may exhibit a rear axle "whining" or "howling" noise. This noise may be audible during light throttle at speeds between 56-72 km/h (35-45 mph) or at highway speeds during acceleration or deceleration. This may be due to the ring and pinion gear set. ACTION: Select the appropriate ring and pinion set from the Parts Block listed below and replace the ring and pinion set. The revised ring and pinion should reduce the possibility of noise. Refer to the appropriate year Thunderbird/cougar Service Manual and the following text for removal and installation procedures. REAR AXLE ASSEMBLY IDENTIFICATION Refer to the metal service identification tag for the rear axle ring gear size, ratio and differential type (Traction-Lok or conventional). The identification tag is attached to the rear axle cover by a cover bolt. CAUTION: SHEET MOLDING COMPOSITE (SMC) PLASTIC REAR AXLE COVERS CANNOT BE REUSED AFTER REMOVAL. A NEW COVER SHOULD BE ORDERED AS SOON AS POSSIBLE TO COMPLETE THE REPAIR ON A TIMELY BASIS. CAUTION: BE SURE TO MARK THE DRIVESHAFT IN RELATION TO THE COMPANION FLANGE SO IT MAY BE REINSTALLED IN ITS ORIGINAL POSITION. CAUTION: DIFFERENTIAL BEARING CAPS MUST BE INSTALLED IN THEIR ORIGINAL POSITIONS AND LOCATIONS AT ASSEMBLY TIME. CAUTION: IF LOOSENED, REMOVED OR DAMAGED, THE SPEED SENSOR RING CANNOT BE REUSED AND MUST BE REPLACED. NOTE: BE SURE TO FILL THE AXLE WITH MOTORCRAFT SAE 80W90 PREMIUM REAR AXLE LUBRICANT (XY-80W90-QL) TO THE LEVEL SPECIFIED IN THE SERVICE MANUAL. FOR TRACTION-LOK DIFFERENTIALS, ADD 118 mL (4 OZ) OF ADDITIVE FRICTION MODIFIER (C8AZ-19B546-A). ROAD TEST THE VEHICLE. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Case: > 97811 > Apr > 97 > Rear Axle - Whining/Howling Noise > Page 6889 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Powertrain Warranty Coverage For 1989-91 Vehicles OPERATION DESCRIPTION TIME 970811A Install New Gear Set 2.5 Hrs. (Includes Drain And Refill DEALER CODING CONDITION BASIC PART NO. CODE 4209 56 OASIS CODES: 509000, 597997, 702200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Case: > 97811 > Apr > 97 > Rear Axle - Whining/Howling Noise > Page 6895 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Powertrain Warranty Coverage For 1989-91 Vehicles OPERATION DESCRIPTION TIME 970811A Install New Gear Set 2.5 Hrs. (Includes Drain And Refill DEALER CODING CONDITION BASIC PART NO. CODE 4209 56 OASIS CODES: 509000, 597997, 702200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Page 6896 Evaporator Case: Service and Repair ***THIS ARTICLE INCLUDES UPDATES MADE BY TSB #94-2-12, DATED JANUARY 26, 1994*** NOTE: Replace the evaporator core and housing assembly with a new assembly which has a relocated evaporator core that allows the condensate to drain into the sump area of the housing rather than into the passenger compartment. Refer to the following procedure for service details. NOTE: Automatic Temperature Control (ATC) equipped units built before 7/1/92 will require a new aspirator assembly (F4SZ-19E628-A) along with the new evaporator case assembly. CAUTION: Observe all safety and service precautions while performing the following service procedure. 1. Record radio stations. 2. Disconnect battery ground cable. 3. Remove steering column lower trim cover. (Remove three (3) screws at bottom, one (1) screw LH side and pull to disengage five (5) snap-in retainers across top). 4. Remove steering column lower opening reinforcement. Six (6) screws retain reinforcement to instrument panel. 5. Remove steering column upper and lower shrouds. 6. Disconnect wiring from steering column. 7. Remove shift interlock switch, if equipped. 8. Disconnect steering column lower universal joint. 9. Support steering column and remove four (4) nuts retaining column to support. Remove column from vehicle. 10. Remove one (1) nut retaining LH side of instrument panel to parking brake bracket. 11. Remove RH and LH side cowl trim panels. 12. Disconnect electrical connections at RH cowl side. 13. Remove two (2) instrument panel-to-floor tunnel nuts. 14. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor. 15. Disconnect wiring, heater and A/C vacuum lines and control cables through glove compartment opening. 16. Remove two (2) screws at RH side retaining instrument panel to cowl side. 17. Remove two (2) screws at LH side retaining instrument panel to cowl side. 18. Remove RH and LH finish panel by pulling up to disengage snap-in retainers, three (3) on RH side and four (4) on LH side. 19. Remove RH and LH roof rail trim panels. 20. Remove four (4) screws retaining instrument panel to cowl top. 21. Gently pull instrument panel away from RH side of cowl panel. 22. Place a drain pan or suitable container under heater hose connections at the cowl panel. 23. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the proper recovery procedure. CAUTION: Observe all safety precautions. 24. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 25. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 26. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 27. Working under the hood, remove three (3) nuts retaining the evaporator case to the cowl panel. 28. Inside the passenger compartment, remove the screw attaching the evaporator case support bracket to the cowl top panel. 29. Remove one (1) nut retaining the bracket below the evaporator case to the cowl panel. 30. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 31. Transfer the following parts from the removed evaporator assembly to the new service evaporator assembly, based on the type of system in the vehicle. NOTE: If the unit is equipped with ATC and was built prior to 7/1/92, you will have to use a new aspirator (F4SZ-19E628-A) that is designed for the new service case and eliminate the old aspirator. Change over to the new aspirator as follows: a. Transfer the gasket from the existing aspirator assembly plate to the back of the blower speed controller so you will seal the mating surface of the controller to the case. Install the blower speed controller to the case without the old aspirator, making certain that the gasket seals properly. b. Discard the existing aspirator assembly and install the new aspirator (F4SZ-19E628-A) in the upper case half, in the existing hole next to the muffler assembly, using a screw (# 10-12x .75 hex washer head self-tapping); obtain locally. c. Using the old aspirator connecting tube, cut it to size (shorten) and install it between the new aspirator and the muffler. 32. Cut off the end of the drain tube located on the bottom of the evaporator case under the heater core area. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical Service Bulletins > Page 6897 Cut Off The End Of The Drain Tube, Do Not Drill. CAUTION: Do not drill out the hole because the heater core could be damaged, Figure 5. Connect A Hose To The Drain Tube. 33. Connect a 1/2" (12.7 mm) outside diameter hose (E8UZ-19K592-A) to the drain tube using a small hose clamp (376240-S100), Figure 6. 34. Install the evaporator case in the vehicle by reversing the removal procedure. a. Drill a hole in the cowl panel to accommodate the new drain tube. See Figure 6 for location. The hole should be about 2" (50.8 mm) below the regular evaporator case drain tube. b. After the new drain tube is through the hole and in permanent position, seal around the tube with body sealer (F1AZ-19562-A). 35. Recharge the A/C system and check the operation of the system. 36. Reset radio stations recorded in step # 1. NOTE: Check the operation of all components after assembly is completed. NOTE: If evaporator core and housing assembly is replaced per this TSB article, it will not be necessary to perform TSB 94-2-9. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor Technical Service Bulletin # 98-18-14 Date: 980914 A/C Evaporator Core - Water Drips Onto Floor Article No. 98-18-14 09/14/98 AIR CONDITIONING - WATER DRIPS ON FLOOR FROM EVAPORATOR WHEN BLOWER IS ON HIGH IN MAX A/C OR NORMAL A/C MODE FORD: 1989-97 THUNDERBIRD LINCOLN-MERCURY: 1989-97 COUGAR LIGHT TRUCK: 1995-96 EXPLORER, RANGER This TSB article is being republished in its entirety to include 1997 Thunderbird and Cougar vehicles, and to revise the Labor Operation Descriptions. ISSUE Water from condensation building on the evaporator core may drip onto the floor when the A/C blower is on HIGH and the A/C mode control is in MAX A/C or Normal A/C position. This may be caused by the evaporator core seals being misaligned. ACTION For Ranger/Explorer, stretch and reposition the evaporator core seal. Refer to the following Ranger/Explorer Service Procedure. For Thunderbird/Cougar, refer to the following Thunderbird/Cougar Diagnostic Tips and Service Procedure. PART NUMBER PART NAME F5TZ-19G204-AB RTV Silicone Sealant OTHER APPLICABLE ARTICLES: 94-2-12, 94-22-5 SUPERSEDES: 96-12-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-97 Model Year Vehicles, Base Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 981814A Stretch And Reposition 2.5 Hrs. Evaporator Core Seals - 1995-96 Ranger/Explorer 981814B Condensate Carryover - Refer 1989-94 To TSB Thunderbird/Cougar 94-2-12 981814C Evaporator Tube Seal And 2.7 Hrs. Leaky Seam Repair 1989-97 Thunderbird/Cougar 981814D Heater Core Cover Seal 2.2 Hrs. Repair - 1989-97 Thunderbird/Cougar 981814E Lower Mounting Stud 0.2 Hr. Retighten - 1989-97 Thunderbird/Cougar Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6906 981814F Water In Passenger Side Refer Kick Panel Repair - To TSB 1994-95 94-22-5 Thunderbird/Cougar DEALER CODING CONDITION BASIC PART NO. CODE 19850 07 OASIS CODES: 110000, 208000, 208300, 208400, 208999 Ranger/Explorer 1. Check the evaporator drain tube for blockage. If blockage is present, clear the tube and recheck. 2. Remove the evaporator/blower case from the engine compartment following the procedures outlined in Section 12 of the 1995 Ranger/Explorer Service Manual. 3. Remove the service cover on the evaporator case. 4. Remove the evaporator core. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6907 5. Inspect the foam evaporator core seals for proper positioning (Figure 1). 6. The seals are positioned on the blower wheel area as marked. There should be no gaps at either end of the seals. Witness marks should be present along the entire length of the seals. If no marks are present then the seals need to be repositioned to provide a better seal. Wipe out any excess moisture and reinstall evaporator core and case assembly. 7. Verify the repair. Thunderbird/Cougar 1. Diagnosis # 1. Condensate carryover. Follow the Service Procedures listed in TSB 94-2-12. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6908 2. Diagnosis # 2a and 2b. Evaporator tube seal or case seam near evaporator tube seal. Repair as follows: a. Remove the evaporator case from the vehicle as outlined in the appropriate model/year Service Manual, Section 12. b. Remove the evaporator tube seal from the case (Figure 3). c. Cut away the portion of the liquid line clip that extends outside the case (Figure 3). d. Apply a generous bead of RTV Silicone Sealant (F5TZ-19G204-AB) to the inside of the case as shown in Figure 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6909 e. Apply a generous bead of RTV Silicone Sealant to the evaporator tube seal as shown in Figure 4. f. Reinstall the evaporator tube seal being careful to make sure the RTV seals around the entire perimeter of the seal. 9. Apply a bead of RTV Silicone Sealant around the perimeter of the seal where it meets the case. h Allow the RTV to fully cure before reinstalling the case. Take care not to disturb the seal during installation of the case. 3. Diagnosis # 2c. Heater core cover seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6910 a. Remove the heater core cover and seal. b. Cut the seal as shown in Figure 6. This prevents the seal from extending beyond the cover and interfering with the RTV. c. Apply a bead of RTV Silicone Sealant to the heater core cover along the inside face as indicated in Figure 5. d. Reinstall heater core cover seal and heater core cover. e. Apply a bead of RTV Silicone Sealant between the heater core cover and the case. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6911 4. Diagnosis # 3a. Loose lower mounting stud. a. Tighten nut as required. 5. Diagnosis # 3b. Water in passenger side kick panel. a. Follow the Service Procedures listed in TSB 94-22-5. Diagnostic Tips The first thing to do when repairing a water leak is to determine the root cause of the leak. Ford Motor Company has noted a number of different locations where water leak issues can arise on the Thunderbird/Cougar. Refer to the following list when addressing a water leak concern. Water may come from the outside of the vehicle as well as the evaporator case. Always check the evaporator drain for blockage prior to performing any of these steps. The following is a list of areas where a water leak is possible: 1. Water dripping from the floor ducts when the A/C is operating on vehicles built Job 1, 1989 through 10/15/93 are most likely exhibiting a condensate carryover from the evaporator core. Refer to TSB 94-2-12 for Service Procedures on this concern. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6912 2. Water dripping onto the floor in vehicles built after 10/15/93 or in vehicles built prior to that date which have been serviced following TSB 94-2-12 may have condensate leaking from one (1) of the following sites (refer to Figure 2): a. The evaporator tube seal. Condensate forms on the liquid line inside the evaporator case. When the blower motor is operated on HIGH, condensate is blown against the inside of the seal and eventually leaks from the case. Condensate droplets will fall on the passenger side, just above the carpeting on the sound absorber. In very high humidity, this leak may appear within 10-15 minutes of A/C system start-up. A leaking seal can be observed in the vehicle with the use of an inspection mirror. Leakage from this area and area b described next, may be significant enough to saturate the carpeting over a long period of time. b. Case seam near evaporator tube seal. There is a seam between the upper and lower case halves adjacent to the recirc door linkage This seam may not be adequately welded during assembly When this occurs, condensate may leak from the case in this area. The seam is not visible Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6913 when the evaporator is assembled in the vehicle It is difficult to determine between leaks from this source, or source a, above. Generally, leaks from this source may wet the recirc door vacuum motor, while leaks from source a, above, fall directly onto the sound absorber. c. Heater core cover seal. This foam seal may become saturated with condensate and drip on the passenger's feet. The source of this condensate leakage is visible through the glove compartment opening. Condensate leaking from this area may fall near the floor ducts, giving the mistaken impression that condensate is dripping from that duct. The volume of condensate from this location is usually low, typically about one (1) drop every several minutes. 3. Water accumulating on the floor can come from these other sources not related to evaporator core condensate. a. Water may enter the vehicle around the evaporator drain seal from the outside due to the lower evaporator case-to-dash mounting stud not being properly torqued. b. Water may leak into the passenger side kick panel on 1994 and 1995 models built through 8/10/94 due to insufficient body sealing in the right A-pillar/cowl area. If the kick panel area does not drain this water due to rustproofing or debris, the water can potentially build up and reach the carpet, or the water may find a path to flow onto the carpet when making its way down from the cowl area. This leak source is very rare and is outlined in TSB 94-22-5 for other wiring corrosion concerns. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor Evaporator Core: Customer Interest Air Conditioning - Water Drips On Floor Article No. 95-23-3 11/20/95 AIR CONDITIONING - WATER DRIPS ON FLOOR FROM EVAPORATOR WHEN BLOWER IS ON HIGH IN MAX A/C OR NORMAL A/C MODE FORD: 1989-95 THUNDERBIRD LINCOLN-MERCURY: 1989-95 COUGAR LIGHT TRUCK: 1995-96 EXPLORER, RANGER ISSUE: Water from condensation building on the evaporator core may drip onto the floor when the A/C blower is on HIGH and the A/C mode control is in MAX A/C or Normal A/C position. This may be caused by the evaporator core seals being misaligned. ACTION: For Ranger/Explorer, stretch and reposition the evaporator core seal. Refer to the Ranger/Explorer Service Procedure. For Thunderbird/Cougar, refer to the Thunderbird/Cougar Service Procedure. SERVICE PROCEDURE RANGER/EXPLORER 1. Check the evaporator drain tube for blockage. If blockage is present, clear the tube and recheck. 2. Remove the evaporator/blower case from the engine compartment following the procedures outlined in Section 12 of the 1995 Ranger/Explorer Service Manual. 3. Remove the service cover on the evaporator case. 4. Remove the evaporator core. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6918 5. Inspect the foam evaporator strip seals for proper positioning (Figure 1). 6. The seals are positioned on the blower wheel area as marked. There should be no gaps at either end of the seals. Witness marks should be present along the entire length of the seals. If no marks are present then the seals need to be repositioned to provide a better seal. Wipe out any excess moisture and reinstall evaporator core and case assembly. 7. Verify the repair. DIAGNOSTIC TIPS THUNDERBIRD/COUGAR The first thing to do when repairing a water leak is to determine the root cause of the leak. Ford has noted a number of different locations where water leak issues can arise on the Thunderbird/Cougar. Refer to the following list when addressing a water leak concern. Water may come from the outside of the vehicle as well as the evaporator case. Always check the evaporator drain for blockage prior to performing any of these steps. The following is a list of areas where a water leak is possible: 1. Water dripping from the floor ducts when the A/C is operating on vehicles built Job 1, 1989 through 10/15/93 are most likely exhibiting a Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6919 condensate carryover from the evaporator core. Refer to TSB 94-2-12 for Service Procedures on this concern. 2. Water dripping onto the floor in vehicles built after 10/15/93 or in vehicles built prior to that date which have been serviced following TSB 94-2-12 may have condensate leaking from one (1) of the following places (refer to Figure 2): a. The evaporator tube seal. Condensate forms on the liquid line inside the evaporator case. When the blower motor is operated on HIGH, condensate is blown against the inside of the seal and eventually leaks from the case. Condensate droplets will fall on the passenger side, just above the carpeting on the sound absorber. In very high humidity, this leak may appear within 10-15 minutes of A/C system start-up. A leaking seal can be observed in the vehicle with the use of an inspection mirror. Leakage from this area and area b described next, may be significant enough to saturate the carpeting over a long period of time. b. Case seam near evaporator tube seal. There is a seam between the upper and lower case halves adjacent to the recirc door linkage. This seam may not be adequately welded during assembly. When this occurs, condensate may leak from the case in this area. The seam is not visible when the evaporator is assembled in the vehicle. It is difficult to determine between leaks from this source, or source a, above. Generally, Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6920 leaks from this source may wet the recirc door vacuum motor, while leaks from source a, above, fall directly onto the sound absorber. c. Heater core cover seal. This foam seal may become saturated with condensate and drip on the passenger 5 feet. The source of this condensate leakage is visible through the glove compartment opening. Condensate leaking from this area may fall near the floor ducts, giving the mistaken impression that condensate is dripping from that duct. The volume of condensate from this location is usually low, typically about one (1) drop every several minutes. 3. Water accumulating on the floor can come from these other sources not related to evaporator core condensate. a. Water may enter the vehicle around the evaporator drain seal from the outside due to the lower evaporator case-to-dash mounting stud not being properly torqued. b. Water may leak into the passenger side kick panel on 1994 and 1995 models built through 8/10/94 due to insufficient body sealing in the right A-pillar/cowl area. If the kick panel area does not drain this water due to rustproofing or debris, the water can potentially build up and reach the carpet, or the water may find a path to flow onto the carpet when making its way down from the cowl area. This leak source is very rare and is outlined in TSB 94-22-5 for other wiring corrosion concerns. SERVICE PROCEDURE THUNDERBIRD/COUGAR 1. Diagnosis # 1. Condensate carryover. Follow the Service Procedures listed in TSB 94-2-12. 2. Diagnosis # 2a and 2b. Evaporator tube seal or case seam near evaporator tube seal. Repair as follows: a. Remove the evaporator case from the vehicle as outlined in the appropriate Service Manual, Section 12. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6921 b. Remove the evaporator tube seal from the case (Figure 3). c. Cut away the portion of the liquid line clip that extends outside of the case. d. Apply a generous bead of RTV sealant to the inside of the case as shown in Figure 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6922 e. Apply a generous bead of RTV to the evaporator tube seal as shown in Figure 4. f. Reinstall the evaporator tube seal being careful to ensure the RTV seals around the entire perimeter of the seal. g. Apply a bead of RTV around the perimeter of the seal where it meets the case. h. Allow the RTV to fully cure before reinstalling the case. Take care not to disturb the seal during installation of the case. 3. Diagnosis # 2c. Heater core cover seal. a. Remove the heater core cover and seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6923 b. Cut the seal as shown in Figure 6. This prevents the seal from extending beyond the cover and interfering with the RTV. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6924 c. Apply a bead of RTV to the heater core cover along the inside face as indicated in Figure 5. d. Reinstall heater core cover seal and heater core cover. e. Apply a bead of RTV between the heater core cover and the case. 4. Diagnosis # 3a. Loose lower mounting stud. a. Tighten nut as required. 5. Diagnosis # 3b. Water in passenger side kick panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6925 a. Follow the Service Procedures listed in TSB 94-22-5. OTHER APPLICABLE ARTICLES: 94-2-12, 94-22-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Base Warranty Coverage For All Others OPERATION DESCRIPTION TIME 952303A Stretch And Reposition 2.5 Hrs. Evaporator Core Seals - 1995-96 Ranger/Explorer 952303B Condensate Carryover - Refer 1989-95 To TSB Thunderbird/Cougar 94-2-12 952303C Evaporator Tube Seal And 2.7 Hrs. Leaky Seam Repair - 1989-95 Thunderbird/Cougar 952303D Heater Core Cover Seal 2.2 Hrs. Repair - 1989-95 Thunderbird/Cougar 952303E Lower Mounting Stud 0.2 Hr. Retighten - 1989-95 Thunderbird/Cougar 952303F Water In Passenger Side Refer Kick Panel Repair - To TSB 1989-95 Thunderbird/Cougar 94-22-5 DEALER CODING CONDITION BASIC PART NO. CODE 19850 36 OASIS CODES: 110000, 208000, 208300, 208400, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts Evaporator Core: Customer Interest A/C - Water Leaks From the Floor Ducts Article No. 94-2-12 01/26/94 AIR CONDITIONING - WATER DRIPS FROM THE FLOOR DUCTS WHEN A/C IS OPERATING VEHICLES BUILT FROM JOB-1 1989 THROUGH 10/15/93 FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR ISSUE: Condensation may drip from the floor duct when the A/C is operating. This occurs because the location of the evaporator core inside the housing allows high velocity air to carry water droplets from the core face beyond the sump area in the housing. ACTION: Replace the evaporator core and housing assembly with a new assembly which has a relocated evaporator core that allows the condensate to drain into the sump area of the housing rather than into the passenger compartment. Refer to the following procedure for service details. NOTE: USE PROCEDURE # 1 FOR 1994 MODELS ONLY AND USE PROCEDURE # 2 FOR 1989-93 MODELS. CAUTION: OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS WHILE PERFORMING THE FOLLOWING SERVICE PROCEDURE. PROCEDURE # 1 - 1994 MODELS BUILT BEFORE 10/15/93 ONLY NOTE: THIS VEHICLE USES THE NON-CHLOROFLUOROCARBON (NON-CFC) BASED REFRIGERANT R-134a. R-134a A/C SYSTEMS REQUIRE THE USE OF SPECIAL SERVICING EQUIPMENT DESIGNED SPECIALLY FOR SERVICING R-134a A/C SYSTEMS CAUTION: DO NOT USE R-12 SPECIAL TOOLS AND EQUIPMENT WHEN SERVICING AN R-134a SYSTEM. DOING SO MAY CAUSE DAMAGE TO THE A/C SYSTEM. REFER TO THE ROTUNDA CATALOG FOR MORE INFORMATION ON R-134a SPECIAL SERVICING EQUIPMENT. 1. Record radio stations. 2. Disconnect battery ground cable. Disconnect positive battery and wait one (1) minute for the air bag diagnostic monitor to deplete the air bag back-up power supply. Refer to Service Manual Section 01-20B. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6930 3. Loosen main wiring connector bolt in engine compartment at LH side of dash panel and separate connectors, Figure 1. 4. Remove the radio antenna through the right front wheel well. Disengage the antenna wire grommet from the sheet metal and push the antenna lead-in cable through the sheet metal into vehicle interior. 5. Remove the screws retaining the RH and LH scuff plates (do not remove the scuff plates from the vehicle). Lift scuff plates and remove door opening weatherstrips from body flanges. 6. Remove both RH and LH windshield side garnish moldings. 7. Remove both RH and LH cowl side trim panels. 8. Remove instrument panel steering column cover: a. remove the three (3) screws along the bottom b. pull on cover to unsnap the three (3) clips across the top. 9. Remove one (1) screw and A/C evaporator register duct from under the steering column tube. 10. Disconnect the electrical connectors at the base of the steering column. 11. Remove the pinch bolt attaching the steering column tube to steering column lower yoke and slightly spread the joint with a screwdriver. 12. Disconnect the multi-function switch connector located under the column assembly. 13. Disconnect the ignition switch connector. 14. While supporting the steering column tube, remove the four (4) steering column tube retaining nuts. 15. Lower steering column and remove shift interlock cable retaining screws and shift actuator cable fitting. Disconnect the electrical connector from shift interlock solenoid. 16. Remove steering column from the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6931 17. Disconnect stop lamp switch, Figure 2. 18. Pull back the floor carpet as required on the RH and LH sides of the vehicle and disconnect the window regulator safety switch connector and the Powertrain Control Module connector. 19. Remove glove compartment: a. Open glove compartment to the stop. b. Unsnap the hydraulic lift from the right side of the glove compartment. c. Remove the three (3) screws at the bottom retaining the glove compartment door hinge and glove compartment to the instrument panel. d. Remove glove compartment from the instrument panel. 20. Reach through the glove compartment opening and disconnect the electrical and vacuum connectors from the heater-A/C evaporator housing. 21. Disconnect the connectors behind the RH kick panel, Figure 3. 22. Disconnect the two (2) speed control amplifier connectors. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6932 23. Remove floor console panel. Refer to the 1994 Thunderbird/Cougar Service Manual, Section 01-12-4 and 01-12-5. NOTE: PROTECT THE INSTRUMENT PANEL SURFACE DURING THE FOLLOWING PROCEDURE. 24. Remove two (2) nuts and one (1) bolt from the instrument panel-to-console mount, Figure 4. 25. Remove two (2) nuts retaining the LH side of instrument panel to cowl side, Figure 4. 26. Remove the nut attaching the RH side of instrument panel to cowl side, Figure 4. NOTE: THE FOLLOWING THREE STEPS REQUIRE TWO TECHNICIANS. 27. Remove 6 bolts from the top of the instrument panel, Figure 4. 28. Carefully pull the instrument panel away from windshield glass, checking for and disconnecting any remaining wiring connectors. 29. Remove the instrument panel from the vehicle. 30. Recover the R-134a refrigerant from the A/C system at the service access gauge port valve, following the proper recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 31. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 32. Place a drain pan or suitable container under heater hose connections at the cowl panel. 33. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 34. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 35. Remove the suction accumulator drier from its bracket then remove the bracket. 36. Remove the three (3) retaining nuts attaching the evaporator housing to the cowl panel (under the hood). 37. Remove one (1) screw at the base of the evaporator housing and one (1) screw at the evaporator housing-to-cowl panel bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6933 38. Remove the evaporator housing from the vehicle. 39. Transfer the parts from the removed evaporator assembly to the new service evaporator assembly, based on the type of system in the vehicle. See illustrations. 40. Install the evaporator case and instrument panel in the vehicle by reversing the removal procedure. 41. Refill coolant and check for leaks. 42. Recharge the A/C system and check the operation of the system. 43. Reset radio stations recorded in step # 1. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. PROCEDURE # 2 - 1989-93 MODELS NOTE: AUTOMATIC TEMPERATURE CONTROL - EQUIPPED UNITS BUILT BEFORE 7/1/92 WILL REQUIRE A NEW ASPIRATOR ASSEMBLY (F4SZ-19E628-A) ALONG WITH THE NEW EVAPORATOR CASE ASSEMBLY. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6934 CAUTION: OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS WHILE PERFORMING THE FOLLOWING SERVICE PROCEDURE. 1. Record radio stations. 2. Disconnect battery ground cable. 3. Remove steering column lower trim cover. (Remove three (3) screws at bottom, one (1) screw LH side and pull to disengage five (5) snap-in retainers across top). 4. Remove steering column lower opening reinforcement. Six (6) screws retain reinforcement to instrument panel. 5. Remove steering column upper and lower shrouds. 6. Disconnect wiring from steering column. 7. Remove shift interlock switch, if equipped. 8. Disconnect steering column lower universal joint. 9. Support steering column and remove four (4) nuts retaining column to support. Remove column from vehicle. 10. Remove one (1) nut retaining LH side of instrument panel to parking brake bracket. 11. Remove RH and LH side cowl trim panels. 12. Disconnect electrical connections at RH cowl side. 13. Remove two (2) instrument panel-to-floor tunnel nuts. 14. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor. 15. Disconnect wiring, heater and A/C vacuum lines and control cables through glove compartment opening. 16. Remove two (2) screws at RH side retaining instrument panel to cowl side. 17. Remove two (2) screws at LH side retaining instrument panel to cowl side. 18. Remove RH and LH finish panel by pulling up to disengage snap-in retainers, three (3) on RH side and four (4) on LH side. 19. Remove RH and LH roof rail trim panels. 20. Remove four (4) screws retaining instrument panel to cowl top. 21. Gently pull instrument panel away from RH side of cowl panel. 22. Place a drain pan or suitable container under heater hose connections at the cowl panel. 23. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the proper recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 24. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 25. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 26. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 27. Working under the hood, remove three (3) nuts retaining the evaporator case to the cowl panel. 28. Inside the passenger compartment, remove the screw attaching the evaporator case support bracket to the cowl top panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6935 29. Remove one (1) nut retaining the bracket below the evaporator case to the cowl panel. 30. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 31. Transfer the following parts from the removed evaporator assembly to the new service evaporator assembly, based on the type of system in the vehicle. NOTE: IF THE UNIT IS EQUIPPED WITH ATC AND WAS BUILT PRIOR TO 7/1/92, YOU WILL HAVE TO USE A NEW ASPIRATOR (F4SZ-19E628-A) THAT IS DESIGNED FOR THE NEW SERVICE CASE AND ELIMINATE THE OLD ASPIRATOR. CHANGE OVER TO THE NEW ASPIRATOR AS FOLLOWS: ^ TRANSFER THE GASKET FROM THE EXISTING ASPIRATOR ASSEMBLY PLATE TO THE BACK OF THE BLOWER SPEED CONTROLLER SO YOU WILL SEAL THE MATING SURFACE OF THE CONTROLLER TO THE CASE. INSTALL THE BLOWER SPEED CONTROLLER TO THE CASE WITHOUT THE OLD ASPIRATOR, MAKING CERTAIN THAT THE GASKET SEALS PROPERLY. ^ DISCARD THE EXISTING ASPIRATOR ASSEMBLY AND INSTALL THE NEW ASPIRATOR (F4SZ-19E628-A) IN THE UPPER CASE HALF, IN THE EXISTING HOLE NEXT TO THE MUFFLER ASSEMBLY, USING A SCREW (# 10-12X .75 HEX WASHER HEAD SELF-TAPPING); OBTAIN LOCALLY. ^ USING THE OLD ASPIRATOR CONNECTING TUBE, CUT IT TO SIZE (SHORTEN) AND INSTALL IT BETWEEN THE NEW ASPIRATOR AND THE MUFFLER. 32. Cut off the end of the drain tube located on the bottom of the evaporator case under the heater core area. Cut Off The End Of The Drain Tube, Do Not Drill. CAUTION: DO NOT DRILL OUT THE HOLE BECAUSE THE HEATER CORE COULD BE DAMAGED, FIGURE 5. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6936 Connect A Hose To The Drain Tube. 33. Connect a 1/2" (12.7 mm) outside diameter hose (E8UZ-19K592-A) to the drain tube using a small hose clamp (376240-S100), Figure 6. 34. Install the evaporator case in the vehicle by reversing the removal procedure. a. Drill a hole in the cowl panel to accommodate the new drain tube. See Figure 2 for location. The hole should be about 2" (50.8 mm) below the regular evaporator case drain tube. b. After the new drain tube is through the hole and in permanent position, seal around the tube with body sealer (F1AZ-19562-A). 35. Recharge the A/C system and check the operation of the system. 36. Reset radio stations recorded in step # 1. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. NOTE: IF EVAPORATOR CORE AND HOUSING ASSEMBLY IS REPLACED PER THIS TSB ARTICLE, IT WILL NOT BE NECESSARY TO PERFORM TSB 94-2-9. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 92-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Models; Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 940212A Remove And Replace 4.5 Hrs. Evaporator Case DEALER CODING BASIC PART NO. CONDITION CODE 19850 08 OASIS CODES: 208000, 208300, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Customer Interest: > 93252 > Dec > 93 > A/C Evaporator Tube - Refrigerant Leaks Evaporator Core: Customer Interest A/C Evaporator Tube - Refrigerant Leaks Article No. 93-25-2 12/08/93 ^ EMISSIONS CONTROL - CARBON CANISTER PURGE HOSE - HOLE WORN IN EVAPORATOR CORE TUBE BY CARBON CANISTER PURGE HOSE ^ AIR CONDITIONING - EVAPORATOR CORE TUBE WORN BY CARBON CANISTER HOSE ^ LEAKS - REFRIGERANT - HOLE WORN IN EVAPORATOR CORE TUBE BY CARBON CANISTER PURGE HOSE FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR This TSB article is being republished in its entirety to include 1992 and 1993 model year vehicles. ISSUE: A refrigerant leak may develop in the evaporator core tube near the spring lock coupling. The leak occurs because the carbon canister purge hose may be routed too close and rubs against one of the evaporator core tubes and eventually wears a hole in it. ACTION: Install a protective sleeve for each evaporator tube, using a 1" (25.2 mm) length of heater hose. Refer to the following procedure for service details. 1. Slit the heater hoses lengthwise and position one around each tube, close to the spring lock coupling. 2. Secure the two hoses in position with bundling straps, as required. 3. Be sure each sleeve is in the correct position to prevent the purge hose from rubbing against the core tubes. 4. Reroute the canister purge hose so that it is above the evaporator core tubes and not in contact with any other vacuum line or wiring harness. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-22-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 932502A Install Protective Sleeve 0.4 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 19860 30 OASIS CODES: 208200, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor Technical Service Bulletin # 98-18-14 Date: 980914 A/C Evaporator Core - Water Drips Onto Floor Article No. 98-18-14 09/14/98 AIR CONDITIONING - WATER DRIPS ON FLOOR FROM EVAPORATOR WHEN BLOWER IS ON HIGH IN MAX A/C OR NORMAL A/C MODE FORD: 1989-97 THUNDERBIRD LINCOLN-MERCURY: 1989-97 COUGAR LIGHT TRUCK: 1995-96 EXPLORER, RANGER This TSB article is being republished in its entirety to include 1997 Thunderbird and Cougar vehicles, and to revise the Labor Operation Descriptions. ISSUE Water from condensation building on the evaporator core may drip onto the floor when the A/C blower is on HIGH and the A/C mode control is in MAX A/C or Normal A/C position. This may be caused by the evaporator core seals being misaligned. ACTION For Ranger/Explorer, stretch and reposition the evaporator core seal. Refer to the following Ranger/Explorer Service Procedure. For Thunderbird/Cougar, refer to the following Thunderbird/Cougar Diagnostic Tips and Service Procedure. PART NUMBER PART NAME F5TZ-19G204-AB RTV Silicone Sealant OTHER APPLICABLE ARTICLES: 94-2-12, 94-22-5 SUPERSEDES: 96-12-6 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-97 Model Year Vehicles, Base Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 981814A Stretch And Reposition 2.5 Hrs. Evaporator Core Seals - 1995-96 Ranger/Explorer 981814B Condensate Carryover - Refer 1989-94 To TSB Thunderbird/Cougar 94-2-12 981814C Evaporator Tube Seal And 2.7 Hrs. Leaky Seam Repair 1989-97 Thunderbird/Cougar 981814D Heater Core Cover Seal 2.2 Hrs. Repair - 1989-97 Thunderbird/Cougar 981814E Lower Mounting Stud 0.2 Hr. Retighten - 1989-97 Thunderbird/Cougar Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6946 981814F Water In Passenger Side Refer Kick Panel Repair - To TSB 1994-95 94-22-5 Thunderbird/Cougar DEALER CODING CONDITION BASIC PART NO. CODE 19850 07 OASIS CODES: 110000, 208000, 208300, 208400, 208999 Ranger/Explorer 1. Check the evaporator drain tube for blockage. If blockage is present, clear the tube and recheck. 2. Remove the evaporator/blower case from the engine compartment following the procedures outlined in Section 12 of the 1995 Ranger/Explorer Service Manual. 3. Remove the service cover on the evaporator case. 4. Remove the evaporator core. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6947 5. Inspect the foam evaporator core seals for proper positioning (Figure 1). 6. The seals are positioned on the blower wheel area as marked. There should be no gaps at either end of the seals. Witness marks should be present along the entire length of the seals. If no marks are present then the seals need to be repositioned to provide a better seal. Wipe out any excess moisture and reinstall evaporator core and case assembly. 7. Verify the repair. Thunderbird/Cougar 1. Diagnosis # 1. Condensate carryover. Follow the Service Procedures listed in TSB 94-2-12. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6948 2. Diagnosis # 2a and 2b. Evaporator tube seal or case seam near evaporator tube seal. Repair as follows: a. Remove the evaporator case from the vehicle as outlined in the appropriate model/year Service Manual, Section 12. b. Remove the evaporator tube seal from the case (Figure 3). c. Cut away the portion of the liquid line clip that extends outside the case (Figure 3). d. Apply a generous bead of RTV Silicone Sealant (F5TZ-19G204-AB) to the inside of the case as shown in Figure 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6949 e. Apply a generous bead of RTV Silicone Sealant to the evaporator tube seal as shown in Figure 4. f. Reinstall the evaporator tube seal being careful to make sure the RTV seals around the entire perimeter of the seal. 9. Apply a bead of RTV Silicone Sealant around the perimeter of the seal where it meets the case. h Allow the RTV to fully cure before reinstalling the case. Take care not to disturb the seal during installation of the case. 3. Diagnosis # 2c. Heater core cover seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6950 a. Remove the heater core cover and seal. b. Cut the seal as shown in Figure 6. This prevents the seal from extending beyond the cover and interfering with the RTV. c. Apply a bead of RTV Silicone Sealant to the heater core cover along the inside face as indicated in Figure 5. d. Reinstall heater core cover seal and heater core cover. e. Apply a bead of RTV Silicone Sealant between the heater core cover and the case. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6951 4. Diagnosis # 3a. Loose lower mounting stud. a. Tighten nut as required. 5. Diagnosis # 3b. Water in passenger side kick panel. a. Follow the Service Procedures listed in TSB 94-22-5. Diagnostic Tips The first thing to do when repairing a water leak is to determine the root cause of the leak. Ford Motor Company has noted a number of different locations where water leak issues can arise on the Thunderbird/Cougar. Refer to the following list when addressing a water leak concern. Water may come from the outside of the vehicle as well as the evaporator case. Always check the evaporator drain for blockage prior to performing any of these steps. The following is a list of areas where a water leak is possible: 1. Water dripping from the floor ducts when the A/C is operating on vehicles built Job 1, 1989 through 10/15/93 are most likely exhibiting a condensate carryover from the evaporator core. Refer to TSB 94-2-12 for Service Procedures on this concern. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6952 2. Water dripping onto the floor in vehicles built after 10/15/93 or in vehicles built prior to that date which have been serviced following TSB 94-2-12 may have condensate leaking from one (1) of the following sites (refer to Figure 2): a. The evaporator tube seal. Condensate forms on the liquid line inside the evaporator case. When the blower motor is operated on HIGH, condensate is blown against the inside of the seal and eventually leaks from the case. Condensate droplets will fall on the passenger side, just above the carpeting on the sound absorber. In very high humidity, this leak may appear within 10-15 minutes of A/C system start-up. A leaking seal can be observed in the vehicle with the use of an inspection mirror. Leakage from this area and area b described next, may be significant enough to saturate the carpeting over a long period of time. b. Case seam near evaporator tube seal. There is a seam between the upper and lower case halves adjacent to the recirc door linkage This seam may not be adequately welded during assembly When this occurs, condensate may leak from the case in this area. The seam is not visible Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 98-18-14 > Sep > 98 > A/C Evaporator Core - Water Drips Onto Floor > Page 6953 when the evaporator is assembled in the vehicle It is difficult to determine between leaks from this source, or source a, above. Generally, leaks from this source may wet the recirc door vacuum motor, while leaks from source a, above, fall directly onto the sound absorber. c. Heater core cover seal. This foam seal may become saturated with condensate and drip on the passenger's feet. The source of this condensate leakage is visible through the glove compartment opening. Condensate leaking from this area may fall near the floor ducts, giving the mistaken impression that condensate is dripping from that duct. The volume of condensate from this location is usually low, typically about one (1) drop every several minutes. 3. Water accumulating on the floor can come from these other sources not related to evaporator core condensate. a. Water may enter the vehicle around the evaporator drain seal from the outside due to the lower evaporator case-to-dash mounting stud not being properly torqued. b. Water may leak into the passenger side kick panel on 1994 and 1995 models built through 8/10/94 due to insufficient body sealing in the right A-pillar/cowl area. If the kick panel area does not drain this water due to rustproofing or debris, the water can potentially build up and reach the carpet, or the water may find a path to flow onto the carpet when making its way down from the cowl area. This leak source is very rare and is outlined in TSB 94-22-5 for other wiring corrosion concerns. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor Evaporator Core: All Technical Service Bulletins Air Conditioning - Water Drips On Floor Article No. 95-23-3 11/20/95 AIR CONDITIONING - WATER DRIPS ON FLOOR FROM EVAPORATOR WHEN BLOWER IS ON HIGH IN MAX A/C OR NORMAL A/C MODE FORD: 1989-95 THUNDERBIRD LINCOLN-MERCURY: 1989-95 COUGAR LIGHT TRUCK: 1995-96 EXPLORER, RANGER ISSUE: Water from condensation building on the evaporator core may drip onto the floor when the A/C blower is on HIGH and the A/C mode control is in MAX A/C or Normal A/C position. This may be caused by the evaporator core seals being misaligned. ACTION: For Ranger/Explorer, stretch and reposition the evaporator core seal. Refer to the Ranger/Explorer Service Procedure. For Thunderbird/Cougar, refer to the Thunderbird/Cougar Service Procedure. SERVICE PROCEDURE RANGER/EXPLORER 1. Check the evaporator drain tube for blockage. If blockage is present, clear the tube and recheck. 2. Remove the evaporator/blower case from the engine compartment following the procedures outlined in Section 12 of the 1995 Ranger/Explorer Service Manual. 3. Remove the service cover on the evaporator case. 4. Remove the evaporator core. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6958 5. Inspect the foam evaporator strip seals for proper positioning (Figure 1). 6. The seals are positioned on the blower wheel area as marked. There should be no gaps at either end of the seals. Witness marks should be present along the entire length of the seals. If no marks are present then the seals need to be repositioned to provide a better seal. Wipe out any excess moisture and reinstall evaporator core and case assembly. 7. Verify the repair. DIAGNOSTIC TIPS THUNDERBIRD/COUGAR The first thing to do when repairing a water leak is to determine the root cause of the leak. Ford has noted a number of different locations where water leak issues can arise on the Thunderbird/Cougar. Refer to the following list when addressing a water leak concern. Water may come from the outside of the vehicle as well as the evaporator case. Always check the evaporator drain for blockage prior to performing any of these steps. The following is a list of areas where a water leak is possible: 1. Water dripping from the floor ducts when the A/C is operating on vehicles built Job 1, 1989 through 10/15/93 are most likely exhibiting a Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6959 condensate carryover from the evaporator core. Refer to TSB 94-2-12 for Service Procedures on this concern. 2. Water dripping onto the floor in vehicles built after 10/15/93 or in vehicles built prior to that date which have been serviced following TSB 94-2-12 may have condensate leaking from one (1) of the following places (refer to Figure 2): a. The evaporator tube seal. Condensate forms on the liquid line inside the evaporator case. When the blower motor is operated on HIGH, condensate is blown against the inside of the seal and eventually leaks from the case. Condensate droplets will fall on the passenger side, just above the carpeting on the sound absorber. In very high humidity, this leak may appear within 10-15 minutes of A/C system start-up. A leaking seal can be observed in the vehicle with the use of an inspection mirror. Leakage from this area and area b described next, may be significant enough to saturate the carpeting over a long period of time. b. Case seam near evaporator tube seal. There is a seam between the upper and lower case halves adjacent to the recirc door linkage. This seam may not be adequately welded during assembly. When this occurs, condensate may leak from the case in this area. The seam is not visible when the evaporator is assembled in the vehicle. It is difficult to determine between leaks from this source, or source a, above. Generally, Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6960 leaks from this source may wet the recirc door vacuum motor, while leaks from source a, above, fall directly onto the sound absorber. c. Heater core cover seal. This foam seal may become saturated with condensate and drip on the passenger 5 feet. The source of this condensate leakage is visible through the glove compartment opening. Condensate leaking from this area may fall near the floor ducts, giving the mistaken impression that condensate is dripping from that duct. The volume of condensate from this location is usually low, typically about one (1) drop every several minutes. 3. Water accumulating on the floor can come from these other sources not related to evaporator core condensate. a. Water may enter the vehicle around the evaporator drain seal from the outside due to the lower evaporator case-to-dash mounting stud not being properly torqued. b. Water may leak into the passenger side kick panel on 1994 and 1995 models built through 8/10/94 due to insufficient body sealing in the right A-pillar/cowl area. If the kick panel area does not drain this water due to rustproofing or debris, the water can potentially build up and reach the carpet, or the water may find a path to flow onto the carpet when making its way down from the cowl area. This leak source is very rare and is outlined in TSB 94-22-5 for other wiring corrosion concerns. SERVICE PROCEDURE THUNDERBIRD/COUGAR 1. Diagnosis # 1. Condensate carryover. Follow the Service Procedures listed in TSB 94-2-12. 2. Diagnosis # 2a and 2b. Evaporator tube seal or case seam near evaporator tube seal. Repair as follows: a. Remove the evaporator case from the vehicle as outlined in the appropriate Service Manual, Section 12. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6961 b. Remove the evaporator tube seal from the case (Figure 3). c. Cut away the portion of the liquid line clip that extends outside of the case. d. Apply a generous bead of RTV sealant to the inside of the case as shown in Figure 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6962 e. Apply a generous bead of RTV to the evaporator tube seal as shown in Figure 4. f. Reinstall the evaporator tube seal being careful to ensure the RTV seals around the entire perimeter of the seal. g. Apply a bead of RTV around the perimeter of the seal where it meets the case. h. Allow the RTV to fully cure before reinstalling the case. Take care not to disturb the seal during installation of the case. 3. Diagnosis # 2c. Heater core cover seal. a. Remove the heater core cover and seal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6963 b. Cut the seal as shown in Figure 6. This prevents the seal from extending beyond the cover and interfering with the RTV. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6964 c. Apply a bead of RTV to the heater core cover along the inside face as indicated in Figure 5. d. Reinstall heater core cover seal and heater core cover. e. Apply a bead of RTV between the heater core cover and the case. 4. Diagnosis # 3a. Loose lower mounting stud. a. Tighten nut as required. 5. Diagnosis # 3b. Water in passenger side kick panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95233 > Nov > 95 > Air Conditioning - Water Drips On Floor > Page 6965 a. Follow the Service Procedures listed in TSB 94-22-5. OTHER APPLICABLE ARTICLES: 94-2-12, 94-22-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Base Warranty Coverage For All Others OPERATION DESCRIPTION TIME 952303A Stretch And Reposition 2.5 Hrs. Evaporator Core Seals - 1995-96 Ranger/Explorer 952303B Condensate Carryover - Refer 1989-95 To TSB Thunderbird/Cougar 94-2-12 952303C Evaporator Tube Seal And 2.7 Hrs. Leaky Seam Repair - 1989-95 Thunderbird/Cougar 952303D Heater Core Cover Seal 2.2 Hrs. Repair - 1989-95 Thunderbird/Cougar 952303E Lower Mounting Stud 0.2 Hr. Retighten - 1989-95 Thunderbird/Cougar 952303F Water In Passenger Side Refer Kick Panel Repair - To TSB 1989-95 Thunderbird/Cougar 94-22-5 DEALER CODING CONDITION BASIC PART NO. CODE 19850 36 OASIS CODES: 110000, 208000, 208300, 208400, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures Evaporator Core: All Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures > Page 6970 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 94114 > Jun > 94 > A/C - Evaporator Core and Case Assembly Application Evaporator Core: All Technical Service Bulletins A/C - Evaporator Core and Case Assembly Application Article No. 94-11-4 06/01/94 AIR CONDITIONING - EVAPORATOR CORE AND CASE ASSEMBLY APPLICATION FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR 1993-94 MARK VIII ISSUE: A service replacement A/C evaporator core/case usage chart is available. ACTION: Refer to the usage chart for correct evaporator core/case application. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement Technical Service Bulletin # 9488 Date: 940420 Evaporator Core - Replacement Article No. 94-8-8 EVAPORATOR CORE REPLACEMENT PROCEDURE FORD: 1989-93 MUSTANG, THUNDERBIRD 1989-94 TAURUS, TEMPO LINCOLN-MERCURY: 1989-93 COUGAR 1989-94 CONTINENTAL, SABLE, TOPAZ This TSB article is being republished in its entirety to correct the TSB number referred to in the Note text of the Thunderbird/Cougar evaporator core replacement procedure. Because the instrument panel area on 1994 Thunderbird/Cougar models was reconfigured for air bags, it is recommended that the entire instrument panel be removed to facilitate replacement of the evaporator core and housing assembly. ISSUE: A procedure has been developed for replacing the evaporator core without removing the instrument panel from the vehicle. Following this procedure will reduce the time required to replace an evaporator core. ACTION: Loosen the instrument panel from the cowl by pulling the right end of the instrument panel rearward. This provides enough clearance to remove the evaporator case from the vehicle. A service procedure for each of the vehicles listed above is presented in this article. Refer to the following procedures for service details. OTHER APPLICABLE ARTICLES: 94-2-12 SUPERSEDES: 94-3-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper For 1992/94 Vehicles And 1991 Lincolns, Basic Warranty Coverage For All Other Models And 1989/90 Major Component Warranty Coverage OPERATION DESCRIPTION TIME 940808A Replace Evaporator Core 4.5 Hrs. (1989-94 Tempo/Topaz) 940808B Replace Evaporator Core 3.2 Hrs. (1989-93 Mustang) 940808C Replace Evaporator Core 4.0 Hrs. (1989-94 Taurus/Sable) 940808D Replace Evaporator Core 3.8 Hrs. (1989-94 Thunderbird / Cougar) 940808E Replace Evaporator Core 4.1 Hrs. (1989-94 Continental) DEALER CODING BASIC PART NO. CONDITION CODE 19860 01 OASIS CODES: 208000, 208200, 290000 Tempo/Topaz TEMPO/TOPAZ EVAPORATOR CORE REPLACEMENT 1. Disconnect battery ground cable. 2. Raise vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 6979 3. Disconnect speedometer cable at transaxle. 4. Lower vehicle. 5. Remove two (2) cover retaining screws at bottom of steering column opening and snap cover out. 6. Remove snap in lower cluster finish panel(s) (Topaz LS is one piece, all others, two pieces) to expose two (2) screws and two (2) bolts. 7. Remove four (4) cluster opening finish panel retaining screws and pull panel rearward. 8. Remove speed control module, if so equipped (two (2) screws). 9. Remove lower steering column shroud (five (5) screws). 10. Disconnect all steering column electrical connections: ignition, washer/wiper, turn signal, key warning buzzer and speed control. On console automatic transmission shift, remove interlock cable retaining screw and disconnect cable from steering column. 11. Loosen, but do not remove, two (2) nuts and two (2) bolts retaining steering column to support bracket and remove upper shroud. 12. Loosen steering column to intermediate shaft clamp connection and remove bolt or nut. 13. Remove two (2) nuts and two (2) bolts retaining steering column to support bracket. 14. Pry open steering column shaft in area of clamp on each side of bolt groove with steering column locked. Open enough to disengage shafts with minimal effort. Remove column. 15. Inspect two (2) steering column bracket clips for damage. If clips have been bent or excessively distorted, they must be replaced. 16. Remove four (4) screws retaining cluster and carefully pull rearward enough to disengage speedometer cable. Loosely install two (2) screws to retain instrument cluster during instrument panel removal. 17. Remove left A-pillar garnish molding (five (5) screws). 18. Remove right A-pillar garnish molding (five (5) screws) 19. Remove left kick panel. 20. Remove one (1) instrument panel-to-steering column support bracket retaining nut, accessible through steering column opening. 21. Remove two (2) lower instrument panel-to-cowl side retaining screws (RH and LH side). 22. Remove two (2) instrument panel vertical brace retaining nuts located on the LH side of glove compartment. 23. Gently pull instrument panel away from RH side of cowl panel. 24. Drain the coolant from the radiator into a clean container. 25. Discharge the refrigerant from the A/C system, following the recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS 26. Disconnect the heater hoses from the heater core. Plug the heater core tubes or blow any coolant from the heater core with low pressure air. 27. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the dash panel. Cap the refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 28. Disconnect the wire harness connector from the blower motor resistor. 29. Remove one (1) screw retaining the bottom of the evaporator case to the cowl panel. 30. Remove the instrument panel brace from the cowl top panel. 31. In the engine compartment, remove two (2) nuts retaining the evaporator case to the cowl panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 6980 32. Loosen the sound insulator from the cowl top panel in the area around the air inlet opening. 33. Remove the two (2) screws retaining the support bracket and the brace to the cowl top panel. 34. Pull the right end of the instrument panel away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 35. Remove the evaporator core from the case following the procedure in the appropriate service manual for cutting the top out of the case. 36. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual. 37. Install the evaporator case in the vehicle by reversing the removal procedure. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. Tauras/Sable TAURUS/SABLE EVAPORATOR CORE REPLACEMENT 1. Disconnect battery ground cable. 2. Remove radio cluster as outlined in the Service Manual, Section 15-01. 3. Remove two (2) bolts and remove the steering column opening cover from under steering column. 4. Remove sound insulators from under steering column. 5. Remove three (3) screws retaining lower steering column shroud and remove shroud. 6. Remove two (2) bolts and steering column reinforcement from under steering column. 7. Disconnect all electrical connections from steering column switches. 8. Remove four (4) nuts retaining steering column support brace, disconnect PRNDL cable (column shift) and lower steering column. 9. Disconnect park brake release cable from park brake and disconnect ignition switch wiring connector. 10. Remove instrument cluster finish panel and disconnect all instrument cluster finish panel electrical connections. 11. Remove four (4) retaining screws from instrument cluster and... a. disconnect speedometer cable (if equipped), b. disconnect wiring and remove instrument cluster. 12. Remove one (1) bolt at steering column opening attaching instrument panel to brace. 13. Remove one (1) instrument panel brace retaining bolt (under the radio area). 14. Remove sound insulator under glove compartment by removing two (2) push nuts that secure insulator to studs on the evaporator case. 15. Remove three (3) screws attaching glove compartment assembly to instrument panel and remove door assembly. 16. Remove LH and RH cowl side trim panels. 17. Disconnect electrical connections at RH cowl side. 18. Remove three (3) screws retaining instrument panel to cowl top panel. 19. Remove one (1) screw at instrument panel RH side. 20. Remove two (2) instrument panel-to-center console nuts. 21. Remove cup holder and shift lever opening retaining screw. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 6981 22. Remove shift lever rearward. 23. Remove shift lever opening cover (snaps out). 24. Remove eight (8) console-to-floor bracket retaining screws (the two (2) rear screws are under the mat in the rear storage bin). 25. Disconnect all necessary electrical connections and remove console. 26. Remove two (2) nuts and two (2) screws retaining instrument panel to cowl panel behind center console. 27. Remove one (1) screw at instrument panel LH side. 28. Gently pull instrument panel away from RH side of cowl panel. 29. Place a drain pan or suitable container under heater hose connections at the cowl panel. 30. Discharge refrigerant from the A/C system at service access gauge port valve located in suction line, following the recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS 31. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 32. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 33. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 34. Remove screw holding instrument panel shake brace to evaporator case and remove instrument panel shake brace. 35. Remove two (2) screws retaining floor register and rear seat duct to bottom of evaporator case. 36. Remove three (3) nuts retaining evaporator case to cowl panel in engine compartment. 37. Remove two (2) screws retaining support brackets to cowl top panel. 38. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 39. Remove the evaporator core from the case following the procedure in the appropriate service manual. 40. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual. 41. Install the evaporator case in the vehicle by reversing the removal procedure. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. Continental CONTINENTAL EVAPORATOR CORE REPLACEMENT 1. Disconnect battery ground cable. 2. Remove RH finish molding by pulling up to unsnap six (6) clips and disconnect wiring. 3. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor. 4. Remove LH finish molding by pulling up to unsnap six (6) clips. 5. Remove four (4) push pins from RH and LH lower insulators. Remove insulators. 6. Remove five (5) screws retaining lower instrument panel steering column cover and remove cover. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 6982 7. Remove four (4) screws retaining lower instrument panel steering column reinforcement. Remove reinforcement. 8. Remove four (4) nuts and absorber assembly. 9. Remove tilt wheel lever. 10. Remove two (2) screws retaining lower steering column shroud. Remove lower steering column shroud. 11. Disconnect PRNDL cable and all steering column electrical connections. 12. Remove four (4) nuts retaining steering column. Lower steering column. 13. Remove screw, at steering column opening, retaining instrument panel to brake pedal support. 14. Remove two (2) screws under ash receptacle which retain instrument panel to evaporator case. 15. Remove headlamp switch knob. 16. Remove five (5) screws from instrument cluster opening finish panel and remove panel. 17. Remove four (4) screws retaining instrument cluster. Disconnect electrical connectors. 18. Remove three (3) screws to remove glove compartment assembly. 19. Remove two (2) screws from instrument panel to cowl top brace and one (1) screw from passenger air bag support bracket. 20. Remove both side demister grilles by snapping out to release. 21. Remove two (2) screws and remove center defrost grille. 22. Remove LH and RH cowl side trim panels. 23. Disconnect electrical connections at RH cowl side panel. 24. Remove two (2) lower screws at instrument panel, one at each end. 25. Remove three (3) upper instrument panel retaining screws and gently pull instrument panel away from RH side of cowl panel. 26. Place a drain pan or suitable container under heater hose connections at the cowl panel. 27. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 28. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 29. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 30. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 31. Remove screw holding instrument panel shake brace to evaporator case and remove instrument panel shake brace. 32. Remove two (2) screws retaining floor register (or rear seat adapter) to bottom of evaporator case. 33. Disconnect the vacuum line, electrical connections and aspirator hose from the evaporator case. 34. Remove three (3) nuts retaining evaporator case to cowl panel in engine compartment. 35. Remove two (2) screws retaining support brackets to cowl top panel. 36. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 6983 37. Remove the evaporator core from the case following the procedure in the appropriate service manual. 38. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual. 39. Install the evaporator case in the vehicle by reversing the removal procedure. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. Thunderbird/Cougar THUNDERBIRD/COUGAR EVAPORATOR CORE REPLACEMENT NOTE: REFER TO TSB 94-2-12 IF WATER DRIPS FROM THE FLOOR DUCTS 1. Disconnect battery ground cable. 2. Remove steering column lower trim cover. (Remove three (3) screws at bottom, one (1) screw LH side and pull to disengage five (5) snap-in retainers across top). 3. Remove steering column lower opening reinforcement. Six (6) screws retain reinforcement to instrument panel. 4. Remove steering column upper and lower shrouds. 5. Disconnect wiring from steering column. 6. Remove shift interlock switch. 7. Disconnect steering column lower universal joint. 8. Support steering column and remove four (4) nuts retaining column to support. Remove column from vehicle. 9. Remove one (1) nut retaining LH side of instrument panel to parking brake bracket. 10. Remove RH and LH side cowl trim panels. 11. Disconnect electrical connections at RH cowl side. 12. Remove two (2) instrument panel-to-floor tunnel nuts. 13. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor. 14. Disconnect wiring, heater and A/C vacuum lines and control cables through glove compartment opening. 15. Remove two (2) screws at RH side retaining instrument panel to cowl side. 16. Remove two (2) screws at LH side retaining instrument panel to cowl side. 17. Remove RH and LH finish panel by pulling up to disengage snap-in retainers, three (3) on RH side and four (4) on LH side. 18. Remove RH and LH roof rail trim panels. 19. Remove four (4) screws retaining instrument panel to cowl top. 20. Gently pull instrument panel away from RH side of cowl panel. 21. Place a drain pan or suitable container under heater hose connections at the cowl panel. 22. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 23. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 6984 evaporator core to prevent the entrance of dirt and excess moisture. 24. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 25. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 26. Working under the hood, remove three (3) nuts retaining the evaporator case to the cowl panel. 27. Inside the passenger compartment, remove the screw attaching the evaporator case support bracket to the cowl top panel. 28. Remove one (1) nut retaining the bracket below the evaporator case to the cowl panel. 29. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 30. Remove the evaporator core from the case following the procedure in the appropriate service manual. 31. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual. 32. Install the evaporator case in the vehicle by reversing the removal procedure. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. Mustang MUSTANG EVAPORATOR CORE REPLACEMENT 1. Disconnect battery ground cable. 2. Remove two (2) access covers at rear of console (snaps out) to gain access to arm rest retaining bolts. 3. Remove armrest-to-floor bracket retaining bolts and remove armrest assembly (snaps out of console). 4. Remove gearshift opening finish panel (snaps out). On vehicles equipped with manual transmissions, shift boot is attached to bottom of finish panel. Remove shift knob and slide boot and finish panel up to shift lever to remove. 5. To remove top finish panel, position emergency brake lever in the UP position. Remove four (4) retaining screws and lift panel up. Disconnect necessary wire connectors. 6. Remove two (2) console-to-rear floor bracket retaining screws. 7. Insert a small screwdriver into two (2) notches at bottom of front upper panel and snap out. 8. There are three (3) combinations of radio cover finish panels: a. Radio opening cover plate with storage bin (radio delete option). b. Radio with storage bin. c. Radio with graphic equalizer (one unit). ^ Combination a: Use a small screwdriver and pry radio cover finish panel out of console. ^ Combinations b and c: The radio must be removed first. Refer to Service Manual, Section 15.01, for procedure. 9. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor. 10. Remove four (4) console bracket retaining screws. Remove console from vehicle. 11. Remove three (3) bolts retaining steering column opening cover and reinforcement panel. Remove cover. 12. Remove steering column opening reinforcement by removing two (2) bolts. 13. Remove two (2) bolts retaining steering column opening reinforcement and remove reinforcement. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 6985 14. Remove six (6) steering column retaining nuts, two (2) retaining the hood release mechanism and four (4) retaining column to lower brake pedal support. Lower steering column to floor. 15. Remove steering column upper and lower shrouds and disconnect wiring from multi-function switch. 16. Remove steering column through-bolt and nut on engine side of cowl panel. Remove steering column from vehicle. 17. Remove brake pedal support nut. 18. Snap out defroster grille. 19. Remove screws from speaker grilles. Snap out speaker covers. 20. Remove front screws retaining RH and LH scuff plates at cowl side trim panels. 21. Remove LH and RH cowl side trim panels. 22. Disconnect electrical connections at RH cowl side panel. 23. Remove cowl side retaining bolts, (one at each end). 24. Remove five (5) cowl top attaching screws. 25. Gently pull instrument panel away from RH side of cowl panel. Disconnect speedometer cable, air conditioning controls and wire connectors. 26. Place a drain pan or suitable container under heater hose connections at the cowl panel. 27. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the recovery procedure. NOTE: OBSERVE ALL SAFETY PRECAUTIONS. 28. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 29. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 30. Remove screw holding air inlet duct and blower housing assembly support brace to cowl top panel. 31. Disconnect the vacuum line (black), from in-line vacuum check valve in engine compartment. 32. Remove three (3) nuts retaining evaporator case to cowl panel in engine compartment. 33. Inside the passenger compartment, remove two (2) screws retaining evaporator case support brackets to cowl top panel. 34. Remove one screw retaining bracket below evaporator case to cowl panel. 35. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 36. Remove the evaporator core from the case following the procedure in the appropriate service manual. 37. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual. 38. Install the evaporator case in the vehicle by reversing the removal procedure. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts Evaporator Core: All Technical Service Bulletins A/C - Water Leaks From the Floor Ducts Article No. 94-2-12 01/26/94 AIR CONDITIONING - WATER DRIPS FROM THE FLOOR DUCTS WHEN A/C IS OPERATING VEHICLES BUILT FROM JOB-1 1989 THROUGH 10/15/93 FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR ISSUE: Condensation may drip from the floor duct when the A/C is operating. This occurs because the location of the evaporator core inside the housing allows high velocity air to carry water droplets from the core face beyond the sump area in the housing. ACTION: Replace the evaporator core and housing assembly with a new assembly which has a relocated evaporator core that allows the condensate to drain into the sump area of the housing rather than into the passenger compartment. Refer to the following procedure for service details. NOTE: USE PROCEDURE # 1 FOR 1994 MODELS ONLY AND USE PROCEDURE # 2 FOR 1989-93 MODELS. CAUTION: OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS WHILE PERFORMING THE FOLLOWING SERVICE PROCEDURE. PROCEDURE # 1 - 1994 MODELS BUILT BEFORE 10/15/93 ONLY NOTE: THIS VEHICLE USES THE NON-CHLOROFLUOROCARBON (NON-CFC) BASED REFRIGERANT R-134a. R-134a A/C SYSTEMS REQUIRE THE USE OF SPECIAL SERVICING EQUIPMENT DESIGNED SPECIALLY FOR SERVICING R-134a A/C SYSTEMS CAUTION: DO NOT USE R-12 SPECIAL TOOLS AND EQUIPMENT WHEN SERVICING AN R-134a SYSTEM. DOING SO MAY CAUSE DAMAGE TO THE A/C SYSTEM. REFER TO THE ROTUNDA CATALOG FOR MORE INFORMATION ON R-134a SPECIAL SERVICING EQUIPMENT. 1. Record radio stations. 2. Disconnect battery ground cable. Disconnect positive battery and wait one (1) minute for the air bag diagnostic monitor to deplete the air bag back-up power supply. Refer to Service Manual Section 01-20B. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6990 3. Loosen main wiring connector bolt in engine compartment at LH side of dash panel and separate connectors, Figure 1. 4. Remove the radio antenna through the right front wheel well. Disengage the antenna wire grommet from the sheet metal and push the antenna lead-in cable through the sheet metal into vehicle interior. 5. Remove the screws retaining the RH and LH scuff plates (do not remove the scuff plates from the vehicle). Lift scuff plates and remove door opening weatherstrips from body flanges. 6. Remove both RH and LH windshield side garnish moldings. 7. Remove both RH and LH cowl side trim panels. 8. Remove instrument panel steering column cover: a. remove the three (3) screws along the bottom b. pull on cover to unsnap the three (3) clips across the top. 9. Remove one (1) screw and A/C evaporator register duct from under the steering column tube. 10. Disconnect the electrical connectors at the base of the steering column. 11. Remove the pinch bolt attaching the steering column tube to steering column lower yoke and slightly spread the joint with a screwdriver. 12. Disconnect the multi-function switch connector located under the column assembly. 13. Disconnect the ignition switch connector. 14. While supporting the steering column tube, remove the four (4) steering column tube retaining nuts. 15. Lower steering column and remove shift interlock cable retaining screws and shift actuator cable fitting. Disconnect the electrical connector from shift interlock solenoid. 16. Remove steering column from the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6991 17. Disconnect stop lamp switch, Figure 2. 18. Pull back the floor carpet as required on the RH and LH sides of the vehicle and disconnect the window regulator safety switch connector and the Powertrain Control Module connector. 19. Remove glove compartment: a. Open glove compartment to the stop. b. Unsnap the hydraulic lift from the right side of the glove compartment. c. Remove the three (3) screws at the bottom retaining the glove compartment door hinge and glove compartment to the instrument panel. d. Remove glove compartment from the instrument panel. 20. Reach through the glove compartment opening and disconnect the electrical and vacuum connectors from the heater-A/C evaporator housing. 21. Disconnect the connectors behind the RH kick panel, Figure 3. 22. Disconnect the two (2) speed control amplifier connectors. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6992 23. Remove floor console panel. Refer to the 1994 Thunderbird/Cougar Service Manual, Section 01-12-4 and 01-12-5. NOTE: PROTECT THE INSTRUMENT PANEL SURFACE DURING THE FOLLOWING PROCEDURE. 24. Remove two (2) nuts and one (1) bolt from the instrument panel-to-console mount, Figure 4. 25. Remove two (2) nuts retaining the LH side of instrument panel to cowl side, Figure 4. 26. Remove the nut attaching the RH side of instrument panel to cowl side, Figure 4. NOTE: THE FOLLOWING THREE STEPS REQUIRE TWO TECHNICIANS. 27. Remove 6 bolts from the top of the instrument panel, Figure 4. 28. Carefully pull the instrument panel away from windshield glass, checking for and disconnecting any remaining wiring connectors. 29. Remove the instrument panel from the vehicle. 30. Recover the R-134a refrigerant from the A/C system at the service access gauge port valve, following the proper recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 31. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 32. Place a drain pan or suitable container under heater hose connections at the cowl panel. 33. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 34. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 35. Remove the suction accumulator drier from its bracket then remove the bracket. 36. Remove the three (3) retaining nuts attaching the evaporator housing to the cowl panel (under the hood). 37. Remove one (1) screw at the base of the evaporator housing and one (1) screw at the evaporator housing-to-cowl panel bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6993 38. Remove the evaporator housing from the vehicle. 39. Transfer the parts from the removed evaporator assembly to the new service evaporator assembly, based on the type of system in the vehicle. See illustrations. 40. Install the evaporator case and instrument panel in the vehicle by reversing the removal procedure. 41. Refill coolant and check for leaks. 42. Recharge the A/C system and check the operation of the system. 43. Reset radio stations recorded in step # 1. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. PROCEDURE # 2 - 1989-93 MODELS NOTE: AUTOMATIC TEMPERATURE CONTROL - EQUIPPED UNITS BUILT BEFORE 7/1/92 WILL REQUIRE A NEW ASPIRATOR ASSEMBLY (F4SZ-19E628-A) ALONG WITH THE NEW EVAPORATOR CASE ASSEMBLY. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6994 CAUTION: OBSERVE ALL SAFETY AND SERVICE PRECAUTIONS WHILE PERFORMING THE FOLLOWING SERVICE PROCEDURE. 1. Record radio stations. 2. Disconnect battery ground cable. 3. Remove steering column lower trim cover. (Remove three (3) screws at bottom, one (1) screw LH side and pull to disengage five (5) snap-in retainers across top). 4. Remove steering column lower opening reinforcement. Six (6) screws retain reinforcement to instrument panel. 5. Remove steering column upper and lower shrouds. 6. Disconnect wiring from steering column. 7. Remove shift interlock switch, if equipped. 8. Disconnect steering column lower universal joint. 9. Support steering column and remove four (4) nuts retaining column to support. Remove column from vehicle. 10. Remove one (1) nut retaining LH side of instrument panel to parking brake bracket. 11. Remove RH and LH side cowl trim panels. 12. Disconnect electrical connections at RH cowl side. 13. Remove two (2) instrument panel-to-floor tunnel nuts. 14. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor. 15. Disconnect wiring, heater and A/C vacuum lines and control cables through glove compartment opening. 16. Remove two (2) screws at RH side retaining instrument panel to cowl side. 17. Remove two (2) screws at LH side retaining instrument panel to cowl side. 18. Remove RH and LH finish panel by pulling up to disengage snap-in retainers, three (3) on RH side and four (4) on LH side. 19. Remove RH and LH roof rail trim panels. 20. Remove four (4) screws retaining instrument panel to cowl top. 21. Gently pull instrument panel away from RH side of cowl panel. 22. Place a drain pan or suitable container under heater hose connections at the cowl panel. 23. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the proper recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 24. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 25. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 26. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 27. Working under the hood, remove three (3) nuts retaining the evaporator case to the cowl panel. 28. Inside the passenger compartment, remove the screw attaching the evaporator case support bracket to the cowl top panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6995 29. Remove one (1) nut retaining the bracket below the evaporator case to the cowl panel. 30. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 31. Transfer the following parts from the removed evaporator assembly to the new service evaporator assembly, based on the type of system in the vehicle. NOTE: IF THE UNIT IS EQUIPPED WITH ATC AND WAS BUILT PRIOR TO 7/1/92, YOU WILL HAVE TO USE A NEW ASPIRATOR (F4SZ-19E628-A) THAT IS DESIGNED FOR THE NEW SERVICE CASE AND ELIMINATE THE OLD ASPIRATOR. CHANGE OVER TO THE NEW ASPIRATOR AS FOLLOWS: ^ TRANSFER THE GASKET FROM THE EXISTING ASPIRATOR ASSEMBLY PLATE TO THE BACK OF THE BLOWER SPEED CONTROLLER SO YOU WILL SEAL THE MATING SURFACE OF THE CONTROLLER TO THE CASE. INSTALL THE BLOWER SPEED CONTROLLER TO THE CASE WITHOUT THE OLD ASPIRATOR, MAKING CERTAIN THAT THE GASKET SEALS PROPERLY. ^ DISCARD THE EXISTING ASPIRATOR ASSEMBLY AND INSTALL THE NEW ASPIRATOR (F4SZ-19E628-A) IN THE UPPER CASE HALF, IN THE EXISTING HOLE NEXT TO THE MUFFLER ASSEMBLY, USING A SCREW (# 10-12X .75 HEX WASHER HEAD SELF-TAPPING); OBTAIN LOCALLY. ^ USING THE OLD ASPIRATOR CONNECTING TUBE, CUT IT TO SIZE (SHORTEN) AND INSTALL IT BETWEEN THE NEW ASPIRATOR AND THE MUFFLER. 32. Cut off the end of the drain tube located on the bottom of the evaporator case under the heater core area. Cut Off The End Of The Drain Tube, Do Not Drill. CAUTION: DO NOT DRILL OUT THE HOLE BECAUSE THE HEATER CORE COULD BE DAMAGED, FIGURE 5. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 94212 > Jan > 94 > A/C - Water Leaks From the Floor Ducts > Page 6996 Connect A Hose To The Drain Tube. 33. Connect a 1/2" (12.7 mm) outside diameter hose (E8UZ-19K592-A) to the drain tube using a small hose clamp (376240-S100), Figure 6. 34. Install the evaporator case in the vehicle by reversing the removal procedure. a. Drill a hole in the cowl panel to accommodate the new drain tube. See Figure 2 for location. The hole should be about 2" (50.8 mm) below the regular evaporator case drain tube. b. After the new drain tube is through the hole and in permanent position, seal around the tube with body sealer (F1AZ-19562-A). 35. Recharge the A/C system and check the operation of the system. 36. Reset radio stations recorded in step # 1. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. NOTE: IF EVAPORATOR CORE AND HOUSING ASSEMBLY IS REPLACED PER THIS TSB ARTICLE, IT WILL NOT BE NECESSARY TO PERFORM TSB 94-2-9. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 92-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/94 Models; Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 940212A Remove And Replace 4.5 Hrs. Evaporator Case DEALER CODING BASIC PART NO. CONDITION CODE 19850 08 OASIS CODES: 208000, 208300, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 93252 > Dec > 93 > A/C Evaporator Tube - Refrigerant Leaks Evaporator Core: All Technical Service Bulletins A/C Evaporator Tube - Refrigerant Leaks Article No. 93-25-2 12/08/93 ^ EMISSIONS CONTROL - CARBON CANISTER PURGE HOSE - HOLE WORN IN EVAPORATOR CORE TUBE BY CARBON CANISTER PURGE HOSE ^ AIR CONDITIONING - EVAPORATOR CORE TUBE WORN BY CARBON CANISTER HOSE ^ LEAKS - REFRIGERANT - HOLE WORN IN EVAPORATOR CORE TUBE BY CARBON CANISTER PURGE HOSE FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR This TSB article is being republished in its entirety to include 1992 and 1993 model year vehicles. ISSUE: A refrigerant leak may develop in the evaporator core tube near the spring lock coupling. The leak occurs because the carbon canister purge hose may be routed too close and rubs against one of the evaporator core tubes and eventually wears a hole in it. ACTION: Install a protective sleeve for each evaporator tube, using a 1" (25.2 mm) length of heater hose. Refer to the following procedure for service details. 1. Slit the heater hoses lengthwise and position one around each tube, close to the spring lock coupling. 2. Secure the two hoses in position with bundling straps, as required. 3. Be sure each sleeve is in the correct position to prevent the purge hose from rubbing against the core tubes. 4. Reroute the canister purge hose so that it is above the evaporator core tubes and not in contact with any other vacuum line or wiring harness. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-22-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992/93 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 932502A Install Protective Sleeve 0.4 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 19860 30 OASIS CODES: 208200, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 891713 > Aug > 89 > A/C - Service Replacement Kits Evaporator Core: All Technical Service Bulletins A/C - Service Replacement Kits AIR CONDITIONING - SERVICE REPLACEMENT KITS Article No. 89-17-13 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Service replacement kits for evaporator cores and evaporator cases, including case covers, are now available. An evaporator core cover must be used to seal the opening made in the top of the case when a core is replaced. ACTION: If service is required, refer to the 1989 Thunderbird/Cougar Shop Manual, Section 36-45. Also use the following supplemental service procedure. NOTE: WHENEVER THE EVAPORATOR CORE IS REPLACED, THE A/C ACCUMULATOR MUST ALSO BE REPLACED. Figure 1 1. Remove the evaporator assembly from the vehicle. 2. Cut the top out of the evaporator case. Use a small saw to cut between the dotted lines as shown in Figure 1. If a new evaporator case and cover kit is being installed, cut the top out of the new evaporator case by using the same method. 3. Remove the old evaporator core from the case. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Evaporator Core: > 891713 > Aug > 89 > A/C - Service Replacement Kits > Page 7005 Figure 2 4. Remove all burrs from the sawed edges of the evaporator case. 5. Position the new cover on the case. 6. Hold the cover in place and drill five 3/16" (7.938 mm) diameter holes for the attaching screws. 7. Install the new evaporator core in the evaporator case. If a new evaporator case and cover kit is being installed, transfer all hardware (evaporator core, heater core, vacuum motors, etc.) from the old evaporator case to the new case. 8. Run a bead of caulking cord rope sealer (D6AZ-19560-A), or equivalent, around the sawed edges of the evaporator case for a tight seal between the cover and the case. 9. Install the service cover on the evaporator case as shown in Figure 2. 10. Tighten the five attaching screws. 11. Install the evaporator case in the vehicle. PART NUMBER PART NAME CLASS E9SZ-19860-B Evaporator Core And Cover Kit B E9SZ-19850-B Evaporator Case And Cover Kit C E9SZ-19B735-A Evaporator Cover B D6AZ-19560-A Caulking Cord Rope Sealer - AG Pkg. of 8 E9SZ-19C836-A Accumulator - 3.8L Base C E9SZ-19C836-B Accumulator - 3.8L C Supercharged OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610, 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures Evaporator Core: All Technical Service Bulletins Air Conditioning - Approved Flushing Procedures Article No. 95-18-4 09/11/95 AIR CONDITIONING - FORD APPROVED FLUSHING PROCEDURES - SERVICE TIP FORD: 1985-86 LTD 1985-88 EXP 1985-94 TEMPO 1985-95 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-96 TAURUS 1989-93 FESTIVA 1989-95 PROBE 1994-95 ASPIRE 1995-96 CONTOUR LINCOLN-MERCURY: 1984-92 MARK VII 1985-86 MARQUIS 1985-87 LYNX 1985-94 TOPAZ 1985-95 COUGAR, GRAND MARQUIS, TOWN CAR 1985-96 CONTINENTAL 1986-96 SABLE 1987-89 TRACER 1991-93 CAPRI 1991-95 TRACER 1993-95 MARK VIII 1995-96 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-95 BRONCO, ECONOLINE, F-150-350 SERIES 1985-96 RANGER 1986-95 AEROSTAR 1991-96 EXPLORER 1993-95 VILLAGER 1995-96 WINDSTAR This TSB is being republished in its entirety to include Labor Operations for system flushing. ISSUE: Ford Motor Company has approved a procedure to provide technicians with a non-CFC method of flushing contaminated A/C system heat exchangers (evaporators and condensers). This procedure allows the A/C components to be cleaned and flushed while installed in the vehicle. The types of contamination flushed include particle matter which results from compressor or desiccant failure and the gummy residue which may form when refrigerant oil is overheated. Some Ford authorized HFC-134a retrofit kit procedures will also require A/C system flushing to remove mineral oil for capacity reasons. ACTION: Refer to the following text for proper flushing procedures. The flushing procedure is a two-step process which involves the use of an A/C Flusher. The Flusher is used to do the following: 1. Circulate the flushing solvent through the A/C system heat exchangers in the reverse direction of normal refrigerant flow (back flushing). Particle matter is filtered from the returning solvent and the solvent is returned to the reservoir for continued circulation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 95184 > Sep > 95 > Air Conditioning - Approved Flushing Procedures > Page 7011 2. Remove the flushing solvent from the A/C system. In this step, pressurized air (90-125 psi/620-862 kPa) is used to push and evaporate any remaining flush solvent from the heat exchangers. Only Rotunda Item No. 014-00990 A/C Flushing kit which includes 014-00991 A/C Flusher, 014-00992 A/C Flusher Filling Kit. and F4AZ-19579-A A/C Flushing Solvent (case of 4 gallons/15 L), is approved for use on Ford vehicles. No other flushing device or solvent is approved by Ford Motor Company for flushing A/C systems. The use of other equipment or solvent may cause damage to the A/C system and the flushing unit. Minimum time for flushing is 15 minutes and minimum time for air flushing is 30 minutes. Failure to continue air purge for the entire 30 minutes as specified may result in residual amounts of flush solvent contaminating the A/C system. Residual flush solvent in a functioning A/C system may lead to A/C system failure. Do not flush through orifice tubes. TXVs, accumulator/driers, receiver/driers, mufflers or hoses. Internal plumbing and material make-up of these components make it impossible to properly remove the debris and/or residual flushing solvent. One (1) gallon (3.8 L) of Ford A/C System Flushing Solvent is used in this device and is intended for one (1) vehicle only. It may be used to flush both heat exchangers on an individual vehicle, but under no circumstances should it be used on more than one (1) vehicle. The filter used when flushing is also intended for use on one (1) vehicle only. NOTE: DURING THE FLUSHING PROCESS, THIS MATERIAL MAY COLLECT RESIDUE FROM THE A/C SYSTEM, WHICH MAY INCLUDE CFC-12. DISPOSE OF THE SOLVENT AND FILTER IN ACCORDANCE WITH FEDERAL, STATE AND LOCAL REGULATIONS. Use of A/C system filter kits as prescribed in TSB 94-15-5 is optional if the A/C system is flushed. Filter kit use is recommended after flushing if the system is highly contaminated. If the hoses are clogged with debris, hose replacement is required. Always remember to match oil properly, replace the accumulator/drier and orifice tube, or TXV and receiver/drier when servicing an A/C system with a compressor or desiccant failure. The following vehicles require A/C system flushing with retrofit kits to remove mineral oil for capacity reasons. ^ 1993 Probe 2.0L and 2.5L ^ 1988-90 Escort 1.9L EFI ^ 1989-93 Thunderbird Super Coupe ^ 1986-92 Mark VII ^ 1991-93 Capri 1.6L and 1.6T ^ 1988-93 Festiva 1 .3L ^ 1987-90 Tracer 1.6L ^ 1985-89 XR4Ti ^ 1988-89 Scorpio OTHER APPLICABLE ARTICLES: 94-15-5 SUPERSEDES: 95-8-1 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991-95 Lincolns And All Other 1992-95 Models OPERATION DESCRIPTION TIME 951804A Flush Evaporator 1.0 Hr. 951804B Flush Condenser 1.0 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208200, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 94114 > Jun > 94 > A/C - Evaporator Core and Case Assembly Application Evaporator Core: All Technical Service Bulletins A/C - Evaporator Core and Case Assembly Application Article No. 94-11-4 06/01/94 AIR CONDITIONING - EVAPORATOR CORE AND CASE ASSEMBLY APPLICATION FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR 1993-94 MARK VIII ISSUE: A service replacement A/C evaporator core/case usage chart is available. ACTION: Refer to the usage chart for correct evaporator core/case application. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement Technical Service Bulletin # 9488 Date: 940420 Evaporator Core - Replacement Article No. 94-8-8 EVAPORATOR CORE REPLACEMENT PROCEDURE FORD: 1989-93 MUSTANG, THUNDERBIRD 1989-94 TAURUS, TEMPO LINCOLN-MERCURY: 1989-93 COUGAR 1989-94 CONTINENTAL, SABLE, TOPAZ This TSB article is being republished in its entirety to correct the TSB number referred to in the Note text of the Thunderbird/Cougar evaporator core replacement procedure. Because the instrument panel area on 1994 Thunderbird/Cougar models was reconfigured for air bags, it is recommended that the entire instrument panel be removed to facilitate replacement of the evaporator core and housing assembly. ISSUE: A procedure has been developed for replacing the evaporator core without removing the instrument panel from the vehicle. Following this procedure will reduce the time required to replace an evaporator core. ACTION: Loosen the instrument panel from the cowl by pulling the right end of the instrument panel rearward. This provides enough clearance to remove the evaporator case from the vehicle. A service procedure for each of the vehicles listed above is presented in this article. Refer to the following procedures for service details. OTHER APPLICABLE ARTICLES: 94-2-12 SUPERSEDES: 94-3-3 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper For 1992/94 Vehicles And 1991 Lincolns, Basic Warranty Coverage For All Other Models And 1989/90 Major Component Warranty Coverage OPERATION DESCRIPTION TIME 940808A Replace Evaporator Core 4.5 Hrs. (1989-94 Tempo/Topaz) 940808B Replace Evaporator Core 3.2 Hrs. (1989-93 Mustang) 940808C Replace Evaporator Core 4.0 Hrs. (1989-94 Taurus/Sable) 940808D Replace Evaporator Core 3.8 Hrs. (1989-94 Thunderbird / Cougar) 940808E Replace Evaporator Core 4.1 Hrs. (1989-94 Continental) DEALER CODING BASIC PART NO. CONDITION CODE 19860 01 OASIS CODES: 208000, 208200, 290000 Tempo/Topaz TEMPO/TOPAZ EVAPORATOR CORE REPLACEMENT 1. Disconnect battery ground cable. 2. Raise vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 7020 3. Disconnect speedometer cable at transaxle. 4. Lower vehicle. 5. Remove two (2) cover retaining screws at bottom of steering column opening and snap cover out. 6. Remove snap in lower cluster finish panel(s) (Topaz LS is one piece, all others, two pieces) to expose two (2) screws and two (2) bolts. 7. Remove four (4) cluster opening finish panel retaining screws and pull panel rearward. 8. Remove speed control module, if so equipped (two (2) screws). 9. Remove lower steering column shroud (five (5) screws). 10. Disconnect all steering column electrical connections: ignition, washer/wiper, turn signal, key warning buzzer and speed control. On console automatic transmission shift, remove interlock cable retaining screw and disconnect cable from steering column. 11. Loosen, but do not remove, two (2) nuts and two (2) bolts retaining steering column to support bracket and remove upper shroud. 12. Loosen steering column to intermediate shaft clamp connection and remove bolt or nut. 13. Remove two (2) nuts and two (2) bolts retaining steering column to support bracket. 14. Pry open steering column shaft in area of clamp on each side of bolt groove with steering column locked. Open enough to disengage shafts with minimal effort. Remove column. 15. Inspect two (2) steering column bracket clips for damage. If clips have been bent or excessively distorted, they must be replaced. 16. Remove four (4) screws retaining cluster and carefully pull rearward enough to disengage speedometer cable. Loosely install two (2) screws to retain instrument cluster during instrument panel removal. 17. Remove left A-pillar garnish molding (five (5) screws). 18. Remove right A-pillar garnish molding (five (5) screws) 19. Remove left kick panel. 20. Remove one (1) instrument panel-to-steering column support bracket retaining nut, accessible through steering column opening. 21. Remove two (2) lower instrument panel-to-cowl side retaining screws (RH and LH side). 22. Remove two (2) instrument panel vertical brace retaining nuts located on the LH side of glove compartment. 23. Gently pull instrument panel away from RH side of cowl panel. 24. Drain the coolant from the radiator into a clean container. 25. Discharge the refrigerant from the A/C system, following the recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS 26. Disconnect the heater hoses from the heater core. Plug the heater core tubes or blow any coolant from the heater core with low pressure air. 27. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the dash panel. Cap the refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 28. Disconnect the wire harness connector from the blower motor resistor. 29. Remove one (1) screw retaining the bottom of the evaporator case to the cowl panel. 30. Remove the instrument panel brace from the cowl top panel. 31. In the engine compartment, remove two (2) nuts retaining the evaporator case to the cowl panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 7021 32. Loosen the sound insulator from the cowl top panel in the area around the air inlet opening. 33. Remove the two (2) screws retaining the support bracket and the brace to the cowl top panel. 34. Pull the right end of the instrument panel away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 35. Remove the evaporator core from the case following the procedure in the appropriate service manual for cutting the top out of the case. 36. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual. 37. Install the evaporator case in the vehicle by reversing the removal procedure. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. Tauras/Sable TAURUS/SABLE EVAPORATOR CORE REPLACEMENT 1. Disconnect battery ground cable. 2. Remove radio cluster as outlined in the Service Manual, Section 15-01. 3. Remove two (2) bolts and remove the steering column opening cover from under steering column. 4. Remove sound insulators from under steering column. 5. Remove three (3) screws retaining lower steering column shroud and remove shroud. 6. Remove two (2) bolts and steering column reinforcement from under steering column. 7. Disconnect all electrical connections from steering column switches. 8. Remove four (4) nuts retaining steering column support brace, disconnect PRNDL cable (column shift) and lower steering column. 9. Disconnect park brake release cable from park brake and disconnect ignition switch wiring connector. 10. Remove instrument cluster finish panel and disconnect all instrument cluster finish panel electrical connections. 11. Remove four (4) retaining screws from instrument cluster and... a. disconnect speedometer cable (if equipped), b. disconnect wiring and remove instrument cluster. 12. Remove one (1) bolt at steering column opening attaching instrument panel to brace. 13. Remove one (1) instrument panel brace retaining bolt (under the radio area). 14. Remove sound insulator under glove compartment by removing two (2) push nuts that secure insulator to studs on the evaporator case. 15. Remove three (3) screws attaching glove compartment assembly to instrument panel and remove door assembly. 16. Remove LH and RH cowl side trim panels. 17. Disconnect electrical connections at RH cowl side. 18. Remove three (3) screws retaining instrument panel to cowl top panel. 19. Remove one (1) screw at instrument panel RH side. 20. Remove two (2) instrument panel-to-center console nuts. 21. Remove cup holder and shift lever opening retaining screw. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 7022 22. Remove shift lever rearward. 23. Remove shift lever opening cover (snaps out). 24. Remove eight (8) console-to-floor bracket retaining screws (the two (2) rear screws are under the mat in the rear storage bin). 25. Disconnect all necessary electrical connections and remove console. 26. Remove two (2) nuts and two (2) screws retaining instrument panel to cowl panel behind center console. 27. Remove one (1) screw at instrument panel LH side. 28. Gently pull instrument panel away from RH side of cowl panel. 29. Place a drain pan or suitable container under heater hose connections at the cowl panel. 30. Discharge refrigerant from the A/C system at service access gauge port valve located in suction line, following the recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS 31. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 32. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 33. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 34. Remove screw holding instrument panel shake brace to evaporator case and remove instrument panel shake brace. 35. Remove two (2) screws retaining floor register and rear seat duct to bottom of evaporator case. 36. Remove three (3) nuts retaining evaporator case to cowl panel in engine compartment. 37. Remove two (2) screws retaining support brackets to cowl top panel. 38. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 39. Remove the evaporator core from the case following the procedure in the appropriate service manual. 40. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual. 41. Install the evaporator case in the vehicle by reversing the removal procedure. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. Continental CONTINENTAL EVAPORATOR CORE REPLACEMENT 1. Disconnect battery ground cable. 2. Remove RH finish molding by pulling up to unsnap six (6) clips and disconnect wiring. 3. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor. 4. Remove LH finish molding by pulling up to unsnap six (6) clips. 5. Remove four (4) push pins from RH and LH lower insulators. Remove insulators. 6. Remove five (5) screws retaining lower instrument panel steering column cover and remove cover. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 7023 7. Remove four (4) screws retaining lower instrument panel steering column reinforcement. Remove reinforcement. 8. Remove four (4) nuts and absorber assembly. 9. Remove tilt wheel lever. 10. Remove two (2) screws retaining lower steering column shroud. Remove lower steering column shroud. 11. Disconnect PRNDL cable and all steering column electrical connections. 12. Remove four (4) nuts retaining steering column. Lower steering column. 13. Remove screw, at steering column opening, retaining instrument panel to brake pedal support. 14. Remove two (2) screws under ash receptacle which retain instrument panel to evaporator case. 15. Remove headlamp switch knob. 16. Remove five (5) screws from instrument cluster opening finish panel and remove panel. 17. Remove four (4) screws retaining instrument cluster. Disconnect electrical connectors. 18. Remove three (3) screws to remove glove compartment assembly. 19. Remove two (2) screws from instrument panel to cowl top brace and one (1) screw from passenger air bag support bracket. 20. Remove both side demister grilles by snapping out to release. 21. Remove two (2) screws and remove center defrost grille. 22. Remove LH and RH cowl side trim panels. 23. Disconnect electrical connections at RH cowl side panel. 24. Remove two (2) lower screws at instrument panel, one at each end. 25. Remove three (3) upper instrument panel retaining screws and gently pull instrument panel away from RH side of cowl panel. 26. Place a drain pan or suitable container under heater hose connections at the cowl panel. 27. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 28. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 29. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 30. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 31. Remove screw holding instrument panel shake brace to evaporator case and remove instrument panel shake brace. 32. Remove two (2) screws retaining floor register (or rear seat adapter) to bottom of evaporator case. 33. Disconnect the vacuum line, electrical connections and aspirator hose from the evaporator case. 34. Remove three (3) nuts retaining evaporator case to cowl panel in engine compartment. 35. Remove two (2) screws retaining support brackets to cowl top panel. 36. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 7024 37. Remove the evaporator core from the case following the procedure in the appropriate service manual. 38. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual. 39. Install the evaporator case in the vehicle by reversing the removal procedure. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. Thunderbird/Cougar THUNDERBIRD/COUGAR EVAPORATOR CORE REPLACEMENT NOTE: REFER TO TSB 94-2-12 IF WATER DRIPS FROM THE FLOOR DUCTS 1. Disconnect battery ground cable. 2. Remove steering column lower trim cover. (Remove three (3) screws at bottom, one (1) screw LH side and pull to disengage five (5) snap-in retainers across top). 3. Remove steering column lower opening reinforcement. Six (6) screws retain reinforcement to instrument panel. 4. Remove steering column upper and lower shrouds. 5. Disconnect wiring from steering column. 6. Remove shift interlock switch. 7. Disconnect steering column lower universal joint. 8. Support steering column and remove four (4) nuts retaining column to support. Remove column from vehicle. 9. Remove one (1) nut retaining LH side of instrument panel to parking brake bracket. 10. Remove RH and LH side cowl trim panels. 11. Disconnect electrical connections at RH cowl side. 12. Remove two (2) instrument panel-to-floor tunnel nuts. 13. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor. 14. Disconnect wiring, heater and A/C vacuum lines and control cables through glove compartment opening. 15. Remove two (2) screws at RH side retaining instrument panel to cowl side. 16. Remove two (2) screws at LH side retaining instrument panel to cowl side. 17. Remove RH and LH finish panel by pulling up to disengage snap-in retainers, three (3) on RH side and four (4) on LH side. 18. Remove RH and LH roof rail trim panels. 19. Remove four (4) screws retaining instrument panel to cowl top. 20. Gently pull instrument panel away from RH side of cowl panel. 21. Place a drain pan or suitable container under heater hose connections at the cowl panel. 22. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the recovery procedure. CAUTION: OBSERVE ALL SAFETY PRECAUTIONS. 23. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 7025 evaporator core to prevent the entrance of dirt and excess moisture. 24. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 25. Disconnect vacuum supply hose from in-line vacuum check valve in engine compartment. 26. Working under the hood, remove three (3) nuts retaining the evaporator case to the cowl panel. 27. Inside the passenger compartment, remove the screw attaching the evaporator case support bracket to the cowl top panel. 28. Remove one (1) nut retaining the bracket below the evaporator case to the cowl panel. 29. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 30. Remove the evaporator core from the case following the procedure in the appropriate service manual. 31. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual. 32. Install the evaporator case in the vehicle by reversing the removal procedure. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED. Mustang MUSTANG EVAPORATOR CORE REPLACEMENT 1. Disconnect battery ground cable. 2. Remove two (2) access covers at rear of console (snaps out) to gain access to arm rest retaining bolts. 3. Remove armrest-to-floor bracket retaining bolts and remove armrest assembly (snaps out of console). 4. Remove gearshift opening finish panel (snaps out). On vehicles equipped with manual transmissions, shift boot is attached to bottom of finish panel. Remove shift knob and slide boot and finish panel up to shift lever to remove. 5. To remove top finish panel, position emergency brake lever in the UP position. Remove four (4) retaining screws and lift panel up. Disconnect necessary wire connectors. 6. Remove two (2) console-to-rear floor bracket retaining screws. 7. Insert a small screwdriver into two (2) notches at bottom of front upper panel and snap out. 8. There are three (3) combinations of radio cover finish panels: a. Radio opening cover plate with storage bin (radio delete option). b. Radio with storage bin. c. Radio with graphic equalizer (one unit). ^ Combination a: Use a small screwdriver and pry radio cover finish panel out of console. ^ Combinations b and c: The radio must be removed first. Refer to Service Manual, Section 15.01, for procedure. 9. Open glove compartment door and depress both sides of glove compartment inward and lower glove compartment door toward floor. 10. Remove four (4) console bracket retaining screws. Remove console from vehicle. 11. Remove three (3) bolts retaining steering column opening cover and reinforcement panel. Remove cover. 12. Remove steering column opening reinforcement by removing two (2) bolts. 13. Remove two (2) bolts retaining steering column opening reinforcement and remove reinforcement. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 9488 > Apr > 94 > Evaporator Core - Replacement > Page 7026 14. Remove six (6) steering column retaining nuts, two (2) retaining the hood release mechanism and four (4) retaining column to lower brake pedal support. Lower steering column to floor. 15. Remove steering column upper and lower shrouds and disconnect wiring from multi-function switch. 16. Remove steering column through-bolt and nut on engine side of cowl panel. Remove steering column from vehicle. 17. Remove brake pedal support nut. 18. Snap out defroster grille. 19. Remove screws from speaker grilles. Snap out speaker covers. 20. Remove front screws retaining RH and LH scuff plates at cowl side trim panels. 21. Remove LH and RH cowl side trim panels. 22. Disconnect electrical connections at RH cowl side panel. 23. Remove cowl side retaining bolts, (one at each end). 24. Remove five (5) cowl top attaching screws. 25. Gently pull instrument panel away from RH side of cowl panel. Disconnect speedometer cable, air conditioning controls and wire connectors. 26. Place a drain pan or suitable container under heater hose connections at the cowl panel. 27. Discharge refrigerant from the A/C system at service access gauge port valve located on suction line, following the recovery procedure. NOTE: OBSERVE ALL SAFETY PRECAUTIONS. 28. Disconnect the liquid line and the suction accumulator/drier inlet tube from the evaporator core at the cowl panel. Cap refrigerant lines and evaporator core to prevent the entrance of dirt and excess moisture. 29. Disconnect heater hoses from heater core tubes and plug hoses with suitable 5/8" (16 mm) and 3/4" (19 mm) plugs. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator core. 30. Remove screw holding air inlet duct and blower housing assembly support brace to cowl top panel. 31. Disconnect the vacuum line (black), from in-line vacuum check valve in engine compartment. 32. Remove three (3) nuts retaining evaporator case to cowl panel in engine compartment. 33. Inside the passenger compartment, remove two (2) screws retaining evaporator case support brackets to cowl top panel. 34. Remove one screw retaining bracket below evaporator case to cowl panel. 35. Carefully pull the right end of the instrument panel away from the cowl panel, pull the evaporator case away from the cowl and remove the evaporator case from the vehicle. Place the evaporator case on a work bench. 36. Remove the evaporator core from the case following the procedure in the appropriate service manual. 37. Install the new core in the case and seal the top of the case as outlined in the appropriate service manual. 38. Install the evaporator case in the vehicle by reversing the removal procedure. NOTE: CHECK THE OPERATION OF ALL COMPONENTS AFTER ASSEMBLY IS COMPLETED Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 891713 > Aug > 89 > A/C - Service Replacement Kits Evaporator Core: All Technical Service Bulletins A/C - Service Replacement Kits AIR CONDITIONING - SERVICE REPLACEMENT KITS Article No. 89-17-13 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Service replacement kits for evaporator cores and evaporator cases, including case covers, are now available. An evaporator core cover must be used to seal the opening made in the top of the case when a core is replaced. ACTION: If service is required, refer to the 1989 Thunderbird/Cougar Shop Manual, Section 36-45. Also use the following supplemental service procedure. NOTE: WHENEVER THE EVAPORATOR CORE IS REPLACED, THE A/C ACCUMULATOR MUST ALSO BE REPLACED. Figure 1 1. Remove the evaporator assembly from the vehicle. 2. Cut the top out of the evaporator case. Use a small saw to cut between the dotted lines as shown in Figure 1. If a new evaporator case and cover kit is being installed, cut the top out of the new evaporator case by using the same method. 3. Remove the old evaporator core from the case. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > All Other Service Bulletins for Evaporator Core: > 891713 > Aug > 89 > A/C - Service Replacement Kits > Page 7031 Figure 2 4. Remove all burrs from the sawed edges of the evaporator case. 5. Position the new cover on the case. 6. Hold the cover in place and drill five 3/16" (7.938 mm) diameter holes for the attaching screws. 7. Install the new evaporator core in the evaporator case. If a new evaporator case and cover kit is being installed, transfer all hardware (evaporator core, heater core, vacuum motors, etc.) from the old evaporator case to the new case. 8. Run a bead of caulking cord rope sealer (D6AZ-19560-A), or equivalent, around the sawed edges of the evaporator case for a tight seal between the cover and the case. 9. Install the service cover on the evaporator case as shown in Figure 2. 10. Tighten the five attaching screws. 11. Install the evaporator case in the vehicle. PART NUMBER PART NAME CLASS E9SZ-19860-B Evaporator Core And Cover Kit B E9SZ-19850-B Evaporator Case And Cover Kit C E9SZ-19B735-A Evaporator Cover B D6AZ-19560-A Caulking Cord Rope Sealer - AG Pkg. of 8 E9SZ-19C836-A Accumulator - 3.8L Base C E9SZ-19C836-B Accumulator - 3.8L C Supercharged OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610, 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7032 Evaporator Core: Service and Repair 1. Disconnect battery negative cable. 2. Remove instrument panel as follows: a. Disconnect main wiring at assembly, on left hand side of fire wall. b. Disengage wiring assembly tabs from dash panel, and push assembly into passenger compartment. c. Remove four steering column lower trim cover attaching screws, and pull trim cover away from dash panel. d. Remove six steering column lower opening reinforcement attaching screws, then the reinforcement. e. Remove lower and upper shrouds from steering column, then disconnect steering column electrical connectors. f. Remove the shift interlock switch. g. Disconnect the steering column lower universal joint. h. While supporting the steering column, remove four retaining nuts then the steering column. i. Remove parking brake bracket-to-instrument panel attaching screw. j. Reinstall the steering column lower opening reinforcement and attaching screws. k. Remove right and left cowl side trim panels. l. Remove center console container and mat. m. Remove two console-to-floor pan retaining screws (found below the container and mat). n. On models with 5-speed transmission, remove gear shift knob. o. Remove two rear finish panel attaching screws, then tilt the finish panel forward, disconnect the electrical connector and remove finish panel. p. Remove two front console-to-instrument panel attaching screws, then the console. q. Remove two instrument panel-to-floor retaining nuts. r. Squeeze sides of glove compartment together to disengage tabs and pivot glove compartment down. s. Disconnect electrical connectors, heater/air conditioning lines and control cables from behind the dash panel. t. Remove right and left instrument panel-to-cowl side attaching screws. u. Remove right and left upper finish panels. v. Remove four instrument panel-to-cowl top retaining screws. w. Remove right and left roof rail trim panel, and door frame weather strip. x. Pull instrument panel away from cowl carefully, and remove any remaining electrical connectors. y. Remove instrument panel from vehicle. 3. Discharge refrigerant from A/C system at service access gauge port valve located on the suction line. 4. Disconnect liquid line and accumulator dryer inlet tube from the evaporator core at dash panel. 5. Cap refrigerant lines and evaporator core tubes to prevent dirt and moisture from entering the system. 6. Remove high and low pressure hoses and cap openings to prevent dirt and moisture from entering the system. 7. Disconnect heater hoses from heater core tubes and plug the hoses. Cap heater core tubes to prevent coolant loss from heater core during removal of evaporator case. Fig. 35 Evaporator core & heater housing assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Technical Service Bulletins > Page 7033 8. Remove the screw attaching air inlet duct and blower housing assembly support brace to cowl top panel, Fig. 23. 9. Disconnect vacuum supply hose from the inline vacuum check valve in engine compartment. 10. Disconnect blower motor wires from wire harness, then wire harness from blower motor resistor. 11. Working under the hood, remove two nuts retaining evaporator case to dash panel. 12. Remove two screws attaching evaporator case support brackets to cowl top panel. 13. Remove one screw or nut retaining the bracket below evaporator case to dash panel. 14. Pull evaporator case carefully away from dash panel and remove evaporator case assembly from vehicle. 15. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair Expansion Block/Orifice Tube: Service and Repair Do not attempt to remove the fixed orifice tube. The fixed orifice tube is an integral part of the liquid line. When a new fixed orifice tube is required, a new liquid line must be installed. However, an orifice tube replacement kit may be used instead of replacing the tube and line assembly. Line & Tube Assembly Replacement 1. Discharge refrigerant from system. 2. Disconnect refrigerant line at condenser outlet connection. Fig. 2 Spring lock coupling disconnect & connect Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Expansion Block/Orifice Tube > Component Information > Service and Repair > Page 7037 3. Disconnect the opposite end of the refrigerant line using the proper spring lock coupling tool, Fig. 2. 4. Route new refrigerant line, and integral fixed orifice tube, with the protective caps installed. 5. Remove protective caps and connect new refrigerant line into the system using new O-rings lubricated with refrigerant oil. 6. Leak test, evacuate and charge refrigerant system. 3. Disconnect refrigerant line at the tube-O end using a wrench on each side of tube-O fittings and remove line from vehicle. 4. Route new refrigerant line, and integral fixed orifice tube, with the protective caps installed. 5. Remove protective caps and connect new refrigerant line into the system using new O-rings lubricated with refrigerant oil. 6. Leak test, evacuate and charge refrigerant system. Orifice Tube Replacement 1. Remove refrigerant line from vehicle as described under ``Line & Tube Assembly Replacement.'' 2. Identify location of orifice tube by three indented notches or a circular depression on metal portion of tube. 3. Note angular position of ends of liquid line for assembly reference. 4. Cut a 2.5 inch section from tube at orifice tube location. Do not cut any closer than one inch from start of bend in tube. 5. Flush out two lengths of refrigerant line to remove any contaminants. 6. Lubricate O-rings with clean refrigerant oil, then assemble orifice tube kit to line. Ensure flow direction arrow points toward evaporator end of line and taper of compression rings is toward compression nut. When properly assembled, the inlet tube is positioned against the orifice tube tabs. 7. With tube hex nut secured in a vise, torque compression nuts to 65-70 ft. lbs. 8. Install liquid line using new lubricated O-rings. 9. Leak test, evacuate and charge refrigerant system. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Core Leak Test Procedure Heater Core: Technical Service Bulletins Heater Core - Core Leak Test Procedure HEATER CORE-CORE LEAK TEST PROCEDURE LEAKS-COOLANT-HEATER CORE LEAK TEST PROCEDURE Article No. 89-14-9 FORD: 1988-89 CROWN VICTORIA, ESCORT, FESTIVA, MUSTANG, PROBE, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR, TRACER LIGHT TRUCK: 1988-89 AEROSTAR, BRONCO, BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER ISSUE: Heater cores may be misdiagnosed and replaced unnecessarily. An inadequate seal between the heater core tubes can allow coolant to follow the tube to the heater core and appear as a leak. ACTION: If a heater core leak is suspected, use the following inspection and core leak testing procedure. INSPECTION 1. Look for evidence of coolant leakage at the hose to heater core attachments. A coolant leak at the hose could follow the heater core tube to the core and appear as a leak in the heater core. 2. Check the system for loose heater hose clamps. The clamps should be tightened to 16-22 in.lbs. (1.8-2.5 N-m). 3. If leakage is found and the hose clamps are tight, check the heater core tubes for distortion or evidence of being bent out of shape. Severe distortion of the tubes by such things as over-torqued clamps could cause leakage at the hose connection. Figure 1 PRESSURE TEST - HEATER CORE IN VEHICLE 1. Drain the coolant from the cooling system. 2. Disconnect the heater hoses from the heater core tubes. 3. Install a short piece of heater hose (approximately 4 inches or 10 cm. long) on each heater core tube. 4. Prepare the heater core as follows: a. Fill the heater core and hoses with water. b. Install plug BT-7422-B and adapter BT-7422-A from Rotunda model 021-0012 or equivalent in the hose ends, Figure 1. c. Secure the hoses, plug and adapter with hose clamps. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Core Leak Test Procedure > Page 7042 Figure 2 Figure 3 5. Air pressure test the heater core as described below: a. Attach the pump and gauge assembly Rotunda model 021-0012 or equivalent to the adapter, Figure 2. b. Close the bleed valve at the base of the gauge. c. Pump 30 psi of air pressure into the heater core, Figure 3. 6. Observe the pressure gauge for a minimum of three minutes. The pressure should not drop. 7. If the pressure does not drop, no leaks are indicated. 8. If the pressure drops, check the hose connections to core tubes for leaks. If the hoses do not leak, remove the heater core from the vehicle and perform the bench air pressure test. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Heater Core - Core Leak Test Procedure > Page 7043 Figure 4 PRESSURE TEST - HEATER CORE ON BENCH, OUT OF VEHICLE 1. Drain all coolant or water from the heater core. 2. Connect the four inch test hoses with the plug and adapter to the core tubes. 3. Connect the air pump and gauge assembly to the adapter, Figure 4. 4. Apply 30 psi of air pressure to the heater core with Rotunda model 021-0012 or equivalent. 5. Submerge the heater core in water. 6. If a leak is observed, service or replace the heater core as necessary. OTHER APPLICABLE ARTICLES: None SUPERSEDES: 87-12-4, Date 6-17-87 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2620 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Technical Service Bulletins > Page 7044 Heater Core: Service and Repair 1. Remove instrument panel, See: Instrument Panel, Gauges and Warning Indicators/Instrument Cluster / Carrier/Service and Repair and evaporator case. See: Evaporator Case/Service and Repair 2. Remove heater core access cover attaching screws, then the access cover from evaporator case. 3. Lift heater core and seals from evaporator case. 4. Remove seals from heater core tubes. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hose/Line HVAC: > 92174 > Aug > 92 > A/C Compressor - Moan At Idle to 1,500RPM Hose/Line HVAC: All Technical Service Bulletins A/C Compressor - Moan At Idle to 1,500RPM Article No. 92-17-4 08/12/92 ^ AIR CONDITIONING - "MOAN" FROM COMPRESSOR AT IDLE TO 1,500 R.P.M. - 3.8L BASE ENGINE - VEHICLES BUILT PRIOR TO 10/15/92 ^ NOISE - "MOAN" FROM A/C COMPRESSOR AT IDLE TO 1,500 R.P.M. - 3.8L BASE ENGINE VEHICLES BUILT PRIOR TO 10/15/92 FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR ISSUE: An air conditioning compressor "moan" may be heard during idle and up to 1,500 R.P.M. The noise may also be described as a "groaning" or "growling" (low pitched humming) sound. ACTION: Install new hose assemblies which incorporate a muffler on both the suction and discharge side of the compressor. Use an accumulator and switch assembly (F1SZ-19C836-B) on the suction side and a manifold and tube assembly (F1SZ-19D734-B) on the discharge side. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 12-03, for service details. PART NUMBER OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992 Models, Basic Warranty For All Other Models OPERATION DESCRIPTION TIME 921704A Replace Suction and 1.1 Hrs. Discharge Hoses A/C Compressor, Includes Discharge, Evacuate And Charge System. DEALER CODING BASIC PART NO. CONDITION CODE 19C836 56 OASIS CODES: 208000, 208999, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical Service Bulletins > Customer Interest for Hose/Line HVAC: > 92174 > Aug > 92 > A/C Compressor - Moan At Idle to 1,500RPM Hose/Line HVAC: Customer Interest A/C Compressor - Moan At Idle to 1,500RPM Article No. 92-17-4 08/12/92 ^ AIR CONDITIONING - "MOAN" FROM COMPRESSOR AT IDLE TO 1,500 R.P.M. - 3.8L BASE ENGINE - VEHICLES BUILT PRIOR TO 10/15/92 ^ NOISE - "MOAN" FROM A/C COMPRESSOR AT IDLE TO 1,500 R.P.M. - 3.8L BASE ENGINE VEHICLES BUILT PRIOR TO 10/15/92 FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR ISSUE: An air conditioning compressor "moan" may be heard during idle and up to 1,500 R.P.M. The noise may also be described as a "groaning" or "growling" (low pitched humming) sound. ACTION: Install new hose assemblies which incorporate a muffler on both the suction and discharge side of the compressor. Use an accumulator and switch assembly (F1SZ-19C836-B) on the suction side and a manifold and tube assembly (F1SZ-19D734-B) on the discharge side. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 12-03, for service details. PART NUMBER OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage For 1992 Models, Basic Warranty For All Other Models OPERATION DESCRIPTION TIME 921704A Replace Suction and 1.1 Hrs. Discharge Hoses A/C Compressor, Includes Discharge, Evacuate And Charge System. DEALER CODING BASIC PART NO. CONDITION CODE 19C836 56 OASIS CODES: 208000, 208999, 702000, 702100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7062 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7063 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7064 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > A/C - Identification of Non Approved Refrigerants > Page 7065 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants Technical Service Bulletin # 99-19-6 Date: 990920 A/C - Identification of Non Approved Refrigerants Article No. 99-19-6 09/20/99 ^ AIR CONDITIONING - IDENTIFICATION OF NON-FORD APPROVED REFRIGERANTS ^ AIR CONDITIONING - PURGING AIR FROM SYSTEM FORD: 1985-1986 LTD 1985-1988 EXP 1985-1994 TEMPO 1985-1997 THUNDERBIRD 1985-2000 CROWN VICTORIA, ESCORT, MUSTANG 1986-2000 TAURUS 1988-1993 FESTIVA 1989-1997 PROBE 1994-1997 ASPIRE 1995-2000 CONTOUR 2000 FOCUS 1985-1990 BRONCO II 1985-1996 BRONCO 1985-1997 F-250 HD, F-350 1985-2000 ECONOLINE, F-150, F-250 LD, RANGER 1986-1997 AEROSTAR 1988-1997 F SUPER DUTY 1991-2000 EXPLORER 1995-2000 WINDSTAR 1997-2000 EXPEDITION 1999-2000 SUPER DUTY F SERIES 1985-1991 CL-CLT-9000 SERIES 1985-1999 L SERIES 1985-2000 F & B SERIES 1986-1998 CARGO SERIES 1997-1998 AEROMAX, LOUISVILLE LINCOLN: 1985-1992 MARK VII 1985-2000 CONTINENTAL, TOWN CAR 1993-1998 MARK VIII 2000 LS 1998-2000 NAVIGATOR MERCURY: 1985-1986 MARQUIS 1985-1987 LYNX 1985-1994 TOPAZ 1985-1997 COUGAR 1985-2000 GRAND MARQUIS 1986-2000 SABLE 1987-1989 TRACER 1991-1994 CAPRI 1991-2000 TRACER 1995-2000 MYSTIQUE 1999-2000 COUGAR 1993-2000 VILLAGER 1997-2000 MOUNTAINEER MERKUR: 1985-1989 XR4TI 1988-1989 SCORPIO Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 7071 This TSB article is being republished in its entirety to add model year vehicles ISSUE A number of non-approved/alternate refrigerants have entered the marketplace and are being advertised as "drop-in replacements" for R-12 and R-134a. The use of non-approved refrigerants such as R-22, hydrocarbons, and other refrigerant blends could cause safety, durability, and performance concerns if they are installed in Ford A/C systems. Identification of the type of refrigerant contained in vehicle A/C systems, before servicing, is necessary to prevent dealer service equipment and refrigerant supplies from being contaminated with non-approved refrigerants. ACTION Refrigerant identification must be performed prior to recovering the refrigerant into a recovery machine to prevent cross-contamination of the recovery machine and other A/C systems being serviced with that recovery machine. Refer to the following text. OTHER APPLICABLE ARTICLES: 94-14-3, 95-18-4 SUPERSEDES: 98-12-8 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1993-2000 Model Year Vehicles, Basic Warranty Coverage For All Other Model Year Vehicles OPERATION DESCRIPTION TIME 991906A Test A/C System For 0.3 Hr. Contaminated Refrigerant DEALER CODING CONDITION BASIC PART NO. CODE R-12 49 OASIS CODES: 208000, 208999 A/C Refrigerant Analyzer Function Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 7072 Ford Motor Company has approved the Rotunda Deluxe A/C Refrigerant Analyzer (198-00003) for use on Ford and Lincoln-Mercury vehicles (Figure 1). The analyzer provides the technician with a quick and easy way to identify the type and percentage of refrigerant (R-134a, R-12, R-22, or flammable hydrocarbon). The analyzer can also provide the percentage of air in the A/C system and automatically purge air from the system. The A/C Refrigerant Analyzer is designed to identify vapor gas samples taken directly from automotive air conditioning systems or refrigerant storage cylinders. Refrigerant vapor passes through the multiple sensor Non-Dispersive Infra-Red (NDIR) sensing unit. The microprocessor calculates each refrigerant type and purity percentage which is displayed on the analyzer's Liquid Crystal Display (LCD). The analyzer identifies the purity percentage of R-134a, R-12, R-22, hydrocarbon; and air in the sample. If the purity percentage of the R-134a or R-12 is 98% or greater by weight, a green "PASS" Light Emitting Diode (LED) will light. If refrigerants R-134a or R-12 do not meet 98% purity levels, the red "FAIL" LED will light. Levels of R-22 and flammable hydrocarbons above 2% will light the red "FAIL" light. If a hydrocarbon is detected above 5%, both the "FAIL" light and "HYDROCARBON" light will illuminate and a horn will sound alerting the user of potential hazards. The percent of air contained in the sample will be displayed if the R-134a or R-12 content is 98% or above. The analyzer eliminates the effect of air Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 7073 when determining the refrigerant sample content because air is not considered a contaminant although air can affect A/C system performance. Air will automatically be purged until a pure refrigerant with a less than 2% by weight air measurement is reached. Recovery of Contaminated Refrigerant If contaminated refrigerant is detected, DO NOT recover the refrigerant into your R-134a or R-12 recovery/recycling equipment. Take the following actions: 1. Repeat the test to verify contaminated refrigerant is present. 2. Advise the customer of the contaminated A/C system and any additional cost to repair the system. The customer may wish to return to the service facility which performed the last A/C service. 3. Recover the contaminated refrigerant using suitable recovery-only equipment designed for capturing and storing contaminated refrigerant. This equipment must only be used to recover contaminated refrigerant to prevent the spread to other vehicles. As an alternative, contact an A/C service facility in your area which has the proper equipment for refrigerant recovery. Repairing A Contaminated A/C System Once the contaminated refrigerant is removed from the system it will be necessary to repair the system. Ford recommends that you do the following to be sure a quality repair is made: 1. Determine the cause of the failure. 2. Determine which parts will need to be replaced. 3. Flush the heat exchangers to remove any oil that may be degraded due to the contaminated refrigerant. 4. Install a new suction/accumulator. 5. Properly oil match the system to verify that the correct amount of clean refrigerant oil is present in the system. 6. Evacuate the system for 45 minutes. 7. Recharge the system, verify proper operation, and leak test. Disposal of Contaminated Refrigerant Disposal of contaminated refrigerant is a new process to the automotive industry Listed below are companies that will assist with disposal of contaminated refrigerant. Ford Motor Company has not evaluated the processes of the listed refrigerant disposal companies and is not endorsing or promoting their companies Business transactions are between the dealership and disposal companies. Disposal costs will vary between $3.00 and $5.00 per pound, plus the cost of round trip cylinder shipping. ^ Omega Refrigerant Reclamation ^ 5263 North Fourth St. ^ Irwindale, CA 91706 ^ (310) 698-0991 FAX: (310) 696-7908 ^ Full Cycle Global ^ 2966 Wireton ^ Blue Island, IL 60406 ^ (708) 388-8551 FAX: (708) 399-6550 ^ U.S. Refrigerant Reclaim, Inc. ^ 12420 North Green River Road ^ Evansville, IN 47711 ^ (800) 207-5931 FAX: (812) 867-1463 ^ Full Cycle Global ^ 343 South Airline Highway Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 99-19-6 > Sep > 99 > A/C - Identification of Non Approved Refrigerants > Page 7074 ^ Gonzales, LA 70737 ^ (504) 644-5333 FAX: (504) 644-1609 ^ CFC Reclamation ^ 1321 Swift North ^ Kansas City, MO 64116 ^ (816) 471-2511 ^ Full Cycle Global ^ 550 James St. ^ Lakewood, NJ 08701 ^ (908) 370-3400 FAX: (908) 370-3088 ^ National Refrigerants, Inc. ^ 11401 Roosevelt Blvd. ^ Philadelphia, PA 19154 ^ (215) 698-6620 FAX: (215) 602-8205 ^ Gartech Refrigerant Reclamation ^ 2002 Platinum ^ Garland, TX 75042 ^ (214) 272-4070 FAX: (214) 272-6548 ^ Refrigerant Reclaim Services ^ 121 S. Norwood Dr. ^ Hurst, TX 76053-7807 ^ (817) 282-0022 FAX: (800) 831-6182 ^ Full Cycle Global ^ 2055 Silber, Suite 109 ^ Houston, TX 77055 ^ (713) 681-7370 FAX: (713) 681-9947 ^ Refrigerant Reclaim, Inc. ^ 122 Old Stage Coach Road ^ Dumfries, VA 22026 ^ (800) 238-5902 FAX: (703) 441-0393 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 7079 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 7080 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 98-12-5 > Jun > 98 > A/C - Filtering Refrigerant After Compressor Replacement > Page 7081 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Substitutes Service Tip Article No. 96-17-10 08/12/96 AIR CONDITIONING - USE OF R-12 REFRIGERANT SUBSTITUTES - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-94 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 COUGAR 1982-94 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1985-94 CARGO SERIES, F & B SERIES, L SERIES This TSB article is being republished in its entirety to list Environmental Protection Agency (EPA) reviewed NC substitutes for R-12 refrigerant. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. ACTION: If service is required, use only new or of known quality recycled refrigerant R-12. Ford Motor Company has approved R-134a as the only refrigerant substitute for R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. INFORMATION FROM THE EPA Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 7086 This information has been taken from EPA documents to address Ford specific applications and recommendations. Further EPA information on ozone-depleting substances and regulations regarding its handling can be found on the Internet at World Wide Web site: http://www.epa.gov/ozone/ In 1994, EPA established the Significant New Alternatives Policy (SNAP) program to review alternatives to ozone-depleting substances like R-12. EPA examines new substitutes for their ozone depleting, global warming, flammability, and toxicity characteristics. The SNAP process does not test these substitutes for A/C system compatibility, reliability, durability, or performance. Under the SNAP rule, each new refrigerant must be used in accordance with the following conditions: 1. Unique Fittings - Each new refrigerant must be used with a unique set of fittings to prevent the accidental mixing of different refrigerants. 2. Unique Equipment - Each refrigerant must have dedicated recovery/recycling equipment for that refrigerant. 3. Labels - Whether a vehicle is originally designed to use a new refrigerant or is retrofitted, the technician must apply a detailed label giving specific information about the alternative. This label covers up information about the old refrigerant and provides valuable details on the alternative and how it was used. The technician is required to fill in their name, company performing the retrofit, address and the date retrofitted. 4. Remove Original Refrigerant - The original R-12 must be removed from the system prior to charging with the new refrigerant. This will guarantee that the largest amount of clean R-12 is available for use in vehicles that still need it. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 961710 > Aug > 96 > A/C - R12 Refrigerant Substitutes Service Tip > Page 7087 A summary of the refrigerants reviewed under EPA's SNAP program for use in motor vehicle air conditioning systems is in the table. OTHER APPLICABLE ARTICLES: 91-9-7, 96-15-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes Refrigerant: Technical Service Bulletins R-12 Refrigerant - Substitutes Article No. 94-14-3 07/13/94 Air Conditioning - Use Of R-12 Refrigerant Substitutes - Service Tip FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER MERKUR: 1986-89 SCORPIO, XR4TI LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1992-94 F-53 1993 VILLAGER MEDIUM/HEAVY TRUCK: 1954-90 C SERIES 1970-94 L SERIES 1979-90 CL-9000, CL-CLT-9000 SERIES 1980-94 F SERIES 1986-94 CARGO SERIES This TSB is being republished in its entirety to include Heavy Truck models. ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C system components. ACTION: If service is required, use only NEW or RECYCLED refrigerant R-12. Ford Motor Company has not tested or approved any R-12 refrigerant substitute at this time. R-134a is approved only for systems which specify R-134a, Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 94-14-3 > Jul > 94 > R-12 Refrigerant - Substitutes > Page 7092 and is not compatible with R-12 systems. R-22 likewise, is not compatible with R-12 systems. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: 91-9-7 SUPERSEDES: 93-23-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208999, 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 93206 > Sep > 93 > Air Conditioning - Use of Correct Fluorescent Tracer Dye Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 9197 > May > 91 > A/C - R12 Refrigerant Service Tips Refrigerant: Technical Service Bulletins A/C - R12 Refrigerant Service Tips Article No. 91-9-7 05/01/91 AIR CONDITIONING - REFRIGERANT R-12 - SERVICE TIPS FORD: 1985-86 LTD 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER 1991 CAPRI MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1988-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK: 1985-90 C SERIES 1985-91 CL-CLT-9000 SERIES, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: A number of manufacturers are producing refrigerant products which are described as being direct replacements for Refrigerant R-12. The use of any unauthorized substitute refrigerant may severely damage the A/C components. ACTION: If service is required, use only NEW or RECYCLED Refrigerant R-12. CAUTION: USING ANY UNAUTHORIZED SUBSTITUTE REFRIGERANT FOR R-12 MAY RESULT IN SEVERE DAMAGE TO THE A/C SYSTEM COMPONENTS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update Technical Service Bulletin # 915B13 Date: 910322 Refrigerant System Leak Testing - Manual Update Article No. 91-5B-13 ^ SHOP MANUAL - 1988 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1989 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1990 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1991 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED FORD: 1988-90 ESCORT 1988-91 CROWN VICTORIA, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-91 COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR ISSUE: Information concerning leak testing the refrigerant system was not covered in the Shop Manual for 1988 through 1991 applications under "Checking For Leaks" in the A/C and Refrigerant System-Service Section. ACTION: Refer to the pages following this TSB article for the updated information. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7105 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7106 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7107 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7108 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7109 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7110 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7111 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7112 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7113 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7114 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7115 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7116 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7117 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7118 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7119 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7120 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7121 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7122 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7123 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7124 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7125 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7126 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7127 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7128 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7129 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > 915B13 > Mar > 91 > Refrigerant System Leak Testing - Manual Update > Page 7130 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7131 Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7132 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7133 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7134 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7135 Refrigerant: Technical Service Bulletins Air Conditioning - Use of Correct Fluorescent Tracer Dye Article No. 93-20-6 09/29/93 AIR CONDITIONING - USE OF CORRECT FLUORESCENT TRACER DYE - SERVICE TIP FORD: 1980-93 CROWN VICTORIA 1981-93 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-93 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-93 TEMPO 1986-93 TAURUS 1988-93 FESTIVA 1989-93 PROBE LINCOLN-MERCURY: 1980-93 GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-93 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-92 MARK VII 1984-93 TOPAZ 1986-93 SABLE 1991-93 CAPRI, TRACER LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150-350 SERIES 1983-93 RANGER 1984-90 BRONCO II 1986-93 AEROSTAR 1988-93 F-47 1991-93 EXPLORER 1993 VILLAGER ISSUE: Use of untested, unapproved fluorescent tracer dyes for A/C system leak checking may damage the air conditioning system. Some of these materials may not be compatible with Ford A/C systems. ACTION: When leak-checking an R-12 A/C system with a "black light", use only Rotunda-supplied Part No. 112-R0027, Fluoro-Lite brand dye. No other dyes have been approved by Ford Motor Company. NOTE: 112-R0027 DYE IS NOT COMPATIBLE WITH R-134a REFRIGERANT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7136 Technical Service Bulletin # 915B13 Date: 910322 Refrigerant System Leak Testing - Manual Update Article No. 91-5B-13 ^ SHOP MANUAL - 1988 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1989 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1990 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED ^ SHOP MANUAL - 1991 - REFRIGERANT SYSTEM LEAK TESTING INFORMATION ADDED FORD: 1988-90 ESCORT 1988-91 CROWN VICTORIA, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-91 COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR ISSUE: Information concerning leak testing the refrigerant system was not covered in the Shop Manual for 1988 through 1991 applications under "Checking For Leaks" in the A/C and Refrigerant System-Service Section. ACTION: Refer to the pages following this TSB article for the updated information. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7137 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7138 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7139 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7140 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7141 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7142 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7143 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7144 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7145 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7146 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7147 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7148 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7149 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7151 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7152 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop 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Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7157 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7158 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7159 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7160 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7161 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Technical Service Bulletins > Technical Service Bulletins for Refrigerant: > Page 7162 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications Refrigerant: Capacity Specifications Refrigerant Specifications Capacity ............................................................................................................................................... ....................................................... 40 oz (2.5 lbs) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Capacity Specifications > Page 7165 Refrigerant: Fluid Type Specifications Type ..................................................................................................................................................... ............................................... Refrigerant 12 (R-12) Ford Part Number ............................................. ........................................................................................................................................ D4AZ-19B519-A Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement Technical Service Bulletin # 98-12-5 Date: 980622 A/C - Filtering Refrigerant After Compressor Replacement Article No. 98-12-5 06/22/98 AIR CONDITIONING - FILTERING REFRIGERANT AFTER A/C COMPRESSOR REPLACEMENT - SERVICE TIPS FORD: 1980-98 CROWN VICTORIA 1981-98 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-97 THUNDERBIRD 1982-98 MUSTANG 1983-86 LTD 1984-94 TEMPO 1986-98 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-98 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1980-98 GRAND MARQUIS, TOWN CAR 1982-83 ZEPHYR 1982-86 CAPRI 1982-87 LN7 1982-97 COUGAR 1982-98 CONTINENTAL 1983-86 MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-98 SABLE 1991-94 CAPRI 1991-98 TRACER 1993-98 MARK VIII 1995-98-MYSTIQUE 1999 COUGAR LIGHT TRUCK: 1980-96 BRONCO 1980-97 F SUPER DUTY 1980-98 ECONOLINE, F-150, F-150, F-350 1983-98 RANGER 1984-90 BRONCO II 1986-97 AEROSTAR 1988-97 F-47 1991-98 EXPLORER 1993-98 VILLAGER 1995-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to revise the Service Procedure and to update the model years. ISSUE Vehicles that have and inoperative A/C compressor, due to internal causes, MUST have the refrigerant system cleaned to remove any debris or contaminants that may be present to prevent damage to the replacement compressor. ACTION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 7170 Install a Service Filter Kit in the refrigerant system prior to installing the replacement compressor. Refer to the following Service Procedure for details. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 96-15-5 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-99 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models And Major Component Warranty Coverage For All Other Lincoins OPERATION DESCRIPTION TIME 981205A Kit Installation 1.2 Hrs. 981205B Extra Time For Refrigerant 0.4 Hr. (R-12) Recovery DEALER CODING CONDITION BASIC PART NO. CODE 19703 49 OASIS CODES: 208000, 208999 Service Procedure THIS PROCEDURE IS OPTIONAL IF THE SYSTEM IS FLUSHED USING THE ROTUNDA A/C FLUSHER. CAUTION THIS FILTERING PROCEDURE MAY BE USED FOR EITHER R-12 OR R-134a REFRIGERANT SYSTEMS. BECAUSE THE TWO (2) SYSTEMS USE DIFFERENT REFRIGERANT OILS AND BECAUSE THE COMPRESSOR COULD BE DAMAGED IF THE WRONG OIL IS USED, SYSTEM IDENTIFICATION IS VERY IMPORTANT. BE SURE SYSTEM IS CORRECTLY IDENTIFIED BEFORE STARTING THE FILTERING PROCEDURE. Each Service Filter Kit includes the following items: ^ One (1) Pancake Filter (to be installed in the liquid line between the condenser and the orifice tube) ^ One (1) Instruction Sheet NOTE ON 1993-94 RANGER/EXPLORER VEHICLES, TECHNICIANS MAY EXPERIENCE DIFFICULTY WHEN CONNECTING THE PANCAKE FILTER HOSE FITTINGS TO THE EVAPORATOR INLET WITH THE ORIFICE TUBE INSTALLED. REMOVE THE OFFICE TUBE AND RUN THE SYSTEM FOR 1 HOUR AS DESCRIBED IN THE FILTERING PROCEDURE. REINSTALL THE ORIFICE TUBE AFTER FILTERING IS COMPLETE. CAUTION FOLLOW ALL REFRIGERANT SYSTEM SAFETY AND SERVICE PRECAUTIONS OUTLINED IN THE APPROPRIATE SERVICE OR WORKSHOP MANUAL. 1. Before removing any refrigerant system components, recover the refrigerant from the system following the recycling methods outlined In the appropriate Service/Workshop Manual. 2. Remove the suction accumulator/drier assembly and drain the oil into a calibrated container. 3. Install a new suction accumulator/drier and add new refrigerant oil to replace the old oil. The quantity of the new oil to be added is the amount to match that drained from the old accumulator plus 60 mL (2 oz). Refer to the Dealer Master Parts Catalog for the correct suction accumulator/drier part number. CAUTION REMEMBER TO USE MOTORCRAFT YN-9-A REFRIGERANT COMPRESSOR OIL WITH R-12 SYSTEMS AND MOTORCRAFT YN-12-C REFRIGERANT COMPRESSOR OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. 4. Install a new orifice tube. Refer to the Dealer Master Parts Catalog for the correct orifice tube part number. If the orifice tube in the vehicle is located in the liquid line between the condenser and the evaporator, replace the liquid line assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 7171 5. Install pancake filter in the liquid line between the condenser and the orifice tube, Figure 1. a. Be sure orifice inlet is toward the condenser. b. Connections can be made using Test Adapter Set D93L-19703-B, or equivalent, and flexible refrigerant hose of 2500 psi burst rating. Individual fittings are also available. 6. Remove the old compressor following Service/Workshop Manual procedures. Drain the oil into a calibrated container. 7. Drain the oil from the replacement compressor into a clean calibrated container. NOTE: IT WILL BE NECESSARY TO TRANSFER THE MAGNET CLUTCH FROM THE OLD COMPRESSOR TO THE REPLACEMENT COMPRESSOR. FOLLOW SERVICE/WORKSHOP MANUAL PROCEDURES. 8. A new FX-15 service compressor contains 207 mL (7 oz.) of R-12 refrigerant oil. A new FS-10 service compressor does not contain any oil and can be used with an R-12 or an R-134a system. CAUTION REMEMBER TO USE YN-9-A (MINERAL) OIL WITH R-12 SYSTEMS AND YN-12-C (PAG) OIL WITH R-134a SYSTEMS. FAILURE TO USE THE CORRECT REFRIGERANT OIL MAY RESULT IN DAMAGE TO SYSTEM COMPONENTS. ^ If the amount of oil drained from the removed compressor is between 90 and 148 mL (3-5 oz), pour the same amount of clean refrigerant oil into the new compressor. ^ If the amount of oil drained from the old compressor is greater than 90 mL (3 oz), pour 90 mL (3 oz) of clean refrigerant oil into the new compressor. 9. Install the new compressor following Service/Workshop Manual procedures. Make sure all mounting bolts are tightened properly. Check the tension of the compressor drive belt. Adjust if necessary. 10. Evacuate, charge and leak test the system, following Service/Workshop Manual procedures. 11. Check all refrigerant system hoses, lines and the position of the newly-installed filters to make sure they do not interfere with other engine compartment components. If necessary, use tie straps to make adjustments. 12. Set the A/C control on Max A/C, high blower and temperature control at full cold. a. Start engine and let idle briefly. b. Be sure A/C system is operating properly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Technical Service Bulletins > A/C - Filtering Refrigerant After Compressor Replacement > Page 7172 13. Gradually bring the engine up to 1200 rpm by running it at lower rpms for short periods (first at 800 rpm, then at 1000 rpm). Set the engine at 1200 rpm and run it for an hour with the A/C system operating. 14. Stop the engine. NOTE: IT WILL BE NECESSARY TO RECOVER THE SYSTEM REFRIGERANT CHARGE BEFORE PROCEEDING. 15. Allow the engine to cool sufficiently to remove the fittings, flexible hoses and pancake filter from the liquid line. 16. Discard the filter. It can be used one (1) tie only. 17. Reconnect the liquid line back into the system. 18. Evacuate, charge and leak test the system. Make any necessary adjustments. 19. Check the operation of the system in all models. PART NUMBER PART NAME F8VZ-19E773-AA Filter Kit F73Z-19577-AA Refrigerant Oil - Motorcraft YN-9-A (For R-12 Refrigerant Systems Only) F7AZ-19589-DA Refrigerant Oil - Motorcraft YN-12-C (PAG-Type Oil For R-134a Refrigerant Systems Only) NOTE THE TOTAL REPAIR TIME IS FOR INSTALLING SERVICE FILTER KIT PER INSTRUCTIONS THIS INCLUDES INSTALLATION OF AND DISCARD OF FILTER. REFER TO SERVICE LABOR TIME STANDARDS MANUALS IF ADDITIONAL LABOR OPERATIONS ARE REQUIRED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C Compressor - Oil Recovery & Measuring Procedure Refrigerant Oil: Technical Service Bulletins A/C Compressor - Oil Recovery & Measuring Procedure Article No. 92-24-6 11/18/92 AIR CONDITIONING - FX-15 AIR COMPRESSOR - OIL RECOVERY AND MEASURING PROCEDURE FORD: 1988-93 TAURUS 1989-93 CROWN VICTORIA, THUNDERBIRD 1992-93 ESCORT, TEMPO LINCOLN-MERCURY: 1988-93 SABLE 1989-93 COUGAR 1991-93 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1992-93 TOPAZ, TRACER LIGHT TRUCK: 1989-90 BRONCO II 1989-93 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1991-93 EXPLORER This article is being republished in its entirety to clarify the information about removing oil from both the "old" and "new" compressors. ISSUE: When replacing the FX-15 Compressor it is very important to accurately match the amount of oil being replaced. Some dealerships have indicated that they are unable to properly match the amounts of oil being replaced. ACTION: Replace the amount of oil being drained from the FX-15 compressor with an equal amount of new oil to assure proper compressor operation. Refer to the following service procedure for service details. SERVICE - PROCEDURE 1. With both "OLD" and "NEW" compressors, remove as much oil as possible. On both compressors, the shaft should be rotated about six to eight revolutions while pouring the oil from the ports. This effectively empties the compressor of oil. a. Obtain a clean container that can also be used as a measuring device. b. Place the disc and hub assembly on the compressor shaft so the shaft can be rotated. c. Rotate the shaft by hand (6) six to (8) eight revolutions, collecting the oil in a clean measuring device. NOTE: SERVICE COMPRESSORS COME PRE-CHARGED WITH 7 OUNCES OF OIL 2. If the amount of oil drained from the old compressor is between (3) three and (5) five fluid ounces (85 and 142 cc), pour the same amount of clean Motorcraft YN-9 refrigerant oil into the new compressor. 3. If the amount of oil that was removed from the old compressor is greater than (5) fluid ounces (142 cc), pour five ounces of clean Motorcraft YN-9 refrigerant oil into the new compressor. 4. If the amount of refrigerant oil that was removed from the old compressor is less than (3) three fluid ounces (85 cc), pour three fluid ounces of clean Motorcraft YN-9 refrigerant oil into the new compressor. NOTE: THE SUCTION/ACCUMULATOR-DRYER AND ORIFICE TUBE MUST BE REPLACED WHENEVER THE COMPRESSOR IS REPLACED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C Compressor - Oil Recovery & Measuring Procedure > Page 7177 Part Number/Name Chart OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 92-18-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200, 208999, 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C Compressor - Oil Recovery & Measuring Procedure > Page 7178 Refrigerant Oil: Technical Service Bulletins A/C Compressor - Oil Recovery/Measuring Procedures Article No. 92-18-4 08/26/92 AIR CONDITIONING - FX-15 AIR COMPRESSOR - OIL RECOVERY AND MEASURING PROCEDURE FORD: 1988-93 TAURUS 1989-93 CROWN VICTORIA, THUNDERBIRD 1992-93 ESCORT, TEMPO LINCOLN-MERCURY: 1988-93 SABLE 1989-93 COUGAR 1991-93 CONTINENTAL, GRAND MARQUIS, TOWN CAR 1992-93 TOPAZ, TRACER LIGHT TRUCK: 1989-90 BRONCO II 1989-93 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER 1990-93 EXPLORER ISSUE: When replacing the FX-15 compressor it is very important to accurately match the amount of oil being replaced. Some dealerships have indicated that they are unable to properly match the amounts of oil being replaced. ACTION: Replace the amount of oil being drained from the FX-15 compressor with an equal amount of new oil, to assure proper compressor operation. Refer to the following service procedure for service details. SERVICE - PROCEDURE 1. Remove as much oil as possible from the compressor. The compressor shaft should be rotated about six to eight revolutions allowing the oil to drain from the compressor ports. a. Obtain a clean container that can be also used as a measuring device. b. Place the disc and hub assembly on the compressor shaft so the shaft can be rotated. c. Rotate the shaft by hand (6) six to (8) eight revolutions allowing the oil to drain from the ports, while collecting the oil in the clean measuring device. NOTE: SERVICE COMPRESSORS COME PRE-CHARGED WITH 7 OUNCES OF OIL 2. If the amount of oil drained from the old compressor is between (3) three and (5) five fluid ounces, pour the same amount of clean Motorcraft YN-9 refrigerant oil into the new compressor. 3. If the amount of oil that was removed from the old compressor is greater than (5) fluid ounces, pour five ounces of clean Motorcraft YN-9 refrigerant oil into the new compressor. 4. If the amount of refrigerant oil that was removed from the old compressor is less than (3) three fluid ounces, pour three fluid ounces of clean Motorcraft YN-9 refrigerant oil into the new compressor. NOTE: THE SUCTION/ACCUMULATOR-DRYER AND ORIFICE TUBE MUST BE REPLACED WHENEVER THE COMPRESSOR IS REPLACED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Technical Service Bulletins > A/C Compressor - Oil Recovery & Measuring Procedure > Page 7179 Part Number OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 208000, 208200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications Refrigerant Oil: Capacity Specifications When it is necessary to replace a component of the refrigerant system, the procedures in this Section must be followed to ensure that the total oil charge in the system is correct after the new part is installed. When the compressor is operated, oil gradually leaves the compressor and is circulated through the system with the refrigerant. Eventually a balanced condition is reached in which a certain amount of oil is retained in the compressor and a certain amount is continually circulated. If a component of the system is removed after the system has been operated, some oil will go with it. To maintain the original total oil charge, it is necessary to compensate for this by replacing the oil in the new replacement part. The procedures for replacing oil are as follows: FX-15 Compressor-3/4 View DURING COMPRESSOR REPLACEMENT A new service replacement FX-15 compressor contains 207ml (7 ounces) of refrigerant oil. Prior to installing the replacement compressor, drain the refrigerant oil from the removed compressor into a calibrated container. Then, drain the refrigerant oil from the new compressor into a clean calibrated container. If the amount of oil drained from the removed compressor was between 90 and 148ml (3 and 5 ounces), pour the same amount of clean refrigerant oil into the new compressor. If the amount of oil that was removed from the oil compressor is greater than 148ml (5 ounces), pour 148ml (5 ounces) of clean refrigerant oil into the new compressor. If the amount of refrigerant oil that was removed from the old compressor is less than 90ml (3 ounces), pour 90ml (3 ounces) of clean refrigerant oil into the new compressor. NOTE: The suction/accumulator-drier and the orifice tube should also be replaced whenever the compressor is replaced. DURING COMPONENT REPLACEMENT When replacing other components of the air conditioning system, measured quantities of the specified refrigerant oil should be added to the component to ensure that the total oil charge in the system is correct before the system is operated. Clean refrigerant oil should be added to the replacement components as follows: ^ Evaporator Core: Add 90ml (3 ounces). ^ Condenser: Add 30ml (1 ounce). ^ Accumulator: Drain oil from removed accumulator drier. Add same amount plus 30ml (1 ounce) of clean refrigerant oil to new accumulator. NOTE: Clean refrigerant oil should be poured directly into the replacement component. If any other components such as an orifice tube or a hose is replaced, no additional refrigerant oil is necessary unless a hose bursts with a fully charged system. Then, the addition of refrigerant oil may be necessary with the amount to be determined by the technician. The suction accumulator-drier should also be replaced under these circumstances. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications > Capacity Specifications > Page 7182 Refrigerant Oil: Fluid Type Specifications FX-15 Compressor-3/4 View The FX-1 5 compressor uses unique, high quality refrigerant oil E73Z-19577-A or Motorcraft YN-9 or an equivalent refrigerant oil meeting Ford specification ESH-M2C31-A2. It is extremely important that only the specified type and quantity of refrigerant oil be used in the FX-15 compressor. If there is a surplus of oil in the system, it will circulate with the refrigerant, reducing the cooling capacity of the system. Using too little oil or an oil not meeting specification will result in poor lubrication of the compressor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: Customer Interest A/C System - Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor > Page 7191 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C System Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor > Page 7197 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Pressure Cycling Switch Diagnostic Procedure AIR CONDITIONING-CLUTCH PRESSURE CYCLING SWITCH DIAGNOSTIC PROCEDURE Article No. 89-14-10 FORD: 1980-89 CROWN VICTORIA 1981-89 ESCORT 1982-88 EXP 1982-89 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-89 TEMPO 1986-89 TAURUS LINCOLN-MERCURY: 1980-89 GRAND MARQUIS, MARK VI, MARK VII, TOWN CAR 1981-87 LYNX 1982-86 CAPRI 1982-89 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-89 TOPAZ 1986-89 SABLE LIGHT TRUCK: 1980-89 BRONCO, F SERIES 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR 1988-89 ECONOLINE ISSUE: Poor air conditioning cooling caused by low or no refrigerant charge often results in unnecessary replacement of the clutch cycling pressure switch. The switch is designed to work on system pressure. It closes at about 46 psi and opens at about 24.5 psi. It has a normal cycle (on and off) rate of 2 to 5 cycles per minute. ACTION: If an inoperative or fast cycling pressure switch is found, use the following diagnostic charts before replacing the pressure switch. DIAGNOSTIC PROCEDURE: 1. Connect a manifold gauge set to the service ports and check the system pressures. They should be above the closing pressure of the switch (46 psi). 2. If the A/C system pressures are above 46 psi and the clutch will not engage, proceed as follows: ^ Check the pressure switch harness connector and harness wires for a continuous open condition. ^ Check for an intermittent open or a poor connection between the connector and the pressure switch terminals. a. If the harness connector and wires are OK, by-pass the pressure switch by jumping the two terminals of the connector. If the clutch still does not engage, THE PRESSURE SWITCH IS NOT DEFECTIVE. Refer to the respective EVTM for the clutch circuit schematic and circuit diagnosis. Repair as necessary. 3. Check the ambient temperature. If the ambient temperature is below 48~ F (9~ C), the system pressure will not be high enough to close the pressure switch (46 psi). 4. If the system does not contain refrigerant, the pressure will not be high enough to close the switch for compressor operation. Leak test, repair, evacuate and charge the system. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 7202 Figure 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 7203 Figure 2 5. If the pressures are above 46 psi and the clutch cycle rate is faster than the normal rate of 2 to 5 cycles per minute, the system is probably low on refrigerant. Check that the system contains the correct refrigerant charge by following the correct diagnostic chart (Figures 1 or 2). WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Pressure Cycling Switch Diagnostic Procedure AIR CONDITIONING-CLUTCH PRESSURE CYCLING SWITCH DIAGNOSTIC PROCEDURE Article No. 89-14-10 FORD: 1980-89 CROWN VICTORIA 1981-89 ESCORT 1982-88 EXP 1982-89 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-89 TEMPO 1986-89 TAURUS LINCOLN-MERCURY: 1980-89 GRAND MARQUIS, MARK VI, MARK VII, TOWN CAR 1981-87 LYNX 1982-86 CAPRI 1982-89 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-89 TOPAZ 1986-89 SABLE LIGHT TRUCK: 1980-89 BRONCO, F SERIES 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR 1988-89 ECONOLINE ISSUE: Poor air conditioning cooling caused by low or no refrigerant charge often results in unnecessary replacement of the clutch cycling pressure switch. The switch is designed to work on system pressure. It closes at about 46 psi and opens at about 24.5 psi. It has a normal cycle (on and off) rate of 2 to 5 cycles per minute. ACTION: If an inoperative or fast cycling pressure switch is found, use the following diagnostic charts before replacing the pressure switch. DIAGNOSTIC PROCEDURE: 1. Connect a manifold gauge set to the service ports and check the system pressures. They should be above the closing pressure of the switch (46 psi). 2. If the A/C system pressures are above 46 psi and the clutch will not engage, proceed as follows: ^ Check the pressure switch harness connector and harness wires for a continuous open condition. ^ Check for an intermittent open or a poor connection between the connector and the pressure switch terminals. a. If the harness connector and wires are OK, by-pass the pressure switch by jumping the two terminals of the connector. If the clutch still does not engage, THE PRESSURE SWITCH IS NOT DEFECTIVE. Refer to the respective EVTM for the clutch circuit schematic and circuit diagnosis. Repair as necessary. 3. Check the ambient temperature. If the ambient temperature is below 48~ F (9~ C), the system pressure will not be high enough to close the pressure switch (46 psi). 4. If the system does not contain refrigerant, the pressure will not be high enough to close the switch for compressor operation. Leak test, repair, evacuate and charge the system. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 7209 Figure 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 7210 Figure 2 5. If the pressures are above 46 psi and the clutch cycle rate is faster than the normal rate of 2 to 5 cycles per minute, the system is probably low on refrigerant. Check that the system contains the correct refrigerant charge by following the correct diagnostic chart (Figures 1 or 2). WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 7211 Refrigerant Pressure Sensor / Switch: Locations Engine Compartment Component Locations On A/C Accumulator Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 7212 Refrigerant Pressure Sensor / Switch: Service and Repair Fig. 6 Accumulator/dryer 1. Disconnect wire harness connector from the pressure switch, Fig. 6. 2. Unscrew pressure switch from top of accumulator dryer. 3. Reverse procedure to install. Lubricate O-ring on the accumulator nipple with refrigerant oil. 4. Check system for leaks and proper operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Locations Compressor Clutch Relay: Locations Engine Compartment Component Locations On Relay Bracket Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description Compressor Clutch Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7219 X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7220 Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7221 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7222 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7223 Compressor Clutch Relay: Testing and Inspection Test Steps Description X1 - CHECK BATTERY VOLTAGE X2 - CHECK BATTERY GROUND X3 - GROUND FAULT ISOLATION X4 - PROCESSOR GROUND FAULT ISOLATION X5 - CHECK SIG RTN CIRCUIT CONTINUITY X6 - MEASURE VOLTAGE AND GROUND TO IRCM X7 - CHECK KEY POWER TO IRCM X8 - CHECK VPWR CIRCUIT CONTINUITY X9 - MEASURE CONTINUITY OF POWER GROUND TO IRCM X11 - CHECK POWER-TO-PUMP(S) CIRCUIT VOLTAGE X12 - CHECK POWER-TO-PUMP(S) CIRCUIT CONTINUITY X13 - CHECK POWER TO IRCM X14 - CHECK POWER-TO-PUMP(S) CIRCUIT FOR SHORTS TO POWER X15 - SERVICE CODE 87/83: CHECK CONTINUITY OF FUEL PUMP CIRCUIT X16 - CHECK APPROPRIATE FUEL PUMP CIRCUIT FOR SHORTS TO POWER AND GROUND X17 - CHECK FUEL PUMP RELAY COIL RESISTANCE X18 - NO HIGH OR LOW FAN X19 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X20 - CHECK FAN MOTOR OPERATION CHECK FAN MOTOR OPERATION X21 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X22 - VERIFY COOLING FAN GROUND X23 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING IRCM X25 - CHECK FAN RUNNING MODE (LOW) X26 - JUMPER HIGH ELECTRIC-DRIVE SIGNAL (HEDF) TO GROUND X27 - CHECK ECT SENSOR X30 - SERVICE CODE 83/563 CHECK HEDF RELAY RESISTANCE X31 - CHECK HEDF CIRCUIT CONTINUITY X32 - CHECK HEDF CIRCUIT FOR SHORTS TO GROUND X33 - CHECK HEDF CIRCUIT FOR SHORTS TO POWER X35 - LOW SPEED FAN ALWAYS ON: CHECK EDF CIRCUIT CONTINUITY X36 - CHECK EDF CIRCUIT FOR SHORT TO POWER X37 - EDF CIRCUIT FAULT ISOLATION X40 - CHECK FAN VOLTAGE X41 - CHECK FAN MOTOR X42 - CHECK FAN RUNNING MODE X43 - MEASURE BATTERY VOLTAGE SUPPLY AT FAN-BYPASSING INTEGRATED CONTROLLER X44 - CHECK EDF CIRCUIT FOR SHORT TO GROUND X45 - VERIFY COOLING FAN GROUND X46 - CHECK ECT SENSOR X50 - CHECK FOR VOLTAGE AT A/C CLUTCH X51 - CHECK FOR CONTINUITY FROM INTEGRATED CONTROLLER TO A/C CLUTCH X52 - ENTER OUTPUT STATE CHECK (REFER TO QUICK TEST APPENDIX) X53 - CHECK WAC OUTPUT FOR PROPER ELECTRICAL OPERATION X54 - CHECK FOR VOLTAGE AT A/C CLUTCH SWITCH X55 - CHECK CONTINUITY OF ACCS TO INTEGRATED CONTROLLER X56 - CHECK CONTINUITY OF ACCS CIRCUIT X57 - CHECK CONTINUITY IN WAC TO INTEGRATED CONTROLLER CIRCUIT X58 - CHECK WAC CIRCUIT FOR SHORTS TO GROUND X59 - CHECK WAC CIRCUIT FOR SHORTS TO POWER X60 - CHECK FOR VOLTAGE AT A/C CLUTCH X80 - SERVICE CODE 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR SHORTS TO GROUND X81 - CHECK FAN RUNNING MODE X82 - FAN ALWAYS ON WITH 88: CHECK EDF PROCESSOR SIGNAL TO INTEGRATED CONTROLLER FOR OPEN CIRCUIT X83 - CHECK EDF CIRCUIT FOR SHORTS TO POWER X84 - CHECK EDF SHORT TO GROUND X90 - SERVICE CODE 95: CHECK INERTIA SWITCH X91 - VERIFY THAT FUEL PUMP IS OFF X92 - CHECK FOR FUEL PUMP RELAY ALWAYS CLOSED X93 - CHECK CONTINUITY OF FPM CIRCUIT X94 - CHECK FOR CONTINUITY BETWEEN FPM CIRCUIT AND GROUND X95 - SERVICE CODE 59 OR 96: CHECK CONTINUITY OF POWER-TO-PUMP CIRCUIT Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7224 X96 - VERIFY FUEL PUMP OPERATION X100 - CONTINUOUS MEMORY CODE 95: CHECK EEC-IV HARNESS X101 - CHECK FPM CIRCUIT X102 - CONTINUOUS MEMORY CODE 59 OR 96 CHECK FOR CONTINUOUS MEMORY CODE 83 OR 87 X103 - CHECK EEC-IV HARNESS X104 - CONTINUOUS MEMORY CODE 83 OR 87: CHECK EEC-IV HARNESS Fig. 23 Integrated Controller Pinpoint Tests X1, X2, X3 & X4 (Part 1 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7225 Fig. 23 Integrated Controller Pinpoint Tests X5, X6, X7 & X8 (Part 2 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7226 Fig. 23 Integrated Controller Pinpoint Tests X9, X11 & X12 (Part 3 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7227 Fig. 23 Integrated Controller Pinpoint Tests X13 & X14 (Part 4 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7228 Fig. 23 Integrated Controller Pinpoint Tests X15 (Part 5 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7229 Fig. 23 Integrated Controller Pinpoint Test X16 & X17 (Part 6 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7230 Fig. 23 Integrated Controller Pinpoint Tests X18, X19, X20 & X21 (Part 7 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7231 Fig. 23 Integrated Controller Pinpoint Test X22 (Part 8 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7232 Fig. 23 Integrated Controller Pinpoint Tests X23 & X25 (Part 9 Of 26) Fig. 23 Integrated Controller Pinpoint Tests X26, X27 & X30 (Part 10 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7233 Fig. 23 Integrated Controller Pinpoint Tests X31 & X32 (Part 11 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7234 Fig. 23 Integrated Controller Pinpoint Tests X33 & X35 (Part 12 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7235 Fig. 23 Integrated Controller Pinpoint Tests X36 & X37 (Part 13 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7236 Fig. 23 Integrated Controller Pinpoint Tests X40, X41, X42 & X43 (Part 14 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7237 Fig. 23 Integrated Controller Pinpoint Tests X44, X45 & X46 (Part 15 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7238 Fig. 23 Integrated Controller Pinpoint Tests X50, X51 & X52 (Part 16 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7239 Fig. 23 Integrated Controller Pinpoint Tests X53, X54 & X55 (Part 17 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7240 Fig. 23 Integrated Controller Pinpoint Tests X56, X57 & X58 (Part 18 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7241 Fig. 23 Integrated Controller Pinpoint Tests X59, X60 & X80 (Part 19 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7242 Fig. 23 Integrated Controller Pinpoint Tests X81, X82 & X83 (Part 20 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7243 Fig. 23 Integrated Controller Pinpoint Tests X84, X90 & X91 (Part 21 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7244 Fig. 23 Integrated Controller Pinpoint Tests X92, X93 & X94 (Part 22 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7245 Fig. 23 Integrated Controller Pinpoint Tests X95 & X96 (Part 23 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7246 Fig. 23 Integrated Controller Pinpoint Tests X100 & X101 (Part 24 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7247 Fig. 23 Integrated Controller Pinpoint Tests X102 & X103 (Part 25 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay > Component Information > Testing and Inspection > Test Steps Description > Page 7248 Fig. 23 Integrated Controller Pinpoint Test X104 (Part 26 Of 26) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Control Module HVAC > Component Information > Service and Repair Control Module HVAC: Service and Repair Fig. 10 Control panel removal 1. Disconnect battery ground cable. 2. Position removal tool T87P-19061 into retaining clip access holes, Fig. 10, then disengage clips by applying pressure away from control panel. Fig. 11 Control panel assembly 3. Pull control assembly away from instrument panel, then disconnect electrical connectors, vacuum harness and temperature control cable from the assembly, Fig. 11. 4. Remove control assembly from instrument panel. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch > Component Information > Locations Blower Motor Switch: Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: Customer Interest A/C System - Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Customer Interest: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor > Page 7264 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C System Chemical/Refrigerator Type Odor Article No. 91-15-5 07/24/91 AIR CONDITIONING - "REFRIGERATOR TYPE SMELL" OR "CHEMICAL TYPE ODOR" A/C SYSTEM - VEHICLES BUILT BEFORE 10/15/90 FORD: 1980-91 CROWN VICTORIA 1981-91 ESCORT 1982-83 FAIRMONT 1982-88 EXP 1982-91 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-91 TEMPO 1986-91 TAURUS 1989-91 PROBE LINCOLN-MERCURY: 1980-91 GRAND MARQUIS, MARK VII, TOWN CAR 1981-87 LYNX 1982-83 LN7, ZEPHYR 1982-86 CAPRI 1982-91 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-91 TOPAZ 1986-91 SABLE LIGHT TRUCK: 1980-91 BRONCO, F-150-350 SERIES 1982-91 RANGER 1983-90 BRONCO II 1986-91 AEROSTAR 1988-91 ECONOLINE, F SUPER DUTY, F-47 1991 EXPLORER This TSB article is being republished in its entirety to include Labor Standards for the Taurus, Sable and Probe vehicle models. ISSUE: A "refrigerator type smell" or "chemical type" odor may come from some A/C systems. As the calibration of the clutch cycling pressure switch drifts downward, the evaporator core temperature may drop too low. This results in a "refrigerator type smell" or "chemical type" odor as the system cycles on and off. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 91155 > Jul > 91 > A/C System - Chemical/Refrigerator Type Odor > Page 7270 Figure 1 ACTION: Install a new recalibrated clutch cycling pressure switch or adjust the existing/non-recalibrated clutch cycling pressure switch. The recalibrated switch can be identified by a specific supplier date code stamped near the fitting end of the switch, Figure 1. ^ Recalibrated switches built in the 1990 calendar year begin with the supplier date code 9041 and run through 9052. ^ Recalibrated switches built in the 1991 calendar year start with the supplier date code 9101 and run through 9152. ADJUSTMENT PROCEDURE Adjust the existing/non-recalibrated A/C cycling pressure switch by using the following service procedure. 1. Disconnect the body wiring harness. 2. Turn the set screw located between the two electrical terminals 3/4 turn clockwise (looking into the electrical connection) Figure 1. 3. Reconnect the body wiring harness. PART NUMBER PART NAME CLASS E35Y-19E561-A A/C Cycling Pressure Switch AM OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911505A Install A/C Cycling 0.3 Hr. Pressure Switch - Town Car, Escort, Lynx, EXP And LN7. 911505B Install A/C Cycling 0.4 Hr. Pressure Switch - Tempo/ Topaz, Taurus/Sable, Probe. 911505C Install A/C Cycling 0.5 Hr. Pressure Switch - Crown Victoria, Grand Marquis, Mark VII, Continental, Thunderbird, Cougar, Fairmont, Zephyr, Mustang, Capri, LTD And Marquis. 911505D Install A/C Cycling 0.4 Hr. Pressure Switch - All Light Trucks. 911505E Adjust A/C Cycling Switch - 0.2 Hr. All DEALER CODING BASIC PART NO. CONDITION CODE 19E661 53 OASIS CODES: 208000, 208999 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Pressure Cycling Switch Diagnostic Procedure AIR CONDITIONING-CLUTCH PRESSURE CYCLING SWITCH DIAGNOSTIC PROCEDURE Article No. 89-14-10 FORD: 1980-89 CROWN VICTORIA 1981-89 ESCORT 1982-88 EXP 1982-89 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-89 TEMPO 1986-89 TAURUS LINCOLN-MERCURY: 1980-89 GRAND MARQUIS, MARK VI, MARK VII, TOWN CAR 1981-87 LYNX 1982-86 CAPRI 1982-89 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-89 TOPAZ 1986-89 SABLE LIGHT TRUCK: 1980-89 BRONCO, F SERIES 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR 1988-89 ECONOLINE ISSUE: Poor air conditioning cooling caused by low or no refrigerant charge often results in unnecessary replacement of the clutch cycling pressure switch. The switch is designed to work on system pressure. It closes at about 46 psi and opens at about 24.5 psi. It has a normal cycle (on and off) rate of 2 to 5 cycles per minute. ACTION: If an inoperative or fast cycling pressure switch is found, use the following diagnostic charts before replacing the pressure switch. DIAGNOSTIC PROCEDURE: 1. Connect a manifold gauge set to the service ports and check the system pressures. They should be above the closing pressure of the switch (46 psi). 2. If the A/C system pressures are above 46 psi and the clutch will not engage, proceed as follows: ^ Check the pressure switch harness connector and harness wires for a continuous open condition. ^ Check for an intermittent open or a poor connection between the connector and the pressure switch terminals. a. If the harness connector and wires are OK, by-pass the pressure switch by jumping the two terminals of the connector. If the clutch still does not engage, THE PRESSURE SWITCH IS NOT DEFECTIVE. Refer to the respective EVTM for the clutch circuit schematic and circuit diagnosis. Repair as necessary. 3. Check the ambient temperature. If the ambient temperature is below 48~ F (9~ C), the system pressure will not be high enough to close the pressure switch (46 psi). 4. If the system does not contain refrigerant, the pressure will not be high enough to close the switch for compressor operation. Leak test, repair, evacuate and charge the system. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 7275 Figure 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 7276 Figure 2 5. If the pressures are above 46 psi and the clutch cycle rate is faster than the normal rate of 2 to 5 cycles per minute, the system is probably low on refrigerant. Check that the system contains the correct refrigerant charge by following the correct diagnostic chart (Figures 1 or 2). WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure Refrigerant Pressure Sensor / Switch: All Technical Service Bulletins A/C - Pressure Cycling Switch Diagnostic Procedure AIR CONDITIONING-CLUTCH PRESSURE CYCLING SWITCH DIAGNOSTIC PROCEDURE Article No. 89-14-10 FORD: 1980-89 CROWN VICTORIA 1981-89 ESCORT 1982-88 EXP 1982-89 MUSTANG, THUNDERBIRD 1983-86 LTD 1984-89 TEMPO 1986-89 TAURUS LINCOLN-MERCURY: 1980-89 GRAND MARQUIS, MARK VI, MARK VII, TOWN CAR 1981-87 LYNX 1982-86 CAPRI 1982-89 CONTINENTAL, COUGAR 1983-86 MARQUIS 1984-89 TOPAZ 1986-89 SABLE LIGHT TRUCK: 1980-89 BRONCO, F SERIES 1983-89 RANGER 1984-89 BRONCO II 1986-89 AEROSTAR 1988-89 ECONOLINE ISSUE: Poor air conditioning cooling caused by low or no refrigerant charge often results in unnecessary replacement of the clutch cycling pressure switch. The switch is designed to work on system pressure. It closes at about 46 psi and opens at about 24.5 psi. It has a normal cycle (on and off) rate of 2 to 5 cycles per minute. ACTION: If an inoperative or fast cycling pressure switch is found, use the following diagnostic charts before replacing the pressure switch. DIAGNOSTIC PROCEDURE: 1. Connect a manifold gauge set to the service ports and check the system pressures. They should be above the closing pressure of the switch (46 psi). 2. If the A/C system pressures are above 46 psi and the clutch will not engage, proceed as follows: ^ Check the pressure switch harness connector and harness wires for a continuous open condition. ^ Check for an intermittent open or a poor connection between the connector and the pressure switch terminals. a. If the harness connector and wires are OK, by-pass the pressure switch by jumping the two terminals of the connector. If the clutch still does not engage, THE PRESSURE SWITCH IS NOT DEFECTIVE. Refer to the respective EVTM for the clutch circuit schematic and circuit diagnosis. Repair as necessary. 3. Check the ambient temperature. If the ambient temperature is below 48~ F (9~ C), the system pressure will not be high enough to close the pressure switch (46 psi). 4. If the system does not contain refrigerant, the pressure will not be high enough to close the switch for compressor operation. Leak test, repair, evacuate and charge the system. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 7282 Figure 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > All Other Service Bulletins for Refrigerant Pressure Sensor / Switch: > 891410 > Jul > 89 > A/C - Pressure Cycling Switch Diagnostic Procedure > Page 7283 Figure 2 5. If the pressures are above 46 psi and the clutch cycle rate is faster than the normal rate of 2 to 5 cycles per minute, the system is probably low on refrigerant. Check that the system contains the correct refrigerant charge by following the correct diagnostic chart (Figures 1 or 2). WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2600, 2610 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 7284 Refrigerant Pressure Sensor / Switch: Locations Engine Compartment Component Locations On A/C Accumulator Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor / Switch, HVAC > Component Information > Technical Service Bulletins > Page 7285 Refrigerant Pressure Sensor / Switch: Service and Repair Fig. 6 Accumulator/dryer 1. Disconnect wire harness connector from the pressure switch, Fig. 6. 2. Unscrew pressure switch from top of accumulator dryer. 3. Reverse procedure to install. Lubricate O-ring on the accumulator nipple with refrigerant oil. 4. Check system for leaks and proper operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Heating and Air Conditioning > Vacuum Tank <--> [Vacuum Reservoir HVAC] > Component Information > Description and Operation Vacuum Tank: Description and Operation Fig. 28 Vacuum reservoirs The vacuum reservoir, Fig. 28, acts as an accumulator and prevents sudden drops or rapid fluctuations in a vacuum signal during acceleration. If vacuum in the reservoir leaks more than 1/2 inch Hg in 1 minute, the reservoir is defective and must be replaced. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Locations Seat Belt Control Module: Locations Body & Chassis Components Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Locations > Page 7294 Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Locations > Page 7295 Seat Belt Control Module: Diagrams Connector View Harness Connector Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Seat Belt Control Module > Component Information > Locations > Page 7296 Seat Belt Control Module: Service and Repair REMOVAL and INSTALLATION 1. Remove LH luggage compartment trim panel. 2. Disengage two cover retaining push pins and remove cover. 3. Remove processor assembly from bracket (snaps on bracket). 4. Disconnect electrical connectors and remove processor. 5. To install, reverse Steps 1 through 4. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions Child Seat Tether Attachment: Service Precautions WARNING: - WHEN USING ANY INFANT OR CHILD RESTRAINT SYSTEM, IT IS IMPORTANT THAT YOU FOLLOW THE INSTRUCTIONS PROVIDED BY THE MANUFACTURER CONCERNING ITS INSTALLATION AND USE. FAILURE TO FOLLOW EACH OF THE RESTRAINT MANUFACTURER'S INSTRUCTIONS CAN RESULT IN A CHILD STRIKING THE VEHICLE'S INTERIOR DURING A SUDDEN STOP OR COLLISION. - IT IS IMPORTANT THAT THE BOLT/ANCHOR BE SECURELY TIGHTENED TO SPECIFICATION. OTHERWISE, THE CHILD SAFETY SEAT MAY NOT BE PROPERLY SECURED AND THE CHILD COULD BE INJURED IN CASE OF A SUDDEN STOP OR ACCIDENT. - CHILDREN HAVING A SEATING HEIGHT GREATER THAN 71 CM (28 INCHES), WHICH IS THE MAXIMUM HEIGHT FOR USE OF THE TOT GUARD, SHOULD USE THE SAFETY BELTS PROVIDED WITH THE VEHICLE. HOWEVER, THE SHOULDER BELT PORTION OF THE LAP SHOULDER SAFETY BELT SHOULD NOT BE USED IF IT CONTACTS THE CHILD'S FACE, CHIN, NECK OR THROAT. IF THE SHOULDER BELT CONTACTS OR REMAINS IN FRONT OF THE CHILD'S FACE, CHIN, NECK OR THROAT, MOVE THE CHILD TO A SEAT WITH A LAP SAFETY BELT ONLY, IF AVAILABLE, OTHERWISE, PLACE THE SHOULDER PORTION BEHIND THE CHILD'S BACK. FAILURE TO FOLLOW THIS PRECAUTION CAN INCREASE THE RISK OR SEVERITY OF INJURY IN THE EVENT OF A COLLISION. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions > Page 7302 Child Seat Tether Attachment: Description and Operation Some aftermarket child safety seats provide a tether strap which goes over the back of the vehicle seat and attaches to an anchorage in the floor or panel behind the rear seat. (Ford's Tot-Guard Child Seat does not require a top tether strap). Three 9 mm (0.35-inch) holes in the package tray structure (behind the rear seat) have been provided to attach the top tether, if required. You may use either attachment, or all if desired for up to three child safety seats. TETHER ATTACHMENT-PACKAGE TRAY Vehicles equipped with a package tray (sill-below the rear window glass) have three 9 mm (0.35-inch) holes provided in the package tray sheet metal structure for attaching the child seat tether. For easy identification, these holes are marked with the letter "T" stamped next to the hole. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment > Component Information > Service Precautions > Page 7303 Child Seat Tether Attachment: Service and Repair 1. From inside the luggage compartment, locate the 9 mm (0.35-inch) holes in the package tray structure. Refer to the following illustration to determine the exact location of the 9 mm (0.35-inch) tether attachment holes. Dimension A is the distance from the centerline of the vehicle to the center of the attachment holes. Dimension B is the approximate distance from the center of the radio speaker grille opening to the center of the tether attachment holes. 2. From inside the luggage compartment, pierce a small hole through the package tray (sill) trim panel. Exercise caution to prevent the piercing tool from hitting and shattering the rear window glass. WARNING: AN ASSISTANT MUST BE INSIDE THE VEHICLE HOLDING THE PACKAGE TRAY DOWN TO PREVENT IT FROM BEING DISLODGED. THE ASSISTANT MUST ALSO AVOID HOLDING THE PACKAGE TRAY DOWN IN THE AREA THAT THE HOLE IS BEING PIERCED TO AVOID HAND OR ARM INJURY. 3. From inside the passenger compartment, enlarge the hole in the trim panel until the bolt/anchor supplied by the restraint manufacturer fits. 4. Install the top tether anchor hardware according to the restraint manufacturer's instructions. WARNING: IT IS IMPORTANT THAT THE BOLT/ANCHOR BE SECURELY TIGHTENED TO THE RESTRAINT MANUFACTURER'S SPECIFICATIONS. OTHERWISE, THE CHILD SAFETY SEAT MAY NOT BE PROPERLY SECURED AND THE CHILD COULD BE INJURED IN CASE OF A SUDDEN STOP OR ACCIDENT. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement Technical Service Bulletin # 92S52 Date: 920902 Recall - Safety Front Safety Belt/Retractor Replacement RECALL 92S52 SAFETY RECALL 1989 Thunderbird And Cougar - Front Safety Belt And Retractor Assemblies Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Dealer Stock Parts Return Instructions Attachment III ^ Technical Instructions Customer Notification Letter Attachment I - Administrative Information Administrative Information OASIS ^ Use OASIS to determine if a vehicle is involved in this or another recall. ^ Tell owners of any other recalls that may be uncompleted. Complete all recall during a single visit by the owner. Promptly Perform Recall On: ^ Affected vehicles on the enclosed list. ^ Other affected vehicles which are brought to your dealership. NOTE: Perform recall on all affected vehicles in dealer stock before delivery to owners. Dealer-Owner Contact/Action ^ Immediately contact any owner of an affected vehicle whose name does not appear on the enclosed list. ^ Arrange a service date. Give the owner a copy of the owner letter. ^ Advise the Company of the vehicle's ownership status change (refer Warranty and Policy Manual - Section 3.3). Dealership Responsibilities ^ Perform this recall service promptly following presentation of the vehicle by the owner. ^ Promptly report to the "Customer Assistance Centre" at Oakville any instance in which an owner will not allow you to complete this recall because of objections in scheduling or for any other reason. Reimbursement For Recall Completion And Claims Preparation Instructions ^ Submit claims for all completed units. ^ Claim reimbursement through the Direct Warranty Entry (DWE) system using the RECALLS screen only (PF # Recall Entry/Retrieval on the DWE Menu Screen). If the claim number contains more than six digits, enter only the last six digits. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7312 NOTE: Use a Form 6125-2, an authorized computer generated claim form or an 1864 Form as an internal repair order to support DWE Entry through the RECALLS screen. Ensure that only the RECALLS screen is used when inputting completion and reimbursement information. ^ Dealers without DWE capability must mail a completed From 1864 (Company Claim Copy No. 2) to Warranty Claims Processing Oakville for reimbursement. Forms submitted must show all parts used and their cost, the parts handling allowance, and be imprinted, dated and signed by authorized dealership personnel. ^ All claims must show 92S52 in the Recall box. Attachment II - Labor and Parts Information Labor Allowances LABOR DESCRIPTION LABOR TIME LABOR CODE Completely Remove and Install both the Driver and Front 1.4 Hrs. B Passenger Safety Belt and Retractor Assemblies (Tongue end assemblies only). Install Plug Buttons in "B" Pillars. Review Revised Belt Use Instructions With Vehicle Owner and Provide Vehicle Owner With The Owner Guide Insert Booklet Administrative Allowance 0.1 Hrs. NOTE: The 0.1 hours Administrative Allowance must be added to the total labor time before inputting. Parts Ordering Information Order your parts requirements through your Servicing Parts Distribution Centre. PART NUMBER COLOUR DESCRIPTION (ONE KIT REQUIRED PER VEHICLE) E9SZ-63611A74-A Currant Red Kit - Safety Belt and Retractor Assembly(1) E9SZ-63611A74-B Light Sandaled Kit - Safety Belt and Retractor Assembly(1) E9SZ-63611A74-C Titanium Kit - Safety Belt and Retractor Assembly(1) E9SZ-63611A74-D Shadow Blue Kit - Safety Belt and Retractor Assembly(1) (1) - Contains: - 1 each of driver and front passenger Safety Belt and Retractor Assemblies (tongue end assemblies only) - 2 plug buttons (part number 378770-S) - Instruction Sheet I.S. 6393 - Owner Guide Insert booklet (Form: 92S52) Dealer Stock Parts Return Instructions The following parts are obsolete and superseded. They are not to be used for servicing any vehicles. All dealership stock of these parts must be returned immediately to your Servicing PDT using Claim Form 562-2 showing "Returned per Safety Recall 92S52". E9SZ-63611A72/73/74-EEE E9SZ-63611A72/73/74-FFF E9SZ-63611A72/73/74-GGG E9SZ-63611A71/73/74-HHH Attachment III - Technical Instructions Technical Instructions Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7313 Affected Vehicles 1989 Thunderbird/Cougar (Active Restraint) General Information ^ Note routing and mounting positions of the safety belt assembly before replacement. Use Tool No. T77L-2100-A, or equivalent, and torque all anchor bolts to the required specification shown for each mounting position. ^ Built-in anchorages are provided in all vehicles. ^ Care should be taken not to cross-thread the anchor bolts. Refer to the 1989 Thunderbird/Cougar Shop Manual, page 41-50-8 "Major Service Operation", if necessary to correct thread damaged Anchor Plates. ^ Replace all covers where applicable. ^ All washers and spacers to be installed in same location as they were prior to removal. ^ Check safety belts for proper routings. CAUTION Check position of factory installed safety belt anchor tabs and install the replacement safety belt and anchor tabs in same position. Care must be exercised when making replacement that all safety belt anchors are positioned as specified. CAUTION Disconnect battery cable before any electrical connections are made to prevent shock hazard. Usage Information Consult the Owner Guide Insert and appropriate Owner Guide for specific lap safety belt and shoulder safety belt use and adjustments. WARNING MAKE SURE THAT YOU AND YOUR PASSENGERS, INCLUDING PREGNANT WOMEN, WEAR SAFETY BELTS. BE SURE THAT LAP BELTS FIT SNUGLY AND AS LOW AS POSSIBLE AROUND THE HIPS. IF SAFETY BELTS ARE NOT USED PROPERLY, THE RISK OF YOU OR YOUR PASSENGERS BEING INJURED IN A COLLISION GREATLY INCREASES. WARNING USE THE SHOULDER BELT ON THE OUTSIDE SHOULDER ONLY. NEVER WEAR THE SHOULDER BELT UNDER THE ARM. EVER SWING IT AROUND THE NECK OVER THE INSIDE SHOULDER. NEVER USE A SINGLE BELT FOR MORE THAN ON PERSON. FAILURE TO FOLLOW THESE PRECAUTIONS COULD INCREASE THE RISK AND/OR SEVERITY OF INJURY IN AN ACCIDENT. WARNING NEVER USE A SINGLE BELT FOR MORE THAN ONE PERSON OR ACROSS MORE THAN ONE SEATING POSITION. THIS GREATLY INCREASES THE RISK THAT ONE OR BOTH OF THE PEOPLE WILL BE INJURED IN A COLLISION. EACH SEATING POSITION IN YOUR VEHICLE HAS A SPECIFIC SAFETY BELT ASSEMBLY WHICH IS MAKE UP OF ONE BUCKLE AND ONE TONGUE THAT ARE DESIGNED TO BE USED AS A PAIR. WARNING ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS THAT ALL SAFETY BELT ASSEMBLIES USED DURING A COLLISION BE REPLACED UNLESS THE BELTS DO NOT SHOW DAMAGE AND CONTINUE TO OPERATE PROPERLY. SAFETY BELTS NOT IN USE DURING A COLLISION SHOULD BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. WHEN REPLACING SAFETY BELT AND BUCKLES, SAFETY CABLE AND BUCKLES, CENTRE ADJUST TONGUES AND BELT AND RETRACTORS, USE ONLY THE REPLACEMENT PARTS SPECIFIED IN THE FORD MASTER PARTS CATALOGS FOR THE MAKE AND MODEL OF THE VEHICLE BEING SERVICED. SAFETY BELT ASSEMBLIES MUST NOT BE INTERCHANGED BETWEEN VEHICLE MODELS. The following provide removal and installation instructions for both driver and front passenger safety belt and retractor assemblies. IMPORTANT: The parts kit contains one each of the driver's and front passenger safety belt and retractor assembly (tongue end assemblies only), two plug buttons and an Owner Guide Insert booklet. NOTE: Buckle end assemblies are not included and are not to be replaced. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7314 Seat Back and Seat Cushion Removal (Refer to Figure 1) 1. Remove the rear seat cushion and rear seat back assembly as follows: 2. Apply knee pressure to the lower portion of the rear seat cushion. Push rearward to disengage the seat cushion from the retainer brackets and remove the seat cushion. 3. Remove the seat back retaining bolts. 4. Grasp the seat back assembly at the bottom and lift it up to disengage the hanger wire from the slotted holes in the package tray. 5. Remove the seat back assembly from the vehicle. Interior Trim Removal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7315 (Refer to Figures 3 and 4) 1. Remove the safety belt D-ring cover. 2. Using Seat Belt Bolt Bit No. T77L-2100-A, or equivalent, remove the bolt retaining the safety belt and D-ring to the "B" pillar assembly. 3. Remove the rear screw retaining the door scuff plate to the floor sill. 4. Remove the two (2) screws retaining the lower quarter trim panel to the body quarter side assembly and remove the panel. 5. Remove the quarter trim finish panel and rear speaker cover assembly. (The speaker cover is retained by locator tabs at the top and snap-on type fasteners at the bottom.) 6. Remove the four (4) screws retaining the rear speaker to the body and remove the rear speaker. 7. Remove the two (2) screws retaining the upper quarter trim panel to the body. 8. Remove the coat hook attaching screw and the coat hook. 9. Remove the front seat shoulder strap guide bezel. 10. Disengage the quarter trim panel. 11. Disconnect the electrical wiring connector from the rear courtesy lamp. Safety Belt and Retractor Assembly Removal (Refer to Figure 4) 1. Using Seat Belt Bolt Bit No. T77L-2100-A, or equivalent, remove the lower bolt retaining the safety belt anchor to the floor sill assembly. 2. Slide the safety belt through the slot in the upper trim panel. 3. Remove the bolt retaining the safety belt retractor assembly to the "B" pillar assembly. 4. From inside the vehicle, rotate the comfort regulator housing and remove it front the "B" pillar. Refer to Figure 4 and View A. 5. Remove the safety belt and retractor assembly from vehicle. Safety Belt and Retractor Assembly Installation (Refer To Figures 3 and 5) 1. Install the safety belt and retractor assembly. Make sure the belt webbing is not twisted. 2. Install the bolt retaining the safety belt retractor assembly to the "B" pillar assembly. Torque the bolt to 30-43 N-m (22-32 Lb.-Ft.). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7316 3. Install the plug button (included in the kit) into the opening in the "B" pillar. Refer to Figure 5, View B. NOTE: Prior to installation wipe clean the outer surface area surrounding the hole. 4. Slide the safety belt through the slot in the upper trim panel. Interior Trim Installation (Refer To Figures 3 and 5) 1. Connect the electrical wiring connector to the rear courtesy lamp. 2. Install the quarter trim panel. 3. Install the front seat shoulder strap guide bezel. 4. Install the coat hook and attaching screw. 5. Install the two (2) screws retaining the upper quarter trim panel to the body. 6. Connect the electrical connector to the speaker. 7. Install the rear speaker to the body using the (4) retaining screws removed in Step 6 of the Interior Trim Removal Procedure. 8. Snap on the quarter trim finish panel and rear speaker cover assembly. 9. Install the lower quarter trim panel to the body quarter side assembly, using the two (2) screws removed in Step 4 of the Interior Trim Removal Procedure. 10. Install the door scuff plate to the floor sill using the screw removed in Step 3 of the Interior Trim Removal Procedure. 11. Position the D-ring to the "B" pillar. Make sure the belt webbing is not twisted. 12. Using Sear Belt Bolt Bit No. T77L-2100-A, or equivalent, install the bolt retaining the safety bolt and D-ring to the "B" pillar assembly. Torque the bolt to 30-43 No-m (22-32 Lb.-Ft.). 13. Make sure the belt webbing is not twisted. Install the lower bolt retaining the safety belt anchor to the floor sill assembly. Torque the bolt to 30-43 No-m (22-32 Lb.-Ft.). 14. Install the safety belt D-ring cover. Seat Back and Seat Cushion Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7317 (Refer To Figures 1 And 2) 1. Install the rear seat cushion and the rear seat back assembly as follows. 2. Position the seat back assembly into the vehicle so that the hanger wire is fully engaged in the package tray slots. 3. Install the seat back lower retaining bolts and tighten securely. 4. Position the seat cushion assembly into the vehicle. 5. Position the rear occupant safety belt buckles and the centre occupant lap belt on top of the cushion. 6. Apply knee pressure to the lower portion of the seat cushion assembly. Push rearward and down to lock seat cushion into position. 7. Check rear seat cushion to ensure it is secured into floor retainer. IMPORTANT Mutilate and scrap all replaced safety belt and retractor assemblies. Safety Restraint Operations Review 1. Ensure that the webbing on all safety belts (front and rear) is not twisted. 2. Check the front and rear restraint systems for proper operation. 3. Remind customer that the new front safety restraint and retractor assembly does not have the comfort regulator feature. 4. Review and demonstrate the new front safety restraint operating instructions with the customer. 5. Give the customer the Owner Guide Insert booklet (contained in the Parts Kit) that provides specific use instructions to be employed with this new front restraint system. Dealer Letter September 2, 1992 To: All Ford of Canada Dealers Attention: Dealer Principal Service Manager Parts Manager Subject: Safety Recall 92S52 - 1989 Thunderbird and Cougar - Front Safety Belt and Retractor Assemblies Replacement ATTENTION: This Safety Recall supersedes and cancels Safety Recall 91S32. In OASIS YES Listings Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7318 YES Recall Time Limitations None Dealer Stock Parts (See Attachment II ) Parts Return No - Mutilate and Scrap. NOTE: Please read and circulate these instructions to your Service, Parts and Sales Personnel. They should become familiar with this recall and respond to owner inquiries. Vehicles Affected All 1989 Model Year Thunderbird and Cougar cars. Reason for Recall A cable in the comfort regulator mechanism in either the safety belts provided in the kits for Safety Recall "91S32" or the factory installed front safety belt assemblies may break or bind causing a malfunction in the retractor mechanism. Should this occur, the front safety belts may not retract after full extension. In this condition the occupant of the vehicle will not be properly restrained if the vehicle is involved in a collision. Service Action To correct this condition, replace the existing driver and front passenger safety belt and retractor assemblies (tongue end assemblies only) with the new design parts and install plug buttons in the comfort regulator plunger holes located in the door openings. The new belt system is the same as that used in 1992 models. Instruct the customer on use of the new belt system and provide the customer the supplemental information (Owner Guide Insert) booklet contained in the parts kit. Company Contacts: (for dealer use only) CONCERN NATURE CONTACT ACTIVITY Technical Technical Assistance Hotline 1-800-665-3577 Claiming Procedures Warranty Claims Hotline for your Region Owner Concerns Customer Assistance Centre Hotline 1-800-565-3673 General Administrative Christine Murray - Recall Administrator ^ Telephone (416) 845-2511 Next. 1495 ^ Facsimile (416) 845-7069 Attachments Attachment I ^ Administrative Information Attachment II ^ Parts Ordering Information ^ Labor Allowances ^ Dealer Stock Parts Return Instructions Attachment III ^ Technical Instructions Owner Letter Mail Date Serial Number: XXXXXXXXXXXXXXXXX 92S52 Customer Name 123 Main Street Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7319 City, PR ANA NAN This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act of Canada. Ford Motor Company of Canada, Limited (Ford) is notifying owners of record about a defect in the front safety belts of 1989 Thunderbird and Cougar cars. This notice applies to your vehicle even if it was serviced under a similar recall announced in May 1991. This notification is with regard to the 1989 Thunderbird or Cougar with the serial number shown above your name and address on this letter. Reason For This Notification And Recall A cable in the comfort regulator mechanism of the front safety belt retractors, of your car, may bend and eventually break. This situation can occur on either the original or on the previous recall installed safety belt assembly. Should this condition occur the safety belt, when fully extended, may not retract and will not properly restrain the seat occupant in the event of a collision. In this condition the normal protection against personal injury provided by the belt assembly would be reduced. Important You should have new front safety belts installed in your car by your Ford or Mercury dealer as promptly as possible. In the meantime, occupants should continue to wear their safety belts, even if the front retractors are broken. If the retractors are not broken, the belts should function normally. If a retractor is broken, the belt will provide partial protection to the occupant if the lap belt portion is buckled snugly about the hips. However, a belt assembly with a broken retractor will provide little or no upper body restraint. New Front Safety Belt Buckling-Up Information The new seat belt assembly will not have the comfort regulator feature that your vehicle has now. Instead, when buckled, the assembly will provide constant light tension about the occupant while allowing comfortable movement. This is the same system as used in 1992 models. When you have the recall performed, your dealer will give you an Owner Guide Insert booklet that provides specific information for using the new front safety belts. You and other vehicle users should read and become familiar with the information in this booklet. We recommend that you retain this booklet with your Owner Guide for future reference. Repairs At no charge to you, your dealer will replace both the driver and front passenger safety belt (tongue end) assemblies on your car. How Long Will It Take? The time needed to repair your vehicle is less than two hours. However, due to service scheduling times, your dealer may need your vehicle for a full working day. Call Your Dealer Call your Ford or Mercury dealer without delay and ask for a service date. Also ask your dealer to check the OASIS system for any other service actions that may be required on your vehicle. If parts are needed and the dealer does not have them in stock, they can be ordered before scheduling your service date. If you have leased this vehicle to another person or organization, please immediately notify the lessee of this recall. When you bring your vehicle in, show the dealer this letter. If you lose the letter, your dealer will still do the work free of charge. Changed Name, Address, Or Sold The Vehicle? If you have changed your name or address, or have sold the vehicle, please fill out the enclosed prepaid postcard. Sign and date it and mail the card to Ford. If you cannot get the recall service performed, contact the Ford "Customer Assistance Centre" at the address identified in the letterhead of this letter. Please identify your vehicle's serial number in any correspondence. We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement Technical Service Bulletin # 91S32 Date: 910501 Recall - Seat Belt Assembly Replacement RECALL 91S32 SAFETY RECALL 1989 Model Thunderbird and Cougar - Seat Belt Assembly Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refunds Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Instructions Customer Notification Letter Attachment I - Administrative Information Administrative Information CARES / OASIS You must use CARES or OASIS to determine if a vehicle is eligible for this or another recall. Tell owners of any other recalls that may not have been completed. Complete all recalls during a single visit by the owner. Promptly Correct ^ Affected vehicles on the enclosed list. ^ Other affected vehicles which are brought to your dealership. NOTE: Correct all affected vehicles in dealer stock before delivery to owners. Dealer-Owner Contact/Action If you are aware of any subject vehicles in your region, and the owner's name does not appear on the enclosed list, immediately contact the owner and arrange a service date. Give the owner a copy of the Owner Letter. Dealership Responsibilities Dealers are responsible to perform this recall service promptly following presentation of the vehicle by the owner. It is important that you promptly report to the "National Owner Relations Office" at Oakville any instance in which an owner will not allow you to complete this recall because of objections in scheduling or for any other reason. Reimbursement For Recall Completion And Claims Submission Instructions ^ Submit claims for all completed units. ^ Claim reimbursement through the Direct Warranty Entry (DWE) system using the RECALLS screen. Use the RECALLS screen only (PF3 Recall Entry/Retrieval on the DWE Menu Screen). If the claim number contains more than six digits, enter only the last six digits. NOTE: Claim Form 1864 will no longer be mailed to owners. Use a Form 6125-2 or an authorized computer generated claim form as an internal repair order to support DWE Entry through the RECALLS screen. Ensure that only the RECALLS screen is used when inputting completion and reimbursement information. ^ Dealers without DWE capability must mail Company Claim Copy No. 2 of a completed Form 1864 to Warranty Claims Processing at Oakville for Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement > Page 7324 reimbursement. Forms submitted must show all parts used and their cost, the parts handling allowance, and be imprinted, dated and signed by authorized dealership personnel. ^ All claims must show 91S32 in the recall box. Refunds Refund requests must be submitted separately from the recall service actions. Refund requests are governed by the following guidelines: ^ Owners/Dealers seeking refund for replacement of front seat belt assemblies (because of broken tension eliminator cables) at their expense prior to the receipt of notice of this recall must present the original copy of their paid repair orders or parts invoices to any Ford or Mercury dealership. ^ Using the DWE Recall Screen, enter the following: - Labor Code..........A - Recall Code..........R91S32 - Enter "REFUND INV # ____________" in the area on the claim designated for PARTS USED. - Enter the owner refund amount as a "MISCELLANEOUS" cost. ^ Please provide prompt refund to all eligible owners having proper documentation regardless of the source of the original service. ^ Retain the copy of the paid repair order or invoice with a copy of the refund request in your service file for reference. ^ Dealers without DWE capability must mail their refund requests on a separate completed 1864 Form with the owner's original paid repair order or parts purchase receipt to Warranty Claims Processing. Enter the 0.3 Hrs. in Box "A" and R91S32 in the Recall box of the Form. Include all amounts in the TOTAL CLAIM box. NOTE: Dealers should ensure that the recall is also performed on all vehicles for which a refund is processed. Attachment II - Labor and Parts Information Labor Allowances OPERATION DESCRIPTION LABOR TIME LABOR CODE Completely Remove and Install both the Driver and Front Passenger Seat Belt Assemblies 0.8 Hrs. B Administrative Allowance 0.1 Hrs. NOTE: The 0.1 hour Administrative Allowance must be added to the total labor time before inputting. Parts Ordering Information Parts will not be direct shipped for this recall. Order requirements through your Servicing Parts Distribution Centre. PART NUMBER COLOUR DESCRIPTION E9SZ-63611A74-EEE Shadow Blue Kit - Seat Belt Assembly Front (Contains 1 each of Front Driver and Passenger Seat Belt Assemblies) E9SZ-63611A74-FFF Currant Red Kit - Seat Belt Assembly Front (Contains 1 each of Front Driver and Passenger Seat Belt Assemblies) E9SZ-63611A74-GGG Light Sandalwood Kit - Seat Belt Assembly Front (Contains 1 each of Front Driver and Passenger Seat Belt Assemblies) E9SZ-63611A74-HHH Titanium Kit - Seat Belt Assembly Front (Contains 1 each of Front Driver and Passenger Seat Belt Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement > Page 7325 Assemblies) Attachment III - Technical Instructions Technical Instructions Removal And Installation Instructions For Both Driver And Front Passenger Seat Belt Assemblies And Buckle Assemblies Interior Trim Removal: Refer to Figures 1 and 2. 1. Remove rear seat cushion assembly. 2. Remove rear seat back assembly. Refer to Body Shop Manual Sec 41-14. 3. Remove safety belt D-ring cover (Figure 2) on both sides. 4. Using Seat Belt Bolt Bit No. T77L2100-A, or equivalent, remove bolt retaining safety belt and D-ring to "B" pillar assembly (Figure 2) on both sides. 5. Remove rear screw retaining door scuff plate to floor sill (both sides). 6. Remove two (2) screws retaining lower quarter trim panel to body quarter side assembly and remove panel (both sides). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement > Page 7326 7. Remove quarter trim finish panel and cover assembly (rear speaker cover) on both sides. (The speaker cover is retained by snap-on type fasteners.) 8. Remove four (4) screws retaining rear speaker to body and remove rear speaker (both sides). 9. Remove two (2) screws retaining upper quarter trim panel to body (both, sides). 10. Remove coat hook attaching screw and coat hook (both sides). 11. Remove front seat shoulder strap guide bezel (both sides). 12. Disengage both quarter trim panels. 13. Disconnect electrical wiring connectors from rear speaker and rear courtesy lamp (both sides). Seat Belt Retractor Assembly And Buckle Assembly Removal: Refer to Figures 2 and 3. 1. Using Seat Belt Bolt Bit No. T77L2100-A, or equivalent, remove lower bolt retaining safety belt anchor to floor sill assembly (both sides). 2. Slide safety belts through slots in upper trim panels. 3. Remove bolt retaining safety belt retractor assembly to "B" pillar assembly (both sides). 4. Press out from B-Pillar the tension eliminator button assembly. 5. Remove both safety belt and retractor assemblies from vehicle. 6. Remove bolts retaining inboard belt and buckle assemblies from seat support assemblies. 7. Disconnect buzzer wiring from floor pan wiring and remove belt and buckle assemblies Safety Belt And Retractor Assembly Installation: 1. Reverse above removal procedure. Make sure belt webbing is not twisted. 2. Install safety belt attaching bolts using Seat Belt Bolt Bit No. T77L2100-A or equivalent. Make sure bolts are torqued to 30-43 N-m (22-32 Lb.-Ft.) 3. Cycle the system several times to ensure proper operation of the retractor. Ensure webbing is not twisted. IMPORTANT NOTE Mutilate and scrap all replaced seat belt assemblies. Dealer Letter May 1, 1991 To: Ford Of Canada Dealers Attention: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement > Page 7327 Dealer Principal, Service Manager, Parts Manager Subject: Safety Recall 91S32 - 1989 Model Thunderbird and Cougar - Seat Belt Assembly Replacement In CARES / OASIS YES Listings YES Recall Time Limitation None Parts Return NO NOTE: Please read and circulate these instructions to your service and parts personnel. They should become familiar with this recall to respond to owner inquiries. Vehicles Affected All 1989 model year Thunderbird and Cougar cars. Reason For Recall The tension eliminator mechanism may fail due to excess cable length which causes bends during installation. Should this occur, the front seat belts will not retract after extension. In this condition the occupant of the vehicle may not be restrained if the vehicle is involved in a collision. Service Action Replace the driver and front passenger seat belt assemblies Refunds When all or a portion of the repair covered by this recall (front seat belt assembly replacement, because of broken tension eliminator cables) has been paid by the owner and/or the dealer prior to the release of the recall, both the owner and/or dealer are eligible for a refund. NOTE: Dealers must ensure that the recall action is also performed on all vehicles for which a refund is processed. Company Contacts: (For dealer use only) CONCERN NATURE CONTACT ACTIVITY Technical Technical Assistance Hotline for your Region Claiming Procedures Warranty Claims Hotline for your Region Owner Relations Owner Relations Hotline for your Region General Administrative Brian Moroz - Recall Administrator ^ Telephone (416) 845-2511 Ext. 1495 ^ Fax (416) 845-7069 Attachments Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Recalls for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement > Page 7328 Owner Letter May 1991 Serial Number: XXXXXXXXXXXXXX 91S32 Customer Name 123 Main Street City, PR ANA NAN This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act of Canada. Ford Motor Company of Canada, Limited (Ford) has determined that a defect exists on 1989 Thunderbird and Cougar cars. Our records indicate you own the 1989 (vehicle) with the serial number shown above your name and address on this letter. Reason for Recall A cable in the tension reliever mechanism of one of the front seat belt retractors of your car may be bent and may eventually break. Should this occur, the seat belt when buckled about an occupant would not properly restrain the occupant in the event of a collision. In this condition, the protection against personal injury provided by the belt assembly would be reduced. Important You should have new seat belts installed in your car by your dealer as promptly as possible. In the meantime, occupants should continue to wear their seat belts, even if the front retractors are broken. If the retractors are not broken, the belts should function normally. If a retractor is broken, the belt will provide partial protection to the occupant if the lap belt portion is buckled snugly about the hips. However, a belt assembly with a broken retractor will provide little or no upper body restraint. Repairs At no charge to you, your dealer will replace both the driver and front passenger seat belt assemblies on your car. How Long Will It Take? The time needed to repair your vehicle is less than one hour. However, due to service scheduling times, your dealer may need your vehicle for a full working day. Call Your Dealer Call your Ford or Mercury dealer without delay and ask for a service date. Also ask your dealer to check the CARES / OASIS systems for any other service actions that may be required on your vehicle. If parts are needed and the dealer does not have them in stock, they can be ordered on a RUSH basis before scheduling your service date. Parts would be expected to arrive within a week. If you have leased this vehicle to another person or organization, please immediately notify the lessee of this recall. When you bring your vehicle in, show the dealer this letter. If you lose the letter, your dealer will still do the work free of charge. Refunds If you paid to have either or both of the front seat belt assemblies replaced because of the broken tension eliminator cables, before receiving this letter, Ford is offering a full refund. For a refund, please give the original copy of your paid work-order or parts receipt to your dealer. In such cases, however, both front seat belt assemblies should again be replaced under this recall. Changed Name, Address, or Sold the Vehicle? If you have changed your name or address, or have sold the vehicle, please fill out the enclosed prepaid postcard. Sign and date it and mail the card to Ford. If you cannot get the recall service performed, contact the "National Owner Relations Office" or the nearest Ford of Canada Regional Office. The addresses and telephone numbers for these offices are shown in your vehicle's Owner Guide. Your Ford or Lincoln Mercury dealer can also give you this information. Please identify your vehicle's serial number in any correspondence. We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement Technical Service Bulletin # 92S52 Date: 920902 Recall - Safety Front Safety Belt/Retractor Replacement RECALL 92S52 SAFETY RECALL 1989 Thunderbird And Cougar - Front Safety Belt And Retractor Assemblies Replacement Dealer Letter Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information ^ Dealer Stock Parts Return Instructions Attachment III ^ Technical Instructions Customer Notification Letter Attachment I - Administrative Information Administrative Information OASIS ^ Use OASIS to determine if a vehicle is involved in this or another recall. ^ Tell owners of any other recalls that may be uncompleted. Complete all recall during a single visit by the owner. Promptly Perform Recall On: ^ Affected vehicles on the enclosed list. ^ Other affected vehicles which are brought to your dealership. NOTE: Perform recall on all affected vehicles in dealer stock before delivery to owners. Dealer-Owner Contact/Action ^ Immediately contact any owner of an affected vehicle whose name does not appear on the enclosed list. ^ Arrange a service date. Give the owner a copy of the owner letter. ^ Advise the Company of the vehicle's ownership status change (refer Warranty and Policy Manual - Section 3.3). Dealership Responsibilities ^ Perform this recall service promptly following presentation of the vehicle by the owner. ^ Promptly report to the "Customer Assistance Centre" at Oakville any instance in which an owner will not allow you to complete this recall because of objections in scheduling or for any other reason. Reimbursement For Recall Completion And Claims Preparation Instructions ^ Submit claims for all completed units. ^ Claim reimbursement through the Direct Warranty Entry (DWE) system using the RECALLS screen only (PF # Recall Entry/Retrieval on the DWE Menu Screen). If the claim number contains more than six digits, enter only the last six digits. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7334 NOTE: Use a Form 6125-2, an authorized computer generated claim form or an 1864 Form as an internal repair order to support DWE Entry through the RECALLS screen. Ensure that only the RECALLS screen is used when inputting completion and reimbursement information. ^ Dealers without DWE capability must mail a completed From 1864 (Company Claim Copy No. 2) to Warranty Claims Processing Oakville for reimbursement. Forms submitted must show all parts used and their cost, the parts handling allowance, and be imprinted, dated and signed by authorized dealership personnel. ^ All claims must show 92S52 in the Recall box. Attachment II - Labor and Parts Information Labor Allowances LABOR DESCRIPTION LABOR TIME LABOR CODE Completely Remove and Install both the Driver and Front 1.4 Hrs. B Passenger Safety Belt and Retractor Assemblies (Tongue end assemblies only). Install Plug Buttons in "B" Pillars. Review Revised Belt Use Instructions With Vehicle Owner and Provide Vehicle Owner With The Owner Guide Insert Booklet Administrative Allowance 0.1 Hrs. NOTE: The 0.1 hours Administrative Allowance must be added to the total labor time before inputting. Parts Ordering Information Order your parts requirements through your Servicing Parts Distribution Centre. PART NUMBER COLOUR DESCRIPTION (ONE KIT REQUIRED PER VEHICLE) E9SZ-63611A74-A Currant Red Kit - Safety Belt and Retractor Assembly(1) E9SZ-63611A74-B Light Sandaled Kit - Safety Belt and Retractor Assembly(1) E9SZ-63611A74-C Titanium Kit - Safety Belt and Retractor Assembly(1) E9SZ-63611A74-D Shadow Blue Kit - Safety Belt and Retractor Assembly(1) (1) - Contains: - 1 each of driver and front passenger Safety Belt and Retractor Assemblies (tongue end assemblies only) - 2 plug buttons (part number 378770-S) - Instruction Sheet I.S. 6393 - Owner Guide Insert booklet (Form: 92S52) Dealer Stock Parts Return Instructions The following parts are obsolete and superseded. They are not to be used for servicing any vehicles. All dealership stock of these parts must be returned immediately to your Servicing PDT using Claim Form 562-2 showing "Returned per Safety Recall 92S52". E9SZ-63611A72/73/74-EEE E9SZ-63611A72/73/74-FFF E9SZ-63611A72/73/74-GGG E9SZ-63611A71/73/74-HHH Attachment III - Technical Instructions Technical Instructions Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7335 Affected Vehicles 1989 Thunderbird/Cougar (Active Restraint) General Information ^ Note routing and mounting positions of the safety belt assembly before replacement. Use Tool No. T77L-2100-A, or equivalent, and torque all anchor bolts to the required specification shown for each mounting position. ^ Built-in anchorages are provided in all vehicles. ^ Care should be taken not to cross-thread the anchor bolts. Refer to the 1989 Thunderbird/Cougar Shop Manual, page 41-50-8 "Major Service Operation", if necessary to correct thread damaged Anchor Plates. ^ Replace all covers where applicable. ^ All washers and spacers to be installed in same location as they were prior to removal. ^ Check safety belts for proper routings. CAUTION Check position of factory installed safety belt anchor tabs and install the replacement safety belt and anchor tabs in same position. Care must be exercised when making replacement that all safety belt anchors are positioned as specified. CAUTION Disconnect battery cable before any electrical connections are made to prevent shock hazard. Usage Information Consult the Owner Guide Insert and appropriate Owner Guide for specific lap safety belt and shoulder safety belt use and adjustments. WARNING MAKE SURE THAT YOU AND YOUR PASSENGERS, INCLUDING PREGNANT WOMEN, WEAR SAFETY BELTS. BE SURE THAT LAP BELTS FIT SNUGLY AND AS LOW AS POSSIBLE AROUND THE HIPS. IF SAFETY BELTS ARE NOT USED PROPERLY, THE RISK OF YOU OR YOUR PASSENGERS BEING INJURED IN A COLLISION GREATLY INCREASES. WARNING USE THE SHOULDER BELT ON THE OUTSIDE SHOULDER ONLY. NEVER WEAR THE SHOULDER BELT UNDER THE ARM. EVER SWING IT AROUND THE NECK OVER THE INSIDE SHOULDER. NEVER USE A SINGLE BELT FOR MORE THAN ON PERSON. FAILURE TO FOLLOW THESE PRECAUTIONS COULD INCREASE THE RISK AND/OR SEVERITY OF INJURY IN AN ACCIDENT. WARNING NEVER USE A SINGLE BELT FOR MORE THAN ONE PERSON OR ACROSS MORE THAN ONE SEATING POSITION. THIS GREATLY INCREASES THE RISK THAT ONE OR BOTH OF THE PEOPLE WILL BE INJURED IN A COLLISION. EACH SEATING POSITION IN YOUR VEHICLE HAS A SPECIFIC SAFETY BELT ASSEMBLY WHICH IS MAKE UP OF ONE BUCKLE AND ONE TONGUE THAT ARE DESIGNED TO BE USED AS A PAIR. WARNING ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS THAT ALL SAFETY BELT ASSEMBLIES USED DURING A COLLISION BE REPLACED UNLESS THE BELTS DO NOT SHOW DAMAGE AND CONTINUE TO OPERATE PROPERLY. SAFETY BELTS NOT IN USE DURING A COLLISION SHOULD BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. WHEN REPLACING SAFETY BELT AND BUCKLES, SAFETY CABLE AND BUCKLES, CENTRE ADJUST TONGUES AND BELT AND RETRACTORS, USE ONLY THE REPLACEMENT PARTS SPECIFIED IN THE FORD MASTER PARTS CATALOGS FOR THE MAKE AND MODEL OF THE VEHICLE BEING SERVICED. SAFETY BELT ASSEMBLIES MUST NOT BE INTERCHANGED BETWEEN VEHICLE MODELS. The following provide removal and installation instructions for both driver and front passenger safety belt and retractor assemblies. IMPORTANT: The parts kit contains one each of the driver's and front passenger safety belt and retractor assembly (tongue end assemblies only), two plug buttons and an Owner Guide Insert booklet. NOTE: Buckle end assemblies are not included and are not to be replaced. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7336 Seat Back and Seat Cushion Removal (Refer to Figure 1) 1. Remove the rear seat cushion and rear seat back assembly as follows: 2. Apply knee pressure to the lower portion of the rear seat cushion. Push rearward to disengage the seat cushion from the retainer brackets and remove the seat cushion. 3. Remove the seat back retaining bolts. 4. Grasp the seat back assembly at the bottom and lift it up to disengage the hanger wire from the slotted holes in the package tray. 5. Remove the seat back assembly from the vehicle. Interior Trim Removal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7337 (Refer to Figures 3 and 4) 1. Remove the safety belt D-ring cover. 2. Using Seat Belt Bolt Bit No. T77L-2100-A, or equivalent, remove the bolt retaining the safety belt and D-ring to the "B" pillar assembly. 3. Remove the rear screw retaining the door scuff plate to the floor sill. 4. Remove the two (2) screws retaining the lower quarter trim panel to the body quarter side assembly and remove the panel. 5. Remove the quarter trim finish panel and rear speaker cover assembly. (The speaker cover is retained by locator tabs at the top and snap-on type fasteners at the bottom.) 6. Remove the four (4) screws retaining the rear speaker to the body and remove the rear speaker. 7. Remove the two (2) screws retaining the upper quarter trim panel to the body. 8. Remove the coat hook attaching screw and the coat hook. 9. Remove the front seat shoulder strap guide bezel. 10. Disengage the quarter trim panel. 11. Disconnect the electrical wiring connector from the rear courtesy lamp. Safety Belt and Retractor Assembly Removal (Refer to Figure 4) 1. Using Seat Belt Bolt Bit No. T77L-2100-A, or equivalent, remove the lower bolt retaining the safety belt anchor to the floor sill assembly. 2. Slide the safety belt through the slot in the upper trim panel. 3. Remove the bolt retaining the safety belt retractor assembly to the "B" pillar assembly. 4. From inside the vehicle, rotate the comfort regulator housing and remove it front the "B" pillar. Refer to Figure 4 and View A. 5. Remove the safety belt and retractor assembly from vehicle. Safety Belt and Retractor Assembly Installation (Refer To Figures 3 and 5) 1. Install the safety belt and retractor assembly. Make sure the belt webbing is not twisted. 2. Install the bolt retaining the safety belt retractor assembly to the "B" pillar assembly. Torque the bolt to 30-43 N-m (22-32 Lb.-Ft.). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7338 3. Install the plug button (included in the kit) into the opening in the "B" pillar. Refer to Figure 5, View B. NOTE: Prior to installation wipe clean the outer surface area surrounding the hole. 4. Slide the safety belt through the slot in the upper trim panel. Interior Trim Installation (Refer To Figures 3 and 5) 1. Connect the electrical wiring connector to the rear courtesy lamp. 2. Install the quarter trim panel. 3. Install the front seat shoulder strap guide bezel. 4. Install the coat hook and attaching screw. 5. Install the two (2) screws retaining the upper quarter trim panel to the body. 6. Connect the electrical connector to the speaker. 7. Install the rear speaker to the body using the (4) retaining screws removed in Step 6 of the Interior Trim Removal Procedure. 8. Snap on the quarter trim finish panel and rear speaker cover assembly. 9. Install the lower quarter trim panel to the body quarter side assembly, using the two (2) screws removed in Step 4 of the Interior Trim Removal Procedure. 10. Install the door scuff plate to the floor sill using the screw removed in Step 3 of the Interior Trim Removal Procedure. 11. Position the D-ring to the "B" pillar. Make sure the belt webbing is not twisted. 12. Using Sear Belt Bolt Bit No. T77L-2100-A, or equivalent, install the bolt retaining the safety bolt and D-ring to the "B" pillar assembly. Torque the bolt to 30-43 No-m (22-32 Lb.-Ft.). 13. Make sure the belt webbing is not twisted. Install the lower bolt retaining the safety belt anchor to the floor sill assembly. Torque the bolt to 30-43 No-m (22-32 Lb.-Ft.). 14. Install the safety belt D-ring cover. Seat Back and Seat Cushion Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7339 (Refer To Figures 1 And 2) 1. Install the rear seat cushion and the rear seat back assembly as follows. 2. Position the seat back assembly into the vehicle so that the hanger wire is fully engaged in the package tray slots. 3. Install the seat back lower retaining bolts and tighten securely. 4. Position the seat cushion assembly into the vehicle. 5. Position the rear occupant safety belt buckles and the centre occupant lap belt on top of the cushion. 6. Apply knee pressure to the lower portion of the seat cushion assembly. Push rearward and down to lock seat cushion into position. 7. Check rear seat cushion to ensure it is secured into floor retainer. IMPORTANT Mutilate and scrap all replaced safety belt and retractor assemblies. Safety Restraint Operations Review 1. Ensure that the webbing on all safety belts (front and rear) is not twisted. 2. Check the front and rear restraint systems for proper operation. 3. Remind customer that the new front safety restraint and retractor assembly does not have the comfort regulator feature. 4. Review and demonstrate the new front safety restraint operating instructions with the customer. 5. Give the customer the Owner Guide Insert booklet (contained in the Parts Kit) that provides specific use instructions to be employed with this new front restraint system. Dealer Letter September 2, 1992 To: All Ford of Canada Dealers Attention: Dealer Principal Service Manager Parts Manager Subject: Safety Recall 92S52 - 1989 Thunderbird and Cougar - Front Safety Belt and Retractor Assemblies Replacement ATTENTION: This Safety Recall supersedes and cancels Safety Recall 91S32. In OASIS YES Listings Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7340 YES Recall Time Limitations None Dealer Stock Parts (See Attachment II ) Parts Return No - Mutilate and Scrap. NOTE: Please read and circulate these instructions to your Service, Parts and Sales Personnel. They should become familiar with this recall and respond to owner inquiries. Vehicles Affected All 1989 Model Year Thunderbird and Cougar cars. Reason for Recall A cable in the comfort regulator mechanism in either the safety belts provided in the kits for Safety Recall "91S32" or the factory installed front safety belt assemblies may break or bind causing a malfunction in the retractor mechanism. Should this occur, the front safety belts may not retract after full extension. In this condition the occupant of the vehicle will not be properly restrained if the vehicle is involved in a collision. Service Action To correct this condition, replace the existing driver and front passenger safety belt and retractor assemblies (tongue end assemblies only) with the new design parts and install plug buttons in the comfort regulator plunger holes located in the door openings. The new belt system is the same as that used in 1992 models. Instruct the customer on use of the new belt system and provide the customer the supplemental information (Owner Guide Insert) booklet contained in the parts kit. Company Contacts: (for dealer use only) CONCERN NATURE CONTACT ACTIVITY Technical Technical Assistance Hotline 1-800-665-3577 Claiming Procedures Warranty Claims Hotline for your Region Owner Concerns Customer Assistance Centre Hotline 1-800-565-3673 General Administrative Christine Murray - Recall Administrator ^ Telephone (416) 845-2511 Next. 1495 ^ Facsimile (416) 845-7069 Attachments Attachment I ^ Administrative Information Attachment II ^ Parts Ordering Information ^ Labor Allowances ^ Dealer Stock Parts Return Instructions Attachment III ^ Technical Instructions Owner Letter Mail Date Serial Number: XXXXXXXXXXXXXXXXX 92S52 Customer Name 123 Main Street Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 92S52 > Sep > 92 > Recall - Safety Front Safety Belt/Retractor Replacement > Page 7341 City, PR ANA NAN This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act of Canada. Ford Motor Company of Canada, Limited (Ford) is notifying owners of record about a defect in the front safety belts of 1989 Thunderbird and Cougar cars. This notice applies to your vehicle even if it was serviced under a similar recall announced in May 1991. This notification is with regard to the 1989 Thunderbird or Cougar with the serial number shown above your name and address on this letter. Reason For This Notification And Recall A cable in the comfort regulator mechanism of the front safety belt retractors, of your car, may bend and eventually break. This situation can occur on either the original or on the previous recall installed safety belt assembly. Should this condition occur the safety belt, when fully extended, may not retract and will not properly restrain the seat occupant in the event of a collision. In this condition the normal protection against personal injury provided by the belt assembly would be reduced. Important You should have new front safety belts installed in your car by your Ford or Mercury dealer as promptly as possible. In the meantime, occupants should continue to wear their safety belts, even if the front retractors are broken. If the retractors are not broken, the belts should function normally. If a retractor is broken, the belt will provide partial protection to the occupant if the lap belt portion is buckled snugly about the hips. However, a belt assembly with a broken retractor will provide little or no upper body restraint. New Front Safety Belt Buckling-Up Information The new seat belt assembly will not have the comfort regulator feature that your vehicle has now. Instead, when buckled, the assembly will provide constant light tension about the occupant while allowing comfortable movement. This is the same system as used in 1992 models. When you have the recall performed, your dealer will give you an Owner Guide Insert booklet that provides specific information for using the new front safety belts. You and other vehicle users should read and become familiar with the information in this booklet. We recommend that you retain this booklet with your Owner Guide for future reference. Repairs At no charge to you, your dealer will replace both the driver and front passenger safety belt (tongue end) assemblies on your car. How Long Will It Take? The time needed to repair your vehicle is less than two hours. However, due to service scheduling times, your dealer may need your vehicle for a full working day. Call Your Dealer Call your Ford or Mercury dealer without delay and ask for a service date. Also ask your dealer to check the OASIS system for any other service actions that may be required on your vehicle. If parts are needed and the dealer does not have them in stock, they can be ordered before scheduling your service date. If you have leased this vehicle to another person or organization, please immediately notify the lessee of this recall. When you bring your vehicle in, show the dealer this letter. If you lose the letter, your dealer will still do the work free of charge. Changed Name, Address, Or Sold The Vehicle? If you have changed your name or address, or have sold the vehicle, please fill out the enclosed prepaid postcard. Sign and date it and mail the card to Ford. If you cannot get the recall service performed, contact the Ford "Customer Assistance Centre" at the address identified in the letterhead of this letter. Please identify your vehicle's serial number in any correspondence. We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement Technical Service Bulletin # 91S32 Date: 910501 Recall - Seat Belt Assembly Replacement RECALL 91S32 SAFETY RECALL 1989 Model Thunderbird and Cougar - Seat Belt Assembly Replacement Dealer Letter Attachment I ^ Administrative Information ^ Refunds Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Instructions Customer Notification Letter Attachment I - Administrative Information Administrative Information CARES / OASIS You must use CARES or OASIS to determine if a vehicle is eligible for this or another recall. Tell owners of any other recalls that may not have been completed. Complete all recalls during a single visit by the owner. Promptly Correct ^ Affected vehicles on the enclosed list. ^ Other affected vehicles which are brought to your dealership. NOTE: Correct all affected vehicles in dealer stock before delivery to owners. Dealer-Owner Contact/Action If you are aware of any subject vehicles in your region, and the owner's name does not appear on the enclosed list, immediately contact the owner and arrange a service date. Give the owner a copy of the Owner Letter. Dealership Responsibilities Dealers are responsible to perform this recall service promptly following presentation of the vehicle by the owner. It is important that you promptly report to the "National Owner Relations Office" at Oakville any instance in which an owner will not allow you to complete this recall because of objections in scheduling or for any other reason. Reimbursement For Recall Completion And Claims Submission Instructions ^ Submit claims for all completed units. ^ Claim reimbursement through the Direct Warranty Entry (DWE) system using the RECALLS screen. Use the RECALLS screen only (PF3 Recall Entry/Retrieval on the DWE Menu Screen). If the claim number contains more than six digits, enter only the last six digits. NOTE: Claim Form 1864 will no longer be mailed to owners. Use a Form 6125-2 or an authorized computer generated claim form as an internal repair order to support DWE Entry through the RECALLS screen. Ensure that only the RECALLS screen is used when inputting completion and reimbursement information. ^ Dealers without DWE capability must mail Company Claim Copy No. 2 of a completed Form 1864 to Warranty Claims Processing at Oakville for Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement > Page 7346 reimbursement. Forms submitted must show all parts used and their cost, the parts handling allowance, and be imprinted, dated and signed by authorized dealership personnel. ^ All claims must show 91S32 in the recall box. Refunds Refund requests must be submitted separately from the recall service actions. Refund requests are governed by the following guidelines: ^ Owners/Dealers seeking refund for replacement of front seat belt assemblies (because of broken tension eliminator cables) at their expense prior to the receipt of notice of this recall must present the original copy of their paid repair orders or parts invoices to any Ford or Mercury dealership. ^ Using the DWE Recall Screen, enter the following: - Labor Code..........A - Recall Code..........R91S32 - Enter "REFUND INV # ____________" in the area on the claim designated for PARTS USED. - Enter the owner refund amount as a "MISCELLANEOUS" cost. ^ Please provide prompt refund to all eligible owners having proper documentation regardless of the source of the original service. ^ Retain the copy of the paid repair order or invoice with a copy of the refund request in your service file for reference. ^ Dealers without DWE capability must mail their refund requests on a separate completed 1864 Form with the owner's original paid repair order or parts purchase receipt to Warranty Claims Processing. Enter the 0.3 Hrs. in Box "A" and R91S32 in the Recall box of the Form. Include all amounts in the TOTAL CLAIM box. NOTE: Dealers should ensure that the recall is also performed on all vehicles for which a refund is processed. Attachment II - Labor and Parts Information Labor Allowances OPERATION DESCRIPTION LABOR TIME LABOR CODE Completely Remove and Install both the Driver and Front Passenger Seat Belt Assemblies 0.8 Hrs. B Administrative Allowance 0.1 Hrs. NOTE: The 0.1 hour Administrative Allowance must be added to the total labor time before inputting. Parts Ordering Information Parts will not be direct shipped for this recall. Order requirements through your Servicing Parts Distribution Centre. PART NUMBER COLOUR DESCRIPTION E9SZ-63611A74-EEE Shadow Blue Kit - Seat Belt Assembly Front (Contains 1 each of Front Driver and Passenger Seat Belt Assemblies) E9SZ-63611A74-FFF Currant Red Kit - Seat Belt Assembly Front (Contains 1 each of Front Driver and Passenger Seat Belt Assemblies) E9SZ-63611A74-GGG Light Sandalwood Kit - Seat Belt Assembly Front (Contains 1 each of Front Driver and Passenger Seat Belt Assemblies) E9SZ-63611A74-HHH Titanium Kit - Seat Belt Assembly Front (Contains 1 each of Front Driver and Passenger Seat Belt Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement > Page 7347 Assemblies) Attachment III - Technical Instructions Technical Instructions Removal And Installation Instructions For Both Driver And Front Passenger Seat Belt Assemblies And Buckle Assemblies Interior Trim Removal: Refer to Figures 1 and 2. 1. Remove rear seat cushion assembly. 2. Remove rear seat back assembly. Refer to Body Shop Manual Sec 41-14. 3. Remove safety belt D-ring cover (Figure 2) on both sides. 4. Using Seat Belt Bolt Bit No. T77L2100-A, or equivalent, remove bolt retaining safety belt and D-ring to "B" pillar assembly (Figure 2) on both sides. 5. Remove rear screw retaining door scuff plate to floor sill (both sides). 6. Remove two (2) screws retaining lower quarter trim panel to body quarter side assembly and remove panel (both sides). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement > Page 7348 7. Remove quarter trim finish panel and cover assembly (rear speaker cover) on both sides. (The speaker cover is retained by snap-on type fasteners.) 8. Remove four (4) screws retaining rear speaker to body and remove rear speaker (both sides). 9. Remove two (2) screws retaining upper quarter trim panel to body (both, sides). 10. Remove coat hook attaching screw and coat hook (both sides). 11. Remove front seat shoulder strap guide bezel (both sides). 12. Disengage both quarter trim panels. 13. Disconnect electrical wiring connectors from rear speaker and rear courtesy lamp (both sides). Seat Belt Retractor Assembly And Buckle Assembly Removal: Refer to Figures 2 and 3. 1. Using Seat Belt Bolt Bit No. T77L2100-A, or equivalent, remove lower bolt retaining safety belt anchor to floor sill assembly (both sides). 2. Slide safety belts through slots in upper trim panels. 3. Remove bolt retaining safety belt retractor assembly to "B" pillar assembly (both sides). 4. Press out from B-Pillar the tension eliminator button assembly. 5. Remove both safety belt and retractor assemblies from vehicle. 6. Remove bolts retaining inboard belt and buckle assemblies from seat support assemblies. 7. Disconnect buzzer wiring from floor pan wiring and remove belt and buckle assemblies Safety Belt And Retractor Assembly Installation: 1. Reverse above removal procedure. Make sure belt webbing is not twisted. 2. Install safety belt attaching bolts using Seat Belt Bolt Bit No. T77L2100-A or equivalent. Make sure bolts are torqued to 30-43 N-m (22-32 Lb.-Ft.) 3. Cycle the system several times to ensure proper operation of the retractor. Ensure webbing is not twisted. IMPORTANT NOTE Mutilate and scrap all replaced seat belt assemblies. Dealer Letter May 1, 1991 To: Ford Of Canada Dealers Attention: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement > Page 7349 Dealer Principal, Service Manager, Parts Manager Subject: Safety Recall 91S32 - 1989 Model Thunderbird and Cougar - Seat Belt Assembly Replacement In CARES / OASIS YES Listings YES Recall Time Limitation None Parts Return NO NOTE: Please read and circulate these instructions to your service and parts personnel. They should become familiar with this recall to respond to owner inquiries. Vehicles Affected All 1989 model year Thunderbird and Cougar cars. Reason For Recall The tension eliminator mechanism may fail due to excess cable length which causes bends during installation. Should this occur, the front seat belts will not retract after extension. In this condition the occupant of the vehicle may not be restrained if the vehicle is involved in a collision. Service Action Replace the driver and front passenger seat belt assemblies Refunds When all or a portion of the repair covered by this recall (front seat belt assembly replacement, because of broken tension eliminator cables) has been paid by the owner and/or the dealer prior to the release of the recall, both the owner and/or dealer are eligible for a refund. NOTE: Dealers must ensure that the recall action is also performed on all vehicles for which a refund is processed. Company Contacts: (For dealer use only) CONCERN NATURE CONTACT ACTIVITY Technical Technical Assistance Hotline for your Region Claiming Procedures Warranty Claims Hotline for your Region Owner Relations Owner Relations Hotline for your Region General Administrative Brian Moroz - Recall Administrator ^ Telephone (416) 845-2511 Ext. 1495 ^ Fax (416) 845-7069 Attachments Attachment I ^ Administrative Information Attachment II ^ Labor Allowances ^ Parts Ordering Information Attachment III ^ Technical Information Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt: > 91S32 > May > 91 > Recall - Seat Belt Assembly Replacement > Page 7350 Owner Letter May 1991 Serial Number: XXXXXXXXXXXXXX 91S32 Customer Name 123 Main Street City, PR ANA NAN This notice is sent to you in accordance with the requirements of the Motor Vehicle Safety Act of Canada. Ford Motor Company of Canada, Limited (Ford) has determined that a defect exists on 1989 Thunderbird and Cougar cars. Our records indicate you own the 1989 (vehicle) with the serial number shown above your name and address on this letter. Reason for Recall A cable in the tension reliever mechanism of one of the front seat belt retractors of your car may be bent and may eventually break. Should this occur, the seat belt when buckled about an occupant would not properly restrain the occupant in the event of a collision. In this condition, the protection against personal injury provided by the belt assembly would be reduced. Important You should have new seat belts installed in your car by your dealer as promptly as possible. In the meantime, occupants should continue to wear their seat belts, even if the front retractors are broken. If the retractors are not broken, the belts should function normally. If a retractor is broken, the belt will provide partial protection to the occupant if the lap belt portion is buckled snugly about the hips. However, a belt assembly with a broken retractor will provide little or no upper body restraint. Repairs At no charge to you, your dealer will replace both the driver and front passenger seat belt assemblies on your car. How Long Will It Take? The time needed to repair your vehicle is less than one hour. However, due to service scheduling times, your dealer may need your vehicle for a full working day. Call Your Dealer Call your Ford or Mercury dealer without delay and ask for a service date. Also ask your dealer to check the CARES / OASIS systems for any other service actions that may be required on your vehicle. If parts are needed and the dealer does not have them in stock, they can be ordered on a RUSH basis before scheduling your service date. Parts would be expected to arrive within a week. If you have leased this vehicle to another person or organization, please immediately notify the lessee of this recall. When you bring your vehicle in, show the dealer this letter. If you lose the letter, your dealer will still do the work free of charge. Refunds If you paid to have either or both of the front seat belt assemblies replaced because of the broken tension eliminator cables, before receiving this letter, Ford is offering a full refund. For a refund, please give the original copy of your paid work-order or parts receipt to your dealer. In such cases, however, both front seat belt assemblies should again be replaced under this recall. Changed Name, Address, or Sold the Vehicle? If you have changed your name or address, or have sold the vehicle, please fill out the enclosed prepaid postcard. Sign and date it and mail the card to Ford. If you cannot get the recall service performed, contact the "National Owner Relations Office" or the nearest Ford of Canada Regional Office. The addresses and telephone numbers for these offices are shown in your vehicle's Owner Guide. Your Ford or Lincoln Mercury dealer can also give you this information. Please identify your vehicle's serial number in any correspondence. We regret the inconvenience this service may cause you, but we want you to have the work done for your safety and satisfaction with your vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical Service Bulletins > Page 7351 Seat Belt: Description and Operation BELT BUCKLE The inboard belt buckle is secured on the slide bar. Attaching the tongue and buckle secures the outboard occupants with both lower and upper restraints. This tongue and belt attachment can be accomplished by a single, continuous movement. LAP SAFETY BELTS Lap safety belts are provided for the center rear seating position with the belts secured to the floorpan. Shoulder Harness Retractor SHOULDER HARNESS The shoulder harness webbing is fixed in a retractor which is located in the quarter panel. This retractor is designed to let the webbing freely move in or out at all times, except during vehicle deceleration. Then, it is automatically locked by a mechanically actuated inertia sensor. The shoulder harness webbing is attached to a retractor. The retractor is located in the quarter panel. The webbing then passes through a guide above and behind the occupant's shoulder which directs the webbing at the proper downward angle over the occupant's shoulder and chest and attaches to the lap belt buckle. The shoulder harness retractor is designed to let the webbing freely move in or out at all times, except during vehicle deceleration, when it is automatically locked by a mechanically actuated inertia sensor. On these vehicles the buckle is routed along the side of the seat and is attached to the slide bar. The slide bar is anchored to the seat track which is anchored to the floorpan. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Active Restraints (Canadian Models) Seat Belt: Service and Repair Active Restraints (Canadian Models) Front Outboard Attachments REMOVAL 1. Remove D-ring cover 2. Insert bolt bit and remove belt bolt. 3. Remove B-pillar upper trim panel. 4. Remove scuff plate/center pillar trim panel retaining screws and panel. 5. Remove safety belt through slot in upper center trim panel. 6. Remove safety belt anchor-to-sill bolt and rubber washer. 7. Remove safety belt retractor bolt. 8. Remove web guide attaching screw and slide guide rearward to remove from B-pillar. 9. Remove outboard safety belt assembly from vehicle. 10. Remove seat and track assembly. 11. Remove inboard belt and buckle assembly. 12. Remove safety bolt from slide bar. 13. Remove inboard knuckle assembly (on LH side of vehicle, disconnect buzzer wiring from floorpan wiring). INSTALLATION 1. Reverse the removal procedure and position the safety belt components. 2. Tighten all attaching bolts to 30-43 Nm (22-32 lb-ft). Cycle the system several times to ensure proper operation of the retractor. Ensure webbing is not twisted. Rear Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7354 REMOVAL and INSTALLATION 1. Remove rear seat cushion. 2. Remove rear seat back. 3. Remove buckle end anchor nuts and remove buckle end belts. 4. Remove upper and lower quarter trim panels. 5. Remove safety belt anchor-to-sill bolt. 6. Snap out bezel in package tray trim panel. 7. Remove rear stoplamp assembly. 8. Remove package tray trim panel. 9. Remove retractor anchor bolt and retractor screw. 10. Remove anchor end of webbing through the opening in the quarter trim panel and the package tray trim panel. 11. Remove outboard safety belt assembly from the vehicle. 12. Repeat procedure on opposite side. 13. To install, reverse Steps 1 through 12. NOTE: Be sure to tighten all retaining bolts to specification. Front Inboard Belt And Buckle Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7355 Seat Support Assembly REMOVAL 1. Remove seat and track assembly. 2. Remove inboard belt and buckle assembly. 3. Remove safety bolt from slide bar. 4. Remove inboard buckle assembly (on LH side of vehicle, disconnect chime wiring from floorpan wiring). INSTALLATION 1. Position buckle assembly to slide bar. Tighten bolt to 30-43 Nm (23-32 lb-ft). 2. Install seat and track assembly. 3. Check restraint system for proper operation. Rear REMOVAL and INSTALLATION 1. Remove rear seat back and cushion. 2. Remove nut and buckle or belt assembly from vehicle. 3. Pry off brass grommet from assembly and discard. 4. To install, line up two anchor tabs on stud and install nut. Tighten nut to 30-43 Nm (22-32 lb-ft). 5. Install rear seat cushion. Safety Belt Without Anchorage Plate Thread Damage The lap/shoulder safety belts are factory installed in their proper locations. If the belts are removed for any reason, they should be installed using proper service procedures. The 7/16 x 20 Torx(r) head anchor bolts must be hand started and then tightened to 30-43 Nm (23-32 lb-ft). 1. Remove the damaged bolt from the anchor reinforcement and discard. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7356 Parts Replacement Chart 2. Install a new bolt and hand tighten. Refer to Parts Replacement Chart for part number. Tighten to 30-43 Nm (23-32 lb-ft). Safety Belt With Anchorage Plate Thread Damage 1. Remove the broken or stripped bolt and discard. 2. Drill out the internal threads in the safety belt anchorage plate with a 27/64-inch drill. 3. Rethread the anchorage plate with a 1/2-13 tap. 4. Blow out the chips. Parts Replacement Chart 5. Install the attachment parts in the proper sequence using proper service procedures. Install new bolt and hand tighten using proper service procedures. Original parts are to be replaced with the service parts indicated in the Parts Replacement Chart. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7357 Seat Belt: Service and Repair Cleaning and Inspection SAFETY BELT MAINTENANCE Safety belt assemblies should be periodically inspected to ensure that they have not become damaged and that they remain in proper operating condition, particularly if they have been subjected to severe stress such as an accident. WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. FORD RECOMMENDS THAT ALL SAFETY BELT ASSEMBLIES IN USE DURING A COLLISION BE REPLACED UNLESS THE COLLISION WAS MINOR AND A QUALIFIED TECHNICIAN FINDS THAT THE BELTS SHOW NO DAMAGE AND CONTINUE TO OPERATE PROPERLY. SAFETY BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. Before installing the new safety belt assembly, the safety belt attaching areas must be inspected for damage and distortion. If the attaching points are damaged and distorted, the sheet metal must be worked back to its original shape and structural integrity. Install the new safety belt(s) using the appropriate instructions. Perform Functional Test Procedure. See: Testing and Inspection/Component Tests and General Diagnostics/Functional Testing Procedures BELT WEBBING Clean the belt webbing only with a mild soap solution recommended for cleaning upholstery or carpets. Follow instructions provided with soap. WARNING: DO NOT BLEACH OR RE-DYE THE WEBBING, AS WEBBING MAY WEAKEN. NOTE: If the retractor of a new safety belt assembly has been bolted into a damaged or distorted mounting area, the new retractor could be warped and may not function. If this is the case, reshape the sheet metal back to its original shape and structural integrity and install another new complete safety belt assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7358 Seat Belt: Service and Repair Passive Restraints (US Models) Drive Belt REMOVAL 1. Cycle the shoulder belt to the full forward position at the "A" pillar. Disengage the shoulder bell from the mini buckle. 2. Remove the rear seat cushion. 3. Remove the rear seat back. 4. Remove the "A" pillar and the quarter panel trim. 5. Disconnect the electrical connectors at the "A" pillar and "B" pillar limit switches. 6. Remove the upper bolt used to retain the vertical belt guide to the quarter inner panel. 7. Disengage the vertical belt guide at the "B" pillar bracket. Release tab. 8. Remove the two bolts retaining the track assembly to the "B" pillar. 9. Remove the sheet metal screw retaining the "A" pillar limit switch bracket to the "A" pillar. 10. While holding the track assembly securely, remove the two bolts retaining the track assembly to the roof rail. 11. Rotate the track assembly downward at the rear to disengage the "A" pillar limit switch bracket from the "A" pillar. 12. While holding the track assembly, rotate the thumb wheel on the motor counterclockwise to allow the tape to be disengaged from the motor's drive gear. 13. Remove the track assembly from the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7359 14. Remove the two screws retaining the "A" pillar limit switch bracket to the track assembly. 15. Gently slide the buckle assembly forward out of the track assembly. 16. Remove the buckle assembly from the drive belt. INSTALLATION 1. Insert drive belt at the front of the track assembly. Prior to drive belt installation, lubricate the track using E7FZ-19590-A or equivalent lubricant. 2. Install the buckle assembly into the large slot at the front end of the drive belt. 3. Slide the drive belt and buckle assembly into the track assembly far enough to allow the installation of the "A" pillar limit switch and bracket assembly. 4. Secure the switch and bracket using the two previously removed screws. 5. Install the drive belt into the vertical guide. 6. Rotate the thumb wheel on the motor clockwise to feed the drive belt through the motor guide and into the lower guide. 7. Rotate the track assembly downward at the rear and position the retaining tab on the "A" pillar limit switch bracket into the forward hole in the "A" pillar. Then, rotate the track assembly upward. 8. Engage the vertical guide retaining tab into the "B" pillar bracket. Then, install but do not tighten the previously removed screw and bolts used to secure the track assembly to the roof rail and "A" pillar. 9. Secure the "B" pillar bracket to the "B" pillar using the previously removed bolts. Tighten the bolts to 22-33 Nm (17-24 lb-ft). 10. Tighten the "A" pillar limit switch attachment to 2.2-3.3 Nm (20-29 lb-in). 11. Tighten the two bolts retaining the track assembly to the roof rail to 4.5-7.0 Nm (40-62 lb-in). 12. Install and tighten the bolt retaining the vertical guide to the quarter panel inner sheet metal to 4.5-7.0 Nm (40-62 lb-in). 13. Connect the electrical connectors at the "A" and "B" pillar limit switches. 14. Install the quarter trim panel and the "A" pillar garnish mouldings. 15. Cycle the mini buckle to the "B" pillar position. 16. Insert the tongue of the shoulder belt into the mini buckle. Make sure there is no twist in the belt (the belt should lay flat against the seat back). 17. Cycle the restraint system a few times to ensure the system operates properly. Shoulder Belt Retractor Switch Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7360 REMOVAL and INSTALLATION 1. Disconnect switch at connector attached to bracket on inboard side of driver's side seat track. 2. Using an ohmmeter, such as Rotunda Digital Volt Ohm Meter 007-00001 or equivalent, set to 200 ohms and probe across switch connector terminals. 3. Switch contacts must be closed when shoulder belt is engaged and tongue is engaged in buckle. 4. When the tongue and buckle are disengaged and the shoulder belt is retracted in excess of 305mm (12 inches) from engaged position, switch contacts should open. 5. Repeat Steps 1 through 4 on front passenger seat shoulder belt retractor switch. 6. If switch is malfunctioning, entire retractor assembly must be replaced. Front Seat Shoulder Strap and Retractor Assembly REMOVAL 1. Cycle shoulder safety straps to A-pillar position. Remove buckle from track carrier, allowing safety strap to retract into retractor. 2. Disconnect seat wiring. 3. Remove front seat and seat track assembly. 4. Remove front attaching nut and bolt. Remove rear Torx(r) head bolt retaining support assembly to seat. Remove support assembly. 5. Remove (rear) Torx(r) head bolt retaining shoulder strap buckle assembly to shoulder strap and retractor assembly. Remove buckle assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7361 6. Remove nut and washer assembly retaining shoulder strap and retractor to shoulder strap support. 7. Rotate retractor away from support and remove retractor. INSTALLATION 1. Grasp shoulder strap and retractor and engage retractor mounting stud into hole in shoulder strap support assembly. Loosely install retaining nut and washer assembly. 2. Rotate retractor towards support, making sure both retractor housing locking hooks engage support assembly and that the retractor (rear) attachment bracket lies on top of support assembly. 3. Position support and retractor assembly to front seat and track assembly. Start remaining retainers. 4. Tighten (front) bolt retaining support bracket to seat track. 5. Tighten (rear) nut retaining support assembly to seat track. 6. Position shoulder strap and buckle assembly to support and install Torx(r) head retaining bolt. NOTE: Make sure all attachments are tightened to specifications. 7. Install front seat and seat track assembly. Connect seat wiring. 8. Connect shoulder safety strap to track carrier. NOTE: Twist shoulder safety belt slightly, prior to connecting to track assembly. Emergency Release Buckle In the event of an accident, the shoulder belt retractor is designed to lock up in order to protect the occupants and may remain locked up after the Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7362 accident. If this occurs, unbuckle the shoulder belt at the B-pillar by pressing the red emergency release button on the buckle for the occupant to exit the vehicle. WARNING: THE VEHICLE SHOULD NOT BE DRIVEN UNLESS THE DOORS ARE FULLY CLOSED AND THE SHOULDER BELTS ARE IN THE LOCKED POSITION AT THE B-PILLAR. Manual Override System IMPORTANT FOR YOUR SAFETY If the shoulder belt does not move rearward, or stops before reaching the "B" pillar position, perform the following steps before driving the vehicle: 1. Open and close door(s). Make sure door is fully closed. 2. Using a coin or screwdriver, remove the cover at the lower end of the "B" pillar interior trim panel and turn the override knob clockwise to move the shoulder belt manually until it stops at the "B" pillar position. 3. If the shoulder belt still does not move to the "B" pillar, the drive belt may be broken, or the motor drive gear stripped. Grasp the belt and pull it toward the "B" pillar while turning the knob on the motor clockwise. This should get the belt to the lowest position on the "B" pillar. This will allow the occupant to manually position the belt over the shoulder until the vehicle can be serviced. CAUTION: If the shoulder belt will not move forward to the "A" pillar position, press the red emergency release button on the buckle to exit the vehicle. Then check to see if the automatic fuel pump shut-off switch has been tripped. NOTE: The fuel pump shut-off switch shuts off power to the fuel pump and the passive restraint system. WARNING: IF THE FUEL PUMP SHUT-OFF SWITCH IS NOT THE CAUSE FOR THE SHOULDER BELT NOT MOVING TO THE "A" PILLAR POSITION, HAVE THE SYSTEM SERVICED BY A QUALIFIED TECHNICIAN AS SOON AS POSSIBLE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7363 Seat Belt: Service and Repair Service Procedures SAFETY BELT MAINTENANCE Safety belt assemblies should be periodically inspected to ensure they are not damaged and are in proper operating condition, particularly if they have been subject to severe stress. WARNING: ALL SAFETY BELT ASSEMBLIES INCLUDING RETRACTORS, AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION. ALL BELT ASSEMBLIES SHOULD BE REPLACED UNLESS A QUALIFIED TECHNICIAN FINDS THE ASSEMBLIES SHOW NO DAMAGE AND OPERATE PROPERLY. WHEN A MOTORIZED PASSIVE RESTRAINT SHOULDER (TORSO) SAFETY BELT IS IN USE DURING A COLLISION IT MUST BE REPLACED ALONG WITH THE MOTORIZED TRACK ASSEMBLY. THE SUPPORT ASSEMBLY (SLIDE BAR) FOR THE FRONT SEAT LAP/SHOULDER SAFETY BELT RETRACTOR ASSEMBLY MUST ALSO BE REPLACED. BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERATION IS NOTED. TWISTED OR JAMMED SAFETY BELTS If the belt jams in the retractor by allowing the belt to retract when it is twisted, use the following procedure to free the webbing: Pull the belt out with both hands to tighten it on the retractor spool. - Feed the belt back into the retractor until it is completely retracted, repeat previous steps if necessary. - Pull the belt out of the retractor as far as it will go. Remove any foreign matter, or untwist the belt as necessary, and let the belt retract. - Extend and retract the belt about five times to make sure the belt retractor operates properly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Safety Belt - Tongue Service Kit Seat Belt Buckle: Technical Service Bulletins Safety Belt - Tongue Service Kit SAFETY BELT - FRONT - SERVICE KIT FOR OUTBOARD SAFETY BELT TONGUE Article No. 90-21-1 FORD: 1986-89 TAURUS 1989 THUNDERBIRD LINCOLN-MERCURY: 1986-89 SABLE 1988-89 CONTINENTAL 1989 COUGAR This TSB article is being republished in its entirety to clarify Tongue Service Kit and Tongue Cover part applications. ISSUE: A new service kit for replacing the front safety belt outboard tongue is now available. Previously, if service was required on the safety belt outboard tongue, the entire safety belt assembly had to be replaced. Thunderbird/Cougar applications are Canadian only. ACTION: If service to the front safety belt outboard tongue is required, use one of the new service kits. Refer to the application chart that follows to determine the correct part usage. Follow the installation instructions provided with the service kit. NOTE: TWO KITS ARE REQUIRED TO SERVICE BOTH FRONT SAFETY BELT OUTBOARD TONGUES OF A VEHICLE. WARNING: INSTRUCTIONS ARE PROVIDED WITH THE SERVICE KITS. INSTALLATION INSTRUCTIONS MUST BE FOLLOWED EXACTLY TO MAKE SURE OF PROPER OPERATION OF THE SAFETY BELT ASSEMBLY. NOTE: NEW SAFETY BELT TONGUE COVER IS ALSO REQUIRED. A new safety belt tongue cover must be installed. The safety belt tongue cover is not included in the service kit. The tongue cover must be ordered as a separate item. OTHER APPLICABLE ARTICLES: 88-25-2 SUPERSEDES: 90-16-1 WARRANTY STATUS: Eligible Under Safety Restraint Coverage, Basic Warranty Coverage OPERATION DESCRIPTION TIME 902101A Install Safety Belt Tongue 0.5 Hr. Service Kits - Both Sides DEALER CODING BASIC PART NO. CONDITION CODE 70610D94 01 OASIS CODES: 104000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Safety Belt - Tongue Service Kit > Page 7368 Seat Belt Buckle: Technical Service Bulletins Seat Belt - Outboard Tongue Service Kit SAFETY BELT - FRONT - SERVICE KIT FOR OUTBOARD SAFETY BELT TONGUE Article No. 90-19-3 FORD: 1986-89 TAURUS 1989 THUNDERBIRD LINCOLN-MERCURY: 1986-89 SABLE 1988-89 CONTINENTAL 1989 COUGAR ISSUE: A new service kit for replacing the front safety belt outboard tongue is now available. Prevoiusly, if service was required on the safety belt outboard tongue, the entire safety belt assembly had to be replaced. This concern applies to Canadian Thunderbird/Cougar only. ACTION: If service to the front safety belt outboard tongue is required, use one of the new service kits. Refer to the application chart that follows to determine the correct part usage. Follow the installation instructions provided with the service kit. WARNING: INSTRUCTIONS ARE PROVIDED WITH THE SERVICE KITS. INSTALLATION INSTRUCTIONS MUST BE FOLLOWED EXACTLY TO MAKE SURE OF PROPER OPERATION OF THE SAFETY BELT ASSEMBLY. A new safety belt tongue cover must be installed. The safety belt tongue cover is not included in the service kit. The tongue cover must be ordered as a separate item. NOTE: THE TONGUE COVERS APPLY TO ALL MODEL YEAR APPLICATIONS. ORDER THE REQUIRED SERVICE PART BASED ON TRIM COLOR. OTHER APPLICABLE ARTICLES: 88-25-2 WARRANTY STATUS: Eligible Under Safety Restraint Coverage, Basic Warranty Coverage OPERATION DESCRIPTION TIME 901903A Install Safety Belt Tongue 0.5 Hr. Service Kit - Both Sides DEALER CODING BASIC PART NO. CONDITION CODE 70610D94 01 OASIS CODES: 104000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Technical Service Bulletins > Page 7369 Seat Belt Buckle: Description and Operation The inboard belt buckle is secured to the slide bar, allowing the buckle to move with the seat. Attaching the tongue and buckle secures the outboard occupants with both lower and upper restraints. This tongue and belt attachment can be accomplished by a single, continuous movement. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckle Seat Belt Buckle: Service and Repair Front Seat Belt Buckle Inboard Belt And Buckle Assembly Seat Support Assembly REMOVAL 1. Remove seat and track assembly. 2. Remove inboard belt and buckle assembly. 3. Remove safety bolt from slide bar. 4. Remove inboard buckle assembly (on LH side of vehicle, disconnect chime wiring from floorpan wiring). INSTALLATION 1. Position buckle assembly to slide bar. Tighten bolt to 30-43 Nm (23-32 lb-ft). 2. Install seat and track assembly. 3. Check restraint system for proper operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle > Component Information > Service and Repair > Front Seat Belt Buckle > Page 7372 Seat Belt Buckle: Service and Repair Rear Seat Belt Buckle REMOVAL and INSTALLATION 1. Remove rear seat back and cushion. 2. Remove nut and buckle or belt assembly from vehicle. 3. Pry off brass grommet from assembly and discard. 4. To install, line up two anchor tabs on stud and install nut. Tighten nut to 30-43 Nm (22-32 lb-ft). 5. Install rear seat cushion. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp Stays ON With Belt Buckled Seat Belt Buckle Switch: Customer Interest Seat Belt Warning Lamp - Stays ON With Belt Buckled LAMP-WARNING STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES SAFETY BELT-WARNING LAMP STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES Article No. 89-14-1 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A safety belt warning lamp that stays "on" even though the safety belt is buckled may be caused by the passive restraint control assembly connectors. The two connectors may have been installed into the control assembly and not taped back to the wire harness on Canadian units without the motorized passive restraint system. Also, the jumper wire assembly to make sure of proper warning lamp/chime operation was not Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp Stays ON With Belt Buckled > Page 7381 installed. ACTION: Disconnect passive restraint control assembly connectors and install a jumper wire assembly. Refer to the following procedure for service details. 1. Remove the left hand interior trim panel in the luggage compartment. Refer to the 1989 Thunderbird/Cougar Shop Manual, Page 45-03-05. 2. Disconnect both passive restraint control assembly connectors and tape them back to the wire harness, Figure 1. 3. Install a jumper wire assembly (E9SZ-14K691-A), Figure 1. 4. Reinstall the luggage compartment trim panel. PART NUMBER PART NAME CLASS E9SZ-14K691-A Jumper Wire Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Safety Restraint Warranty Coverage OPERATION DESCRIPTION TIME 891401A Install Jumper Wire 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 14A504 79 OASIS CODES: 1051, 2300, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled Seat Belt Buckle Switch: All Technical Service Bulletins Seat Belt Warning Lamp - Stays ON With Belt Buckled LAMP-WARNING STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES SAFETY BELT-WARNING LAMP STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES Article No. 89-14-1 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A safety belt warning lamp that stays "on" even though the safety belt is buckled may be caused by the passive restraint control assembly connectors. The two connectors may have been installed into the control assembly and not taped back to the wire harness on Canadian units without the motorized passive restraint system. Also, the jumper wire assembly to make sure of proper warning lamp/chime operation was not Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled > Page 7387 installed. ACTION: Disconnect passive restraint control assembly connectors and install a jumper wire assembly. Refer to the following procedure for service details. 1. Remove the left hand interior trim panel in the luggage compartment. Refer to the 1989 Thunderbird/Cougar Shop Manual, Page 45-03-05. 2. Disconnect both passive restraint control assembly connectors and tape them back to the wire harness, Figure 1. 3. Install a jumper wire assembly (E9SZ-14K691-A), Figure 1. 4. Reinstall the luggage compartment trim panel. PART NUMBER PART NAME CLASS E9SZ-14K691-A Jumper Wire Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Safety Restraint Warranty Coverage OPERATION DESCRIPTION TIME 891401A Install Jumper Wire 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 14A504 79 OASIS CODES: 1051, 2300, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 7388 Seat Belt Buckle Switch: Locations In Driver's Seat Belt Buckle Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Locations Seat Belt Control Module: Locations Body & Chassis Components Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Locations > Page 7392 Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Locations > Page 7393 Seat Belt Control Module: Diagrams Connector View Harness Connector Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Control Module > Component Information > Locations > Page 7394 Seat Belt Control Module: Service and Repair REMOVAL and INSTALLATION 1. Remove LH luggage compartment trim panel. 2. Disengage two cover retaining push pins and remove cover. 3. Remove processor assembly from bracket (snaps on bracket). 4. Disconnect electrical connectors and remove processor. 5. To install, reverse Steps 1 through 4. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Specifications Seat Belt Guide Track: Specifications B-Pillar Bracket-to-B-Pillar Bolts .................................................................................................................................................... 23-33 Nm (17-24 lb-ft) Lower Guide-to-Quarter Panel Screws .......................................................................................................................................... 4.5-7.0 Nm (40-62 lb-in) Track Assembly-to-Roof Rail Screws ........................................................................................................................................... 4.5-7.0 Nm (40-62 lb-in) Vertical Guide-to-Quarter Panel Screws ........................................................................................................................................ 4.5-7.0 Nm (40-62 lb-in) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Track and Motor Assembly Seat Belt Guide Track: Service and Repair Track and Motor Assembly REMOVAL 1. Cycle the shoulder belt to the full forward position at the "A" pillar. Disengage the shoulder belt from the mini buckle. 2. Remove the rear seat cushion. 3. Remove the rear seat back. 4. Remove the "A" pillar and the quarter panel trim. 5. Disconnect the electrical connectors at the "A" pillar limit switch and at the motor assembly. 6. Remove the two bolts retaining the vertical belt guide to the quarter inner panel. 7. Remove the three bolts retaining the lower belt guide to the quarter inner panel. 8. Remove the two bolts retaining the motor assembly to the quarter inner panel. 9. Disengage the vertical belt guide at the "B" pillar bracket. 10. Remove the two bolts retaining the track assembly to the "B" pillar. 11. Remove the sheet metal screw retaining the 'A" pillar limit switch bracket to the "A" pillar. 12. While holding the track assembly securely, remove the two bolts retaining the track assembly to the roof rail. 13. Rotate the track assembly downward at the rear to disengage the "A" pillar limit switch bracket from the "A" pillar. 14. Remove the track and motor assembly from the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Track and Motor Assembly > Page 7400 INSTALLATION 1. Position the retaining tab on the "A" pillar limit switch bracket into the forward hole in the "A" pillar. Then rotate the track assembly upward. 2. Install but do not tighten the previously removed screw and bolts used to secure the track assembly to the roof rail and the "A" pillar. 3. Secure the "B" pillar bracket to the "B" pillar using the previously removed bolts. Tighten the bolts to 23-33 Nm (17-24 lb-ft). 4. Tighten the "A" pillar limit switch attachment to 2.2-3.3 Nm (20-29 lb-in). 5. Tighten the two bolts retaining the track assembly to the roof rail to 4.5-7.0 Nm (40-62 lb-in). 6. Engage the locating tab on the motor bracket into the slot in the quarter panel inner sheet metal. Then, install the two motor attaching bolts and tighten the bolts to 4.5-7.0 Nm (40- 62 lb-in). 7. Engage the vertical guide retaining tab into the "B" pillar bracket. Then, secure the guide to the quarter panel inner sheet metal using the two previously removed bolts. Tighten the bolts to 4.5-7.0 Nm (40-62 lb-in). 8. Secure the lower belt guide to the quarter inner panel using the three previously removed bolts. Tighten the bolts to 4.5-7.0 Nm (40-62 lb-in). 9. Connect the electrical connectors at the "A" pillar limit switch and at the motor. 10. Install the quarter trim panel and the "A" pillar garnish mouldings. 11. Cycle the mini buckle to the "B" pillar position. 12. Insert the tongue of the shoulder belt into the mini buckle. Make sure there is no twist in the belt (the belt should lay flat against the seat back). 13. Cycle the restraint system a few times to ensure the system operates properly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Track and Motor Assembly > Page 7401 Seat Belt Guide Track: Service and Repair Motor and Bracket Assembly REMOVAL and INSTALLATION 1. Remove the rear seat cushion and rear seat back assembly. 2. Remove the "A" pillar and the quarter panel trim. 3. Remove the lower bolt retaining the vertical guide to the quarter panel inner sheet metal. 4. Disengage the lower guide from the motor guide. 5. Disconnect the electrical connector at the motor. 6. Remove the two bolts retaining the motor to the quarter panel inner sheet metal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Guide Track > Component Information > Service and Repair > Track and Motor Assembly > Page 7402 7. Disengage the vertical guide from the motor guide. 8. Rotate the thumb wheel on the motor counterclockwise to disengage the drive belt from the motor drive gear. 9. Remove the motor and bracket assembly from the vehicle. 10. To install, reverse Steps 1 through 9. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Motor > Component Information > Specifications Seat Belt Motor: Specifications Motor Attaching Screws ....................................................................................................................... ......................................... 4.5-7.0 Nm (40-62 lb-in) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Motor > Component Information > Service and Repair > Track and Motor Assembly Seat Belt Motor: Service and Repair Track and Motor Assembly REMOVAL 1. Cycle the shoulder belt to the full forward position at the "A" pillar. Disengage the shoulder belt from the mini buckle. 2. Remove the rear seat cushion. 3. Remove the rear seat back. 4. Remove the "A" pillar and the quarter panel trim. 5. Disconnect the electrical connectors at the "A" pillar limit switch and at the motor assembly. 6. Remove the two bolts retaining the vertical belt guide to the quarter inner panel. 7. Remove the three bolts retaining the lower belt guide to the quarter inner panel. 8. Remove the two bolts retaining the motor assembly to the quarter inner panel. 9. Disengage the vertical belt guide at the "B" pillar bracket. 10. Remove the two bolts retaining the track assembly to the "B" pillar. 11. Remove the sheet metal screw retaining the 'A" pillar limit switch bracket to the "A" pillar. 12. While holding the track assembly securely, remove the two bolts retaining the track assembly to the roof rail. 13. Rotate the track assembly downward at the rear to disengage the "A" pillar limit switch bracket from the "A" pillar. 14. Remove the track and motor assembly from the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Motor > Component Information > Service and Repair > Track and Motor Assembly > Page 7408 INSTALLATION 1. Position the retaining tab on the "A" pillar limit switch bracket into the forward hole in the "A" pillar. Then rotate the track assembly upward. 2. Install but do not tighten the previously removed screw and bolts used to secure the track assembly to the roof rail and the "A" pillar. 3. Secure the "B" pillar bracket to the "B" pillar using the previously removed bolts. Tighten the bolts to 23-33 Nm (17-24 lb-ft). 4. Tighten the "A" pillar limit switch attachment to 2.2-3.3 Nm (20-29 lb-in). 5. Tighten the two bolts retaining the track assembly to the roof rail to 4.5-7.0 Nm (40-62 lb-in). 6. Engage the locating tab on the motor bracket into the slot in the quarter panel inner sheet metal. Then, install the two motor attaching bolts and tighten the bolts to 4.5-7.0 Nm (40- 62 lb-in). 7. Engage the vertical guide retaining tab into the "B" pillar bracket. Then, secure the guide to the quarter panel inner sheet metal using the two previously removed bolts. Tighten the bolts to 4.5-7.0 Nm (40-62 lb-in). 8. Secure the lower belt guide to the quarter inner panel using the three previously removed bolts. Tighten the bolts to 4.5-7.0 Nm (40-62 lb-in). 9. Connect the electrical connectors at the "A" pillar limit switch and at the motor. 10. Install the quarter trim panel and the "A" pillar garnish mouldings. 11. Cycle the mini buckle to the "B" pillar position. 12. Insert the tongue of the shoulder belt into the mini buckle. Make sure there is no twist in the belt (the belt should lay flat against the seat back). 13. Cycle the restraint system a few times to ensure the system operates properly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Motor > Component Information > Service and Repair > Track and Motor Assembly > Page 7409 Seat Belt Motor: Service and Repair Motor and Bracket Assembly REMOVAL and INSTALLATION 1. Remove the rear seat cushion and rear seat back assembly. 2. Remove the "A" pillar and the quarter panel trim. 3. Remove the lower bolt retaining the vertical guide to the quarter panel inner sheet metal. 4. Disengage the lower guide from the motor guide. 5. Disconnect the electrical connector at the motor. 6. Remove the two bolts retaining the motor to the quarter panel inner sheet metal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Motor > Component Information > Service and Repair > Track and Motor Assembly > Page 7410 7. Disengage the vertical guide from the motor guide. 8. Rotate the thumb wheel on the motor counterclockwise to disengage the drive belt from the motor drive gear. 9. Remove the motor and bracket assembly from the vehicle. 10. To install, reverse Steps 1 through 9. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation SAFETY BELT WARNING CHIME CIRCUITRY When the ignition switch is turned to the RUN or START position, power is supplied to the tone generator chime assembly. The thermal timer supplies power to one side of the warning lamp (from 4 to 8 seconds) through the passive restraint module. Power is also supplied to one side of the warning lamp when either of the passive belt reel switches is open (shoulder belt disconnected), or whenever either shoulder belt transport is not properly located at the "B" pillar after the lap belt warning indication period is over. The opposite side of the lamp goes directly to ground. The chime goes to ground through the LH seat lap belt buckle switch, or through the passive restraint module, whenever either of the passive belt reel switches is open. All modes of operation use a constant (non-flashing) signal for the lamp. SAFETY BELT WARNING INDICATOR The safety belt warning indicator lamp in the instrument cluster will illuminate four to eight seconds. In the unlikely event the shoulder belt should stall before it reaches the B-pillar, the indicator lamp will remain illuminated after nine seconds and the chime will sound after 16 seconds until the shoulder belt is in its locked position at the B-pillar. If only the indicator lamp remains illuminated, check to ensure both shoulder belts are latched to the emergency release buckle. If they are latched, and the indicator lamp and chime remain on, perform Manual Override System procedures before driving the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Reminder Lamp: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled Seat Belt Reminder Lamp: Customer Interest Seat Belt Warning Lamp - Stays ON With Belt Buckled LAMP-WARNING STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES SAFETY BELT-WARNING LAMP STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES Article No. 89-14-1 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A safety belt warning lamp that stays "on" even though the safety belt is buckled may be caused by the passive restraint control assembly connectors. The two connectors may have been installed into the control assembly and not taped back to the wire harness on Canadian units without the motorized passive restraint system. Also, the jumper wire assembly to make sure of proper warning lamp/chime operation was not Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Reminder Lamp: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled > Page 7422 installed. ACTION: Disconnect passive restraint control assembly connectors and install a jumper wire assembly. Refer to the following procedure for service details. 1. Remove the left hand interior trim panel in the luggage compartment. Refer to the 1989 Thunderbird/Cougar Shop Manual, Page 45-03-05. 2. Disconnect both passive restraint control assembly connectors and tape them back to the wire harness, Figure 1. 3. Install a jumper wire assembly (E9SZ-14K691-A), Figure 1. 4. Reinstall the luggage compartment trim panel. PART NUMBER PART NAME CLASS E9SZ-14K691-A Jumper Wire Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Safety Restraint Warranty Coverage OPERATION DESCRIPTION TIME 891401A Install Jumper Wire 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 14A504 79 OASIS CODES: 1051, 2300, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Reminder Lamp: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled Seat Belt Reminder Lamp: All Technical Service Bulletins Seat Belt Warning Lamp - Stays ON With Belt Buckled LAMP-WARNING STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES SAFETY BELT-WARNING LAMP STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES Article No. 89-14-1 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A safety belt warning lamp that stays "on" even though the safety belt is buckled may be caused by the passive restraint control assembly connectors. The two connectors may have been installed into the control assembly and not taped back to the wire harness on Canadian units without the motorized passive restraint system. Also, the jumper wire assembly to make sure of proper warning lamp/chime operation was not Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Reminder Lamp: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled > Page 7428 installed. ACTION: Disconnect passive restraint control assembly connectors and install a jumper wire assembly. Refer to the following procedure for service details. 1. Remove the left hand interior trim panel in the luggage compartment. Refer to the 1989 Thunderbird/Cougar Shop Manual, Page 45-03-05. 2. Disconnect both passive restraint control assembly connectors and tape them back to the wire harness, Figure 1. 3. Install a jumper wire assembly (E9SZ-14K691-A), Figure 1. 4. Reinstall the luggage compartment trim panel. PART NUMBER PART NAME CLASS E9SZ-14K691-A Jumper Wire Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Safety Restraint Warranty Coverage OPERATION DESCRIPTION TIME 891401A Install Jumper Wire 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 14A504 79 OASIS CODES: 1051, 2300, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > Page 7429 Seat Belt Reminder Lamp: Description and Operation SAFETY BELT WARNING CHIME CIRCUITRY When the ignition switch is turned to the RUN or START position, power is supplied to the tone generator chime assembly. The thermal timer supplies power to one side of the warning lamp (from 4 to 8 seconds) through the passive restraint module. Power is also supplied to one side of the warning lamp when either of the passive belt reel switches is open (shoulder belt disconnected), or whenever either shoulder belt transport is not properly located at the "B" pillar after the lap belt warning indication period is over. The opposite side of the lamp goes directly to ground. The chime goes to ground through the LH seat lap belt buckle switch, or through the passive restraint module, whenever either of the passive belt reel switches is open. All modes of operation use a constant (non-flashing) signal for the lamp. SAFETY BELT WARNING INDICATOR The safety belt warning indicator lamp in the instrument cluster will illuminate four to eight seconds. In the unlikely event the shoulder belt should stall before it reaches the B-pillar, the indicator lamp will remain illuminated after nine seconds and the chime will sound after 16 seconds until the shoulder belt is in its locked position at the B-pillar. If only the indicator lamp remains illuminated, check to ensure both shoulder belts are latched to the emergency release buckle. If they are latched, and the indicator lamp and chime remain on, perform Manual Override System procedures before driving the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Specifications Seat Belt Retractor: Specifications Shoulder Belt Retractor-to-Seat Track Assembly Torx Bolt ............................................................................................................ 30-43 Nm (22-32 lb-ft) Shoulder Belt Retractor-to-Seat Track Assembly Front Nut and Bolt ................................................................................................... 7-11 Nm (5-8 lb-ft) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Active Restraints (Canadian Models) Seat Belt Retractor: Description and Operation Active Restraints (Canadian Models) Shoulder Harness Retractor SHOULDER HARNESS The shoulder harness webbing is fixed in a retractor which is located in the quarter panel. This retractor is designed to let the webbing freely move in or out at all times, except during vehicle deceleration. Then, it is automatically locked by a mechanically actuated inertia sensor. The shoulder harness webbing is attached to a retractor. The retractor is located in the quarter panel. The webbing then passes through a guide above and behind the occupant's shoulder which directs the webbing at the proper downward angle over the occupant's shoulder and chest and attaches to the lap belt buckle. The shoulder harness retractor is designed to let the webbing freely move in or out at all times, except during vehicle deceleration, when it is automatically locked by a mechanically actuated inertia sensor. On these vehicles the buckle is routed along the side of the seat and is attached to the slide bar. The slide bar is anchored to the seat track which is anchored to the floorpan. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Description and Operation > Active Restraints (Canadian Models) > Page 7435 Seat Belt Retractor: Description and Operation Passive Restraints (US Models) FRONT PASSENGER LAP BELT RETRACTOR The dual locking mode passenger seat lap belt retractor is available only on vehicles equipped with motorized passive restraints. The vehicle is equipped with a dual locking mode lap belt retractor for the front seat passenger. The retractor modes function as follows: Vehicle Sensitive (Emergency) Locking Mode: The lap belt retractor will allow the occupant freedom of movement, locking tight only on hard braking, hard cornering or impacts of approximately 8 km/h (5mph) or more. The retractor cannot be made to lock by jerking on the belt. Automatic Locking Mode: The lap belt retractor will remain locked and does not allow the occupant freedom of movement. This mode provides for the following: a. The feeling of a tight lap belt on the hips. b. Child seat or infant carrier installation. This mode must be used when installing a child seat or infant carrier on the front passenger seat. To switch the retractor from the emergency locking mode to the automatic locking mode, perform the following steps: - After buckling the lap belt, grasp the lap belt below the child seat instruction label and pull upward until all of the stored belt has been extracted and a click is heard. At this time the lap belt retractor is in the automatic locking mode. - Allow the belt to retract. A clicking sound will be heard as the belt retracts. This indicates that the retractor is in the automatic locking mode. Then pull downward on the belt to remove any slack in the belt. NOTE: When the lap belt is unbuckled and allowed to retract completely, the retractor will switch to the vehicle sensitive (emergency) locking mode. WARNING: FRONT AND REAR SEAT OCCUPANTS (INCLUDING PREGNANT WOMEN) SHOULD WEAR BOTH LAP AND SHOULDER BELTS, FOR OPTIMUM PROTECTION IN AN ACCIDENT. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Active Restraints (Canadian Models) Seat Belt Retractor: Service and Repair Active Restraints (Canadian Models) Front Outboard Attachments REMOVAL 1. Remove D-ring cover 2. Insert bolt bit and remove belt bolt. 3. Remove B-pillar upper trim panel. 4. Remove scuff plate/center pillar trim panel retaining screws and panel. 5. Remove safety belt through slot in upper center trim panel. 6. Remove safety belt anchor-to-sill bolt and rubber washer. 7. Remove safety belt retractor bolt. 8. Remove web guide attaching screw and slide guide rearward to remove from B-pillar. 9. Remove outboard safety belt assembly from vehicle. 10. Remove seat and track assembly. 11. Remove inboard belt and buckle assembly. 12. Remove safety bolt from slide bar. 13. Remove inboard knuckle assembly (on LH side of vehicle, disconnect buzzer wiring from floorpan wiring). INSTALLATION 1. Reverse the removal procedure and position the safety belt components. 2. Tighten all attaching bolts to 30-43 Nm (22-32 lb-ft). Cycle the system several times to ensure proper operation of the retractor. Ensure webbing is not twisted. Rear Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7438 REMOVAL and INSTALLATION 1. Remove rear seat cushion. 2. Remove rear seat back. 3. Remove buckle end anchor nuts and remove buckle end belts. 4. Remove upper and lower quarter trim panels. 5. Remove safety belt anchor-to-sill bolt. 6. Snap out bezel in package tray trim panel. 7. Remove rear stoplamp assembly. 8. Remove package tray trim panel. 9. Remove retractor anchor bolt and retractor screw. 10. Remove anchor end of webbing through the opening in the quarter trim panel and the package tray trim panel. 11. Remove outboard safety belt assembly from the vehicle. 12. Repeat procedure on opposite side. 13. To install, reverse Steps 1 through 12. NOTE: Be sure to tighten all retaining bolts to specification. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7439 Seat Belt Retractor: Service and Repair Passive Restraint System (Motorized Seat Belts) Drive Belt REMOVAL 1. Cycle the shoulder belt to the full forward position at the "A" pillar. Disengage the shoulder bell from the mini buckle. 2. Remove the rear seat cushion. 3. Remove the rear seat back. 4. Remove the "A" pillar and the quarter panel trim. 5. Disconnect the electrical connectors at the "A" pillar and "B" pillar limit switches. 6. Remove the upper bolt used to retain the vertical belt guide to the quarter inner panel. 7. Disengage the vertical belt guide at the "B" pillar bracket. Release tab. 8. Remove the two bolts retaining the track assembly to the "B" pillar. 9. Remove the sheet metal screw retaining the "A" pillar limit switch bracket to the "A" pillar. 10. While holding the track assembly securely, remove the two bolts retaining the track assembly to the roof rail. 11. Rotate the track assembly downward at the rear to disengage the "A" pillar limit switch bracket from the "A" pillar. 12. While holding the track assembly, rotate the thumb wheel on the motor counterclockwise to allow the tape to be disengaged from the motor's drive gear. 13. Remove the track assembly from the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7440 14. Remove the two screws retaining the "A" pillar limit switch bracket to the track assembly. 15. Gently slide the buckle assembly forward out of the track assembly. 16. Remove the buckle assembly from the drive belt. INSTALLATION 1. Insert drive belt at the front of the track assembly. Prior to drive belt installation, lubricate the track using E7FZ-19590-A or equivalent lubricant. 2. Install the buckle assembly into the large slot at the front end of the drive belt. 3. Slide the drive belt and buckle assembly into the track assembly far enough to allow the installation of the "A" pillar limit switch and bracket assembly. 4. Secure the switch and bracket using the two previously removed screws. 5. Install the drive belt into the vertical guide. 6. Rotate the thumb wheel on the motor clockwise to feed the drive belt through the motor guide and into the lower guide. 7. Rotate the track assembly downward at the rear and position the retaining tab on the "A" pillar limit switch bracket into the forward hole in the "A" pillar. Then, rotate the track assembly upward. 8. Engage the vertical guide retaining tab into the "B" pillar bracket. Then, install but do not tighten the previously removed screw and bolts used to secure the track assembly to the roof rail and "A" pillar. 9. Secure the "B" pillar bracket to the "B" pillar using the previously removed bolts. Tighten the bolts to 22-33 Nm (17-24 lb-ft). 10. Tighten the "A" pillar limit switch attachment to 2.2-3.3 Nm (20-29 lb-in). 11. Tighten the two bolts retaining the track assembly to the roof rail to 4.5-7.0 Nm (40-62 lb-in). 12. Install and tighten the bolt retaining the vertical guide to the quarter panel inner sheet metal to 4.5-7.0 Nm (40-62 lb-in). 13. Connect the electrical connectors at the "A" and "B" pillar limit switches. 14. Install the quarter trim panel and the "A" pillar garnish mouldings. 15. Cycle the mini buckle to the "B" pillar position. 16. Insert the tongue of the shoulder belt into the mini buckle. Make sure there is no twist in the belt (the belt should lay flat against the seat back). 17. Cycle the restraint system a few times to ensure the system operates properly. Shoulder Belt Retractor Switch Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7441 REMOVAL and INSTALLATION 1. Disconnect switch at connector attached to bracket on inboard side of driver's side seat track. 2. Using an ohmmeter, such as Rotunda Digital Volt Ohm Meter 007-00001 or equivalent, set to 200 ohms and probe across switch connector terminals. 3. Switch contacts must be closed when shoulder belt is engaged and tongue is engaged in buckle. 4. When the tongue and buckle are disengaged and the shoulder belt is retracted in excess of 305mm (12 inches) from engaged position, switch contacts should open. 5. Repeat Steps 1 through 4 on front passenger seat shoulder belt retractor switch. 6. If switch is malfunctioning, entire retractor assembly must be replaced. Front Seat Shoulder Strap and Retractor Assembly REMOVAL 1. Cycle shoulder safety straps to A-pillar position. Remove buckle from track carrier, allowing safety strap to retract into retractor. 2. Disconnect seat wiring. 3. Remove front seat and seat track assembly. 4. Remove front attaching nut and bolt. Remove rear Torx(r) head bolt retaining support assembly to seat. Remove support assembly. 5. Remove (rear) Torx(r) head bolt retaining shoulder strap buckle assembly to shoulder strap and retractor assembly. Remove buckle assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor > Component Information > Service and Repair > Active Restraints (Canadian Models) > Page 7442 6. Remove nut and washer assembly retaining shoulder strap and retractor to shoulder strap support. 7. Rotate retractor away from support and remove retractor. INSTALLATION 1. Grasp shoulder strap and retractor and engage retractor mounting stud into hole in shoulder strap support assembly. Loosely install retaining nut and washer assembly. 2. Rotate retractor towards support, making sure both retractor housing locking hooks engage support assembly and that the retractor (rear) attachment bracket lies on top of support assembly. 3. Position support and retractor assembly to front seat and track assembly. Start remaining retainers. 4. Tighten (front) bolt retaining support bracket to seat track. 5. Tighten (rear) nut retaining support assembly to seat track. 6. Position shoulder strap and buckle assembly to support and install Torx(r) head retaining bolt. NOTE: Make sure all attachments are tightened to specifications. 7. Install front seat and seat track assembly. Connect seat wiring. 8. Connect shoulder safety strap to track carrier. NOTE: Twist shoulder safety belt slightly, prior to connecting to track assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Warning Timer > Component Information > Description and Operation Seat Belt Warning Timer: Description and Operation SAFETY BELT WARNING CHIME CIRCUITRY When the ignition switch is turned to the RUN or START position, power is supplied to the tone generator chime assembly. The thermal timer supplies power to one side of the warning lamp (from 4 to 8 seconds) through the passive restraint module. Power is also supplied to one side of the warning lamp when either of the passive belt reel switches is open (shoulder belt disconnected), or whenever either shoulder belt transport is not properly located at the "B" pillar after the lap belt warning indication period is over. The opposite side of the lamp goes directly to ground. The chime goes to ground through the LH seat lap belt buckle switch, or through the passive restraint module, whenever either of the passive belt reel switches is open. All modes of operation use a constant (non-flashing) signal for the lamp. SAFETY BELT WARNING INDICATOR The safety belt warning indicator lamp in the instrument cluster will illuminate four to eight seconds. In the unlikely event the shoulder belt should stall before it reaches the B-pillar, the indicator lamp will remain illuminated after nine seconds and the chime will sound after 16 seconds until the shoulder belt is in its locked position at the B-pillar. If only the indicator lamp remains illuminated, check to ensure both shoulder belts are latched to the emergency release buckle. If they are latched, and the indicator lamp and chime remain on, perform Manual Override System procedures before driving the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications Seat Belt Retractor Limit Switch: Specifications A-Pillar Limit Switch Bracket Screws ........................................................................................................................................... 2.2-3.3 Nm (20-29 lb-in) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications > Page 7449 Seat Belt Retractor Limit Switch: Locations Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications > Page 7450 Seat Belt Retractor Limit Switch: Service and Repair REMOVAL and INSTALLATION 1. Disconnect switch from wiring harness. 2. Using an ohmmeter such as Rotunda Digital Volt Ohm Meter 007-00001 or equivalent, probe across switch terminals. NOTE: Switch is normally closed when plunger in free (extended) position. Switch must open when plunger is depressed. 3. Remove Torx(r) bolt and move spacer downward. This will allow limit switch removal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications > Page 7451 4. To install, reverse Steps 1, 2 and 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled Seat Belt Buckle Switch: Customer Interest Seat Belt Warning Lamp - Stays ON With Belt Buckled LAMP-WARNING STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES SAFETY BELT-WARNING LAMP STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES Article No. 89-14-1 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A safety belt warning lamp that stays "on" even though the safety belt is buckled may be caused by the passive restraint control assembly connectors. The two connectors may have been installed into the control assembly and not taped back to the wire harness on Canadian units without the motorized passive restraint system. Also, the jumper wire assembly to make sure of proper warning lamp/chime operation was not Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Customer Interest for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled > Page 7461 installed. ACTION: Disconnect passive restraint control assembly connectors and install a jumper wire assembly. Refer to the following procedure for service details. 1. Remove the left hand interior trim panel in the luggage compartment. Refer to the 1989 Thunderbird/Cougar Shop Manual, Page 45-03-05. 2. Disconnect both passive restraint control assembly connectors and tape them back to the wire harness, Figure 1. 3. Install a jumper wire assembly (E9SZ-14K691-A), Figure 1. 4. Reinstall the luggage compartment trim panel. PART NUMBER PART NAME CLASS E9SZ-14K691-A Jumper Wire Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Safety Restraint Warranty Coverage OPERATION DESCRIPTION TIME 891401A Install Jumper Wire 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 14A504 79 OASIS CODES: 1051, 2300, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled Seat Belt Buckle Switch: All Technical Service Bulletins Seat Belt Warning Lamp - Stays ON With Belt Buckled LAMP-WARNING STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES SAFETY BELT-WARNING LAMP STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES Article No. 89-14-1 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A safety belt warning lamp that stays "on" even though the safety belt is buckled may be caused by the passive restraint control assembly connectors. The two connectors may have been installed into the control assembly and not taped back to the wire harness on Canadian units without the motorized passive restraint system. Also, the jumper wire assembly to make sure of proper warning lamp/chime operation was not Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Belt Buckle Switch: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled > Page 7467 installed. ACTION: Disconnect passive restraint control assembly connectors and install a jumper wire assembly. Refer to the following procedure for service details. 1. Remove the left hand interior trim panel in the luggage compartment. Refer to the 1989 Thunderbird/Cougar Shop Manual, Page 45-03-05. 2. Disconnect both passive restraint control assembly connectors and tape them back to the wire harness, Figure 1. 3. Install a jumper wire assembly (E9SZ-14K691-A), Figure 1. 4. Reinstall the luggage compartment trim panel. PART NUMBER PART NAME CLASS E9SZ-14K691-A Jumper Wire Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Safety Restraint Warranty Coverage OPERATION DESCRIPTION TIME 891401A Install Jumper Wire 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 14A504 79 OASIS CODES: 1051, 2300, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Buckle Switch > Component Information > Technical Service Bulletins > Page 7468 Seat Belt Buckle Switch: Locations In Driver's Seat Belt Buckle Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications Seat Belt Retractor Limit Switch: Specifications A-Pillar Limit Switch Bracket Screws ........................................................................................................................................... 2.2-3.3 Nm (20-29 lb-in) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications > Page 7472 Seat Belt Retractor Limit Switch: Locations Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications > Page 7473 Seat Belt Retractor Limit Switch: Service and Repair REMOVAL and INSTALLATION 1. Disconnect switch from wiring harness. 2. Using an ohmmeter such as Rotunda Digital Volt Ohm Meter 007-00001 or equivalent, probe across switch terminals. NOTE: Switch is normally closed when plunger in free (extended) position. Switch must open when plunger is depressed. 3. Remove Torx(r) bolt and move spacer downward. This will allow limit switch removal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Seat Belt Retractor Limit Switch > Component Information > Specifications > Page 7474 4. To install, reverse Steps 1, 2 and 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > Customer Interest for Antenna Mast: > 91111 > May > 91 > Fixed Antenna - Whistling Wind Noise Antenna Mast: Customer Interest Fixed Antenna - Whistling Wind Noise Article No. 91-11-1 5/30/91 ^ ANTENNA - STANDARD - WIND NOISE TYPE "WHISTLE" ^ WINDNOISE - "WHISTLE" FROM STANDARD ANTENNA FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: A "whistling" type windnoise from the fixed antenna mast may be caused by the base shape and size of the antenna mast. This usually occurs when the vehicle is driven at 60-65 MPH, (96-105 km/H) with crosswinds of 12-18 MPH, (19-29 km/H). ACTION: Use the following service procedure to see if a new service antenna mast is required. The new antenna mast has a vinyl sleeve to reduce windnoise. 1. Remove the fixed antenna mast. 2. Test drive the vehicle to see if whistle is eliminated. 3. If whistle is gone, install a new service black antenna mast (E9SZ-18A886-A). 4. Tighten lower antenna mast to 3.5 to 5.5 N-m (31-49 lb.in.) PART NUMBER PART NAME CLASS E9SZ-18A886-A Antenna Mast C SUPERSEDES: 89-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911101A Replace Antenna Mast 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 18A886 56 OASIS CODES: 701000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Mast > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna Mast: > 91111 > May > 91 > Fixed Antenna Whistling Wind Noise Antenna Mast: All Technical Service Bulletins Fixed Antenna - Whistling Wind Noise Article No. 91-11-1 5/30/91 ^ ANTENNA - STANDARD - WIND NOISE TYPE "WHISTLE" ^ WINDNOISE - "WHISTLE" FROM STANDARD ANTENNA FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: A "whistling" type windnoise from the fixed antenna mast may be caused by the base shape and size of the antenna mast. This usually occurs when the vehicle is driven at 60-65 MPH, (96-105 km/H) with crosswinds of 12-18 MPH, (19-29 km/H). ACTION: Use the following service procedure to see if a new service antenna mast is required. The new antenna mast has a vinyl sleeve to reduce windnoise. 1. Remove the fixed antenna mast. 2. Test drive the vehicle to see if whistle is eliminated. 3. If whistle is gone, install a new service black antenna mast (E9SZ-18A886-A). 4. Tighten lower antenna mast to 3.5 to 5.5 N-m (31-49 lb.in.) PART NUMBER PART NAME CLASS E9SZ-18A886-A Antenna Mast C SUPERSEDES: 89-11-8 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911101A Replace Antenna Mast 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 18A886 56 OASIS CODES: 701000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Motor > Component Information > Locations Antenna Motor: Locations I/P Components Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Motor > Component Information > Locations > Page 7493 Body & Chassis Components Inside RH Fender Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna Switch, Power > Component Information > Locations Antenna Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > Customer Interest for Antenna Cable: > 90267 > Dec > 90 > Radio Poor AM/FM Reception Antenna Cable: Customer Interest Radio - Poor AM/FM Reception Article No. 90-26-7 RADIO - POOR AM/FM RECEPTION FORD: 1986-90 TAURUS 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1986-90 SABLE 1989-91 COUGAR ISSUE: Poor AM/FM radio reception may sometimes occur. There may be slow deterioration of distant stations, followed by a loss of strong local stations. This condition may be caused by internal corrosion in the antenna connector at the antenna base end. ACTION: Check the antenna connector at the antenna for corrosion and, if necessary, replace the antenna cable. Lubriplate DS-ES must be applied to the female end of the antenna connector end and around the antenna cable. Refer to the appropriate model year Shop Manual, Section 35-10, for service details. NOTE: BEFORE REPLACING THE ANTENNA CABLE, APPLY GREASE LUBRIPLATE DS-ES TO THE FEMALE CONNECTOR AT THE ANTENNA END AND AROUND THE ANTENNA CABLE WHERE IT ENTERS THE CONNECTOR. THIS WILL KEEP MOISTURE AND ROAD SPLASH OUT. PART NUMBER PART NAME CLASS Lubriplate DS-ES Grease - Procure Locally E6DZ-18812-A Antenna Cable - Taurus/Sable C (Non-Power) E6DZ-18812-B Antenna Cable - Taurus/Sable BM (Power) EGSZ-18812-A Antenna Cable - C Thunderbird/Cougar (Non-Power) E9SZ-18812-B Antenna Cable - C Thunderbird/Cougar (Power) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902607A Replace Antenna Cable 1.0 Hr DEALER CODING BASIC PART NO. CONDITION CODE 18812 84 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > Customer Interest for Antenna Cable: > 891611 > Aug > 89 > Radio - Interference On AM Band Antenna Cable: Customer Interest Radio - Interference On AM Band RADIO-INTERFERENCE ON AM RADIO BAND Article No. 89-16-11 FORD: 1988-89 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1988-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR ISSUE: Radio interference such as ignition noise, a whining sound, or weak reception may occur on the AM radio band. This may be caused by a poor ground connection at the antenna lead-in cable or loose antenna attaching hardware. ACTION: Check and tighten the antenna mounting hardware by using the following service procedure. Figure 1 CONTINENTAL, TOWN CAR, MARK VII ONLY 1. Determine if the antenna connection is the cause of the concern by connecting a jumper from the lead-in cable to the mast housing as shown in figure 1. Do not disconnect the lead-in cable for this test. 2. Listen to the radio for a reduction in interference noise. If a noise reduction is apparent, rework the antenna lead-in cable as described in the following steps. 3. Disconnect the antenna lead-in cable from the mast housing with a twisting motion. Figure 2 4. Rework the antenna lead-in connector by bending the brass tangs approximately .060 inches (1.5 mm) away from the body surface, Figure 2. This will improve the electrical contact between the lead-in connector and its mating socket on the mast housing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > Customer Interest for Antenna Cable: > 891611 > Aug > 89 > Radio - Interference On AM Band > Page 7510 5. Reconnect the lead-in cable to the socket in the mast housing. 6. Check the radio for improved performance. ALL OTHER CARLINES Check the antenna mounting hardware installation torque using the procedure Section 35-10 of the appropriate Car Shop Manual. The correct torque values are shown in the following Power Antenna Hardware Torque Chart. POWER ANTENNA HARDWARE TORQUE CHART TORQUE TORQUE REQUIRED REQUIRED VEHICLE (N-m) (in.lbs.) Continental 3.5 to 5.0 31 to 44 Town Car 5.5 to 8.0 49 to 71 Ford, Mercury 5.5 to 8.0 49 to 71 Thunderbird/Cougar 3.5 to 5.0 31 to 44 Taurus/Sable 3.5 to 5.0 31 to 44 Mark VII 3.5 to 5.0 31 to 44 NOTE: ALL MANUAL ANTENNA MAST TORQUE REQUIREMENTS FOR ALL VEHICLES ARE 3.4 TO 3.6 N-m (30 to 32 in.lbs.). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891611A Correct Poor Connection At 0.3 Hr. Antenna Lead-In Cable DEALER CODING BASIC PART NO. CONDITION CODE 18813 33 OASIS CODES: 2200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna Cable: > 90267 > Dec > 90 > Radio - Poor AM/FM Reception Antenna Cable: All Technical Service Bulletins Radio - Poor AM/FM Reception Article No. 90-26-7 RADIO - POOR AM/FM RECEPTION FORD: 1986-90 TAURUS 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1986-90 SABLE 1989-91 COUGAR ISSUE: Poor AM/FM radio reception may sometimes occur. There may be slow deterioration of distant stations, followed by a loss of strong local stations. This condition may be caused by internal corrosion in the antenna connector at the antenna base end. ACTION: Check the antenna connector at the antenna for corrosion and, if necessary, replace the antenna cable. Lubriplate DS-ES must be applied to the female end of the antenna connector end and around the antenna cable. Refer to the appropriate model year Shop Manual, Section 35-10, for service details. NOTE: BEFORE REPLACING THE ANTENNA CABLE, APPLY GREASE LUBRIPLATE DS-ES TO THE FEMALE CONNECTOR AT THE ANTENNA END AND AROUND THE ANTENNA CABLE WHERE IT ENTERS THE CONNECTOR. THIS WILL KEEP MOISTURE AND ROAD SPLASH OUT. PART NUMBER PART NAME CLASS Lubriplate DS-ES Grease - Procure Locally E6DZ-18812-A Antenna Cable - Taurus/Sable C (Non-Power) E6DZ-18812-B Antenna Cable - Taurus/Sable BM (Power) EGSZ-18812-A Antenna Cable - C Thunderbird/Cougar (Non-Power) E9SZ-18812-B Antenna Cable - C Thunderbird/Cougar (Power) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902607A Replace Antenna Cable 1.0 Hr DEALER CODING BASIC PART NO. CONDITION CODE 18812 84 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna Cable: > 891611 > Aug > 89 > Radio - Interference On AM Band Antenna Cable: All Technical Service Bulletins Radio - Interference On AM Band RADIO-INTERFERENCE ON AM RADIO BAND Article No. 89-16-11 FORD: 1988-89 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1988-89 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR ISSUE: Radio interference such as ignition noise, a whining sound, or weak reception may occur on the AM radio band. This may be caused by a poor ground connection at the antenna lead-in cable or loose antenna attaching hardware. ACTION: Check and tighten the antenna mounting hardware by using the following service procedure. Figure 1 CONTINENTAL, TOWN CAR, MARK VII ONLY 1. Determine if the antenna connection is the cause of the concern by connecting a jumper from the lead-in cable to the mast housing as shown in figure 1. Do not disconnect the lead-in cable for this test. 2. Listen to the radio for a reduction in interference noise. If a noise reduction is apparent, rework the antenna lead-in cable as described in the following steps. 3. Disconnect the antenna lead-in cable from the mast housing with a twisting motion. Figure 2 4. Rework the antenna lead-in connector by bending the brass tangs approximately .060 inches (1.5 mm) away from the body surface, Figure 2. This will improve the electrical contact between the lead-in connector and its mating socket on the mast housing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antenna > Antenna, Radio > Antenna Cable > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Antenna Cable: > 891611 > Aug > 89 > Radio - Interference On AM Band > Page 7520 5. Reconnect the lead-in cable to the socket in the mast housing. 6. Check the radio for improved performance. ALL OTHER CARLINES Check the antenna mounting hardware installation torque using the procedure Section 35-10 of the appropriate Car Shop Manual. The correct torque values are shown in the following Power Antenna Hardware Torque Chart. POWER ANTENNA HARDWARE TORQUE CHART TORQUE TORQUE REQUIRED REQUIRED VEHICLE (N-m) (in.lbs.) Continental 3.5 to 5.0 31 to 44 Town Car 5.5 to 8.0 49 to 71 Ford, Mercury 5.5 to 8.0 49 to 71 Thunderbird/Cougar 3.5 to 5.0 31 to 44 Taurus/Sable 3.5 to 5.0 31 to 44 Mark VII 3.5 to 5.0 31 to 44 NOTE: ALL MANUAL ANTENNA MAST TORQUE REQUIREMENTS FOR ALL VEHICLES ARE 3.4 TO 3.6 N-m (30 to 32 in.lbs.). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891611A Correct Poor Connection At 0.3 Hr. Antenna Lead-In Cable DEALER CODING BASIC PART NO. CONDITION CODE 18813 33 OASIS CODES: 2200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Horn > Alarm Horn Relay > Component Information > Locations Alarm Horn Relay: Locations Body & Chassis Components LH Side Of Trunk, Behind Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Antitheft Mode Switch > Component Information > Locations Antitheft Mode Switch: Locations Body & Chassis Components LH Side Of Trunk, Near Anti-Theft Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Antitheft Relay > Component Information > Locations Antitheft Relay: Locations Body & Chassis Components LH Side Of Trunk, Near Anti-Theft Module Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Customer Interest: > 94103 > May > 94 > Keyless Entry - Key Pad Illumination Non Functional Keyless Entry Key-Pad: Customer Interest Keyless Entry - Key Pad Illumination Non Functional Article No. 94-10-3 05/18/94 ^ DOOR LOCKS - KEYLESS ENTRY SYSTEM - KEYPAD ILLUMINATION DOES NOT FUNCTION ^ KEYLESS ENTRY SYSTEM - KEYPAD ILLUMINATION DOES NOT FUNCTION FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR 1990-92 CONTINENTAL, TOWN CAR This TSB article is being republished in its entirety to request dealers to sort and return the older inventory to the facing PDC'S. See Attention Parts Manager Page of this TSB for information about handling obsolete parts. ISSUE: Keyless entry system keypad illumination may not be functional. This may be due to water entry into the keypad. ACTION: Replace the keypad assembly with an improved design keypad having a date code of 2D01 or later (1992 APRIL 01). Refer to the appropriate Service Manual, Section 01-14B, for removal and installation instructions. NOTE: DATE CODES MAY BE IN EITHER OF TWO CONFIGURATIONS, i.e. "2D01" OR "2DA." THE DATE CODE OF 2DO1 IS "1992/APRIL/01;" THE DATE CODE OF 2EA IS "1992/MAY/1ST WEEK;" SIMILARLY, THE DATE CODE OF 2DB IS "1992/APRIL/2ND WEEK." Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-6-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 941003A Remove And Replace The 0.8 Hr. Keypad Actuator - Town Car 941003B Remove And Replace The 0.6 Hr. Keypad Actuator - Thunderbird/Cougar/Continental DEALER CODING BASIC PART NO. CONDITION CODE 14A626 49 OASIS CODES: 112000, 203000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 94103 > May > 94 > Keyless Entry - Key Pad Illumination Non Functional Keyless Entry Key-Pad: All Technical Service Bulletins Keyless Entry - Key Pad Illumination Non Functional Article No. 94-10-3 05/18/94 ^ DOOR LOCKS - KEYLESS ENTRY SYSTEM - KEYPAD ILLUMINATION DOES NOT FUNCTION ^ KEYLESS ENTRY SYSTEM - KEYPAD ILLUMINATION DOES NOT FUNCTION FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR 1990-92 CONTINENTAL, TOWN CAR This TSB article is being republished in its entirety to request dealers to sort and return the older inventory to the facing PDC'S. See Attention Parts Manager Page of this TSB for information about handling obsolete parts. ISSUE: Keyless entry system keypad illumination may not be functional. This may be due to water entry into the keypad. ACTION: Replace the keypad assembly with an improved design keypad having a date code of 2D01 or later (1992 APRIL 01). Refer to the appropriate Service Manual, Section 01-14B, for removal and installation instructions. NOTE: DATE CODES MAY BE IN EITHER OF TWO CONFIGURATIONS, i.e. "2D01" OR "2DA." THE DATE CODE OF 2DO1 IS "1992/APRIL/01;" THE DATE CODE OF 2EA IS "1992/MAY/1ST WEEK;" SIMILARLY, THE DATE CODE OF 2DB IS "1992/APRIL/2ND WEEK." Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-6-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 941003A Remove And Replace The 0.8 Hr. Keypad Actuator - Town Car 941003B Remove And Replace The 0.6 Hr. Keypad Actuator - Thunderbird/Cougar/Continental DEALER CODING BASIC PART NO. CONDITION CODE 14A626 49 OASIS CODES: 112000, 203000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Key-Pad: > 8921 > Jan > 89 > Driveshaft - Vibration Propeller Shaft: All Technical Service Bulletins Driveshaft - Vibration ^ CROSSMEMBER - CENTER SUPPORT BRACKET INSTALLATION - VEHICLES BUILT BEFORE 2/01/89 ^ VIBRATION - CENTER SUPPORT BRACKET CONTACTS DRIVESHAFT - VEHICLES BUILT BEFORE 2/01/89 Article No. 89-2-1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A driveline vibration between 5-10 MPH (8-16 Km/h) may be caused by the driveshaft contacting the crossmember center support bracket. The crossmember center support bracket may have been initially installed backwards. ACTION: Inspect the position of the crossmember center support bracket to determine if service is required. Refer to the following procedure for service details. FIGURE 1 1. Remove the four (4) bolts holding the body reinforcement, Figure 1. 2. Remove the two (2) bolts and one (1) nut retaining the heat shield. 3. Position the heat shield aside. 4. Make sure the arrow on the center support bracket is pointing toward the rear of the vehicle, Figure 1. If not proceed to Step 5. If okay proceed to Step 8. 5. Remove the two (2) bolts that hold the center support bracket to the body reinforcement, Figure 1. 6. Rotate the center support bracket 180 degrees so the arrow on the bracket points toward the rear of the vehicle. 7. Install the two (2) bolts that hold the center support bracket to the body reinforcement. 8. Reposition the heat shield. 9. Reinstall the two (2) bolts and one (1) nut that retains the heat shield. 10. Reinstall the four (4) bolts that retain the body reinforcement, Figure 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION : 890201A - Inspect TIME: 0.4 Hr. OPERATION: 890201B - Inspect and Correct TIME: 0.5 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Key-Pad: > 8921 > Jan > 89 > Driveshaft - Vibration > Page 7554 DLR. CODING: Basic Part No. 5A041 Condition Code: 79 OASIS CODES: 5950, 7210, 7211, 7212, 7213 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > All Other Service Bulletins for Keyless Entry Key-Pad: > 8921 > Jan > 89 > Driveshaft - Vibration > Page 7560 DLR. CODING: Basic Part No. 5A041 Condition Code: 79 OASIS CODES: 5950, 7210, 7211, 7212, 7213 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 7561 Keyless Entry Key-Pad: Locations Body & Chassis Components Lower Rear Of LH Door Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Amplifier, Sound System > Component Information > Locations Amplifier: Locations Body & Chassis Components Below RH Side Of Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc Player (CD) > Component Information > Technical Service Bulletins > Radio - Locked In Compact Disc Mode Compact Disc Player (CD): Technical Service Bulletins Radio - Locked In Compact Disc Mode RADIO-HIGH-LEVEL AUDIO SYSTEM (HLAS)-LOCKED IN COMPACT DISC MODE-VEHICLES BUILT BEFORE 2/28/89 Article No. 89-15-7 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR ISSUE: An inoperative radio and compact disc player may be caused if a "lock-up" condition occurs when operating the radio in the compact disc mode. When this happens, the C.D. Player will not function and it locks the radio in the "C.D. Mode". ACTION: Use the following service procedure to determine if the compact disc player requires service. 1. Check to see if the radio is "locked up". Make sure the "lock-up" is not due to other factors such as a poor electrical ground or blown fuse. 2. Remove the compact disc player. Refer to the 1989 Thunderbird/Cougar Shop Manual, Page 35-01-7 or the 1989 Continental Car Shop Manual, Page 35-01-8 for removal procedures. 3. Return the C.D. Player to the nearest authorized Ford Repair Station for repair. Refer to Audio Service Bulletin # EX89-6 for details. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891507A Remove & Install Compact 0.6 Hr. Disc Player DEALER CODING BASIC PART NO. CONDITION CODE 18D806 42 OASIS CODES: 2200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Locations Radio/Stereo Noise Filter: Locations Engine Compartment. Below RH Fender Apron Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo > Radio/Stereo Noise Filter > Component Information > Locations > Page 7577 Rear Of Engine Below RH Fender Apron Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 91188 > Sep > 91 > Radio Speakers - Distorted Sound Speaker: Customer Interest Radio Speakers - Distorted Sound Article No. 91-18-8 09/05/91 RADIO-SOUND DISTORTION FROM SPEAKERS-JBL SOUND SYSTEMS-VEHICLES BUILT BEFORE 9/1/90 FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR, TOWN CAR LIGHT TRUCK: 1991 EXPLORER This TSB article is being republished in its entirety to provide vehicle application information in the Parts Block. ISSUE: Objectional sound distortion, which sounds like speaker rattle or vibration when the sound system is set at advanced bass and/or high volume, may be caused by missing foam insulation normally added to the JBL subwoofer speaker during production. ACTION: Install new subwoofer speakers which have been redesigned and are now available. These new subwoofer speakers can be identified by a production date code that began on August 17, 1990 and appears on the speaker enclosure. Refer to the appropriate Car or Truck Shop Manual for service details. NOTE: THE DATE CODE ON THE ENCLOSURE WILL APPEAR AS THE DAY OF THE YEAR (COUNT 1 TO 365), FOLLOWED BY YEAR OF PRODUCTION, FOLLOWED BY SHIFT. EXAMPLE FOR DATE CODE 22801: ^ 228 - DENOTES THE 228TH DAY OF THE YEAR, (AUGUST 17). ^ 0 - DENOTES THE 1990 YEAR OF PRODUCTION. ^ 1 OR 0 LAST DIGIT DENOTES SHIFT. PART NUMBER PART NAME CLASS E9WY-18808-A Enclosure Subwoofer B (Thunderbird / Cougar) FOVY-18808-D Enclosure Assembly Radio C (Town Car) F1TZ-18C804-A Enclosure Amplifier & Bracket C Assembly (Explorer 2 Door) F1TZ-18C804-B Enclosure Amplifier & Bracket C Assembly (Explorer 4 Door) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-16 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911808A Replace Speaker - 0.6 Hr. Thunderbird/Cougar 911808B Replace Speaker - Town 0.3 Hr. Car 911808C Replace Speaker - Explorer 0.6 Hr. (Two Door) 911808D Replace Sreaker - Explorer 0.3 Hr. (Four Door) DEALER CODING BASIC PART NO. CONDITION CODE 18808 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > Customer Interest for Speaker: > 9068 > Mar > 90 > Rear Speakers - Sound Is Distorted Speaker: Customer Interest Rear Speakers - Sound Is Distorted RADIO - REAR SPEAKER - DISTORTED SOUND - VEHICLES BUILT FROM 8/01/88 THROUGH 11/30/89 Article No. 90-6-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The sound from one or both of the conventional rear speakers may be distorted because the speaker was twisted during installation. This can occur if... ^ There is an uneven mounting surface due to the NVH cover installed behind the speaker ^ One or more of the speaker mounting screws was over-tightened. ACTION: Inspect the speaker to make sure four (4) mounting screws were installed. If necessary, install two (2) additional mounting screws. Refer to the following procedure for service details. 1. Loosen the rear speaker mounting screws. 2. If the sound distortion does not go away after loosening the screws, it is not related to this concern. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 35-01 for additional diagnosis. 3. If the distortion is eliminated, proceed as follows: a. Re-secure the speakers. b. Tighten all four (4) mounting screws evenly to 5-10 lb.in. (.6-1.1 N-m). c. If the speaker was mounted with only two (2) screws, install two (2) additional screws (56915-S2). Tighten screws evenly to 5-10 lb.in. (.6-1.1 N-m). 4. Make sure the distortion is no longer present. PART NUMBER PART NAME CLASS E9SZ-18808-A Speaker B 56915-S2 Screws - Pkg. of 6 S OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 900608A Correct Speaker Distortion 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 18808 56 OASIS CODES: 2200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 91188 > Sep > 91 > Radio Speakers - Distorted Sound Speaker: All Technical Service Bulletins Radio Speakers - Distorted Sound Article No. 91-18-8 09/05/91 RADIO-SOUND DISTORTION FROM SPEAKERS-JBL SOUND SYSTEMS-VEHICLES BUILT BEFORE 9/1/90 FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR, TOWN CAR LIGHT TRUCK: 1991 EXPLORER This TSB article is being republished in its entirety to provide vehicle application information in the Parts Block. ISSUE: Objectional sound distortion, which sounds like speaker rattle or vibration when the sound system is set at advanced bass and/or high volume, may be caused by missing foam insulation normally added to the JBL subwoofer speaker during production. ACTION: Install new subwoofer speakers which have been redesigned and are now available. These new subwoofer speakers can be identified by a production date code that began on August 17, 1990 and appears on the speaker enclosure. Refer to the appropriate Car or Truck Shop Manual for service details. NOTE: THE DATE CODE ON THE ENCLOSURE WILL APPEAR AS THE DAY OF THE YEAR (COUNT 1 TO 365), FOLLOWED BY YEAR OF PRODUCTION, FOLLOWED BY SHIFT. EXAMPLE FOR DATE CODE 22801: ^ 228 - DENOTES THE 228TH DAY OF THE YEAR, (AUGUST 17). ^ 0 - DENOTES THE 1990 YEAR OF PRODUCTION. ^ 1 OR 0 LAST DIGIT DENOTES SHIFT. PART NUMBER PART NAME CLASS E9WY-18808-A Enclosure Subwoofer B (Thunderbird / Cougar) FOVY-18808-D Enclosure Assembly Radio C (Town Car) F1TZ-18C804-A Enclosure Amplifier & Bracket C Assembly (Explorer 2 Door) F1TZ-18C804-B Enclosure Amplifier & Bracket C Assembly (Explorer 4 Door) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-16 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911808A Replace Speaker - 0.6 Hr. Thunderbird/Cougar 911808B Replace Speaker - Town 0.3 Hr. Car 911808C Replace Speaker - Explorer 0.6 Hr. (Two Door) 911808D Replace Sreaker - Explorer 0.3 Hr. (Four Door) DEALER CODING BASIC PART NO. CONDITION CODE 18808 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speaker: > 9068 > Mar > 90 > Rear Speakers - Sound Is Distorted Speaker: All Technical Service Bulletins Rear Speakers - Sound Is Distorted RADIO - REAR SPEAKER - DISTORTED SOUND - VEHICLES BUILT FROM 8/01/88 THROUGH 11/30/89 Article No. 90-6-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The sound from one or both of the conventional rear speakers may be distorted because the speaker was twisted during installation. This can occur if... ^ There is an uneven mounting surface due to the NVH cover installed behind the speaker ^ One or more of the speaker mounting screws was over-tightened. ACTION: Inspect the speaker to make sure four (4) mounting screws were installed. If necessary, install two (2) additional mounting screws. Refer to the following procedure for service details. 1. Loosen the rear speaker mounting screws. 2. If the sound distortion does not go away after loosening the screws, it is not related to this concern. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 35-01 for additional diagnosis. 3. If the distortion is eliminated, proceed as follows: a. Re-secure the speakers. b. Tighten all four (4) mounting screws evenly to 5-10 lb.in. (.6-1.1 N-m). c. If the speaker was mounted with only two (2) screws, install two (2) additional screws (56915-S2). Tighten screws evenly to 5-10 lb.in. (.6-1.1 N-m). 4. Make sure the distortion is no longer present. PART NUMBER PART NAME CLASS E9SZ-18808-A Speaker B 56915-S2 Screws - Pkg. of 6 S OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 900608A Correct Speaker Distortion 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 18808 56 OASIS CODES: 2200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest: > 91177 > Aug > 91 > Tape Player - Hissing Noise Tape Player: Customer Interest Tape Player - Hissing Noise Article No. 91-17-7 08/21/91 ^ RADIO - TAPE PLAYER - MAKES HISSING NOISE - CARS WITH VEHICLE MAINTENANCE MONITOR (VMM) ^ NOISE - "HISS" FROM TAPE PLAYER DURING QUIET PASSAGES - VEHICLES WITH VMM FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hissing noise may be heard from the tape player during quiet passages. This occurs because of electromagnetic interference from the transformer being picked up by the head of the tape player. ACTION: Install a new vehicle maintenance monitor. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-38, for service details. NOTE: SUSPECT VEHICLE MAINTENANCE MONITORS MUST BE REPLACED ONLY BY A VMM WITH A DATE CODE OF MAY 1990 OR LATER. THE DATE CODE IS ON A LABEL LOCATED ON THE TOP OF THE MODULE IN MONTH/DAY/YEAR FORMAT. FOR EXAMPLE, 10/09/90 MEANS OCTOBER 9, 1990. THIS ISSUE DOES NOT AFFECT 1991 MODELS. PART NUMBER PART NAME CLASS F1SZ-10E850-A Vehicle Maintenance Monitor B WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911707A Install Vehicle Maintenance 0.3 Hr. Monitor DEALER CODING BASIC PART NO. CONDITION CODE 10E850 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > Customer Interest: > 891412 > Jul > 89 > Radio - Controls Lock Up When In Tape Mode Tape Player: Customer Interest Radio - Controls Lock Up When In Tape Mode RADIO-ELECTRONIC PREMIUM CASSETTE (EPC)- CONTROLS LOCK UP WHEN RADIO IS IN TAPE MODEVEHICLES WITH HIGH LEVEL AUDIO SYSTEM (HLAS) OR JBL AUDIO SYSTEM Article No. 89-14-12 FORD: 1989 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989 BRONCO II ISSUE: The electronic premium cassette (EPC) radio controls may occasionally lock-up when the radio is in the "TAPE" mode. The lock-up usually occurs under the following conditions. ^ When inserting a cassette cartridge with the ignition power switch turned "OFF" and/or with the radio power switch in the "OFF POSITION". ^ When leaving a cassette cartridge inserted in the "TAPE" mode and turning the radio power switch "OFF" or the vehicle ignition switch "OFF". ACTION: To clear the occasional lock-up condition, use the following procedure. 1. While the engine is running a. Turn the radio system power "OFF." b. Turn the radio system power "ON" using a quick motion with the switch. 2. When the vehicle is parked a. Leave the radio system power "ON." b. Turn the ignition switch "OFF." c. Turn the ignition switch "ON." PREVENTIVE ACTIONS To prevent the lock-up condition, use the following procedure. 1. Eject the tape prior to switching the radio system power "OFF." 2. Do not insert tape when the vehicle ignition or radio system power is "OFF." NOTE: REPLACING THE RADIO WILL NOT FIX THE LOCK-UP CONDITION. ADVISING THE CUSTOMER HOW TO CLEAR AND PREVENT THE LOCK-UP CONDITION WILL ENHANCE HIS SATIFACTION WITH THE UNIT AND ELIMINATE UNNECESSARY SERVICE CALLS. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91177 > Aug > 91 > Tape Player Hissing Noise Tape Player: All Technical Service Bulletins Tape Player - Hissing Noise Article No. 91-17-7 08/21/91 ^ RADIO - TAPE PLAYER - MAKES HISSING NOISE - CARS WITH VEHICLE MAINTENANCE MONITOR (VMM) ^ NOISE - "HISS" FROM TAPE PLAYER DURING QUIET PASSAGES - VEHICLES WITH VMM FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hissing noise may be heard from the tape player during quiet passages. This occurs because of electromagnetic interference from the transformer being picked up by the head of the tape player. ACTION: Install a new vehicle maintenance monitor. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-38, for service details. NOTE: SUSPECT VEHICLE MAINTENANCE MONITORS MUST BE REPLACED ONLY BY A VMM WITH A DATE CODE OF MAY 1990 OR LATER. THE DATE CODE IS ON A LABEL LOCATED ON THE TOP OF THE MODULE IN MONTH/DAY/YEAR FORMAT. FOR EXAMPLE, 10/09/90 MEANS OCTOBER 9, 1990. THIS ISSUE DOES NOT AFFECT 1991 MODELS. PART NUMBER PART NAME CLASS F1SZ-10E850-A Vehicle Maintenance Monitor B WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911707A Install Vehicle Maintenance 0.3 Hr. Monitor DEALER CODING BASIC PART NO. CONDITION CODE 10E850 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 891412 > Jul > 89 > Radio Controls Lock Up When In Tape Mode Tape Player: All Technical Service Bulletins Radio - Controls Lock Up When In Tape Mode RADIO-ELECTRONIC PREMIUM CASSETTE (EPC)- CONTROLS LOCK UP WHEN RADIO IS IN TAPE MODEVEHICLES WITH HIGH LEVEL AUDIO SYSTEM (HLAS) OR JBL AUDIO SYSTEM Article No. 89-14-12 FORD: 1989 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989 BRONCO II ISSUE: The electronic premium cassette (EPC) radio controls may occasionally lock-up when the radio is in the "TAPE" mode. The lock-up usually occurs under the following conditions. ^ When inserting a cassette cartridge with the ignition power switch turned "OFF" and/or with the radio power switch in the "OFF POSITION". ^ When leaving a cassette cartridge inserted in the "TAPE" mode and turning the radio power switch "OFF" or the vehicle ignition switch "OFF". ACTION: To clear the occasional lock-up condition, use the following procedure. 1. While the engine is running a. Turn the radio system power "OFF." b. Turn the radio system power "ON" using a quick motion with the switch. 2. When the vehicle is parked a. Leave the radio system power "ON." b. Turn the ignition switch "OFF." c. Turn the ignition switch "ON." PREVENTIVE ACTIONS To prevent the lock-up condition, use the following procedure. 1. Eject the tape prior to switching the radio system power "OFF." 2. Do not insert tape when the vehicle ignition or radio system power is "OFF." NOTE: REPLACING THE RADIO WILL NOT FIX THE LOCK-UP CONDITION. ADVISING THE CUSTOMER HOW TO CLEAR AND PREVENT THE LOCK-UP CONDITION WILL ENHANCE HIS SATIFACTION WITH THE UNIT AND ELIMINATE UNNECESSARY SERVICE CALLS. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tape Player: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times Valve: All Technical Service Bulletins Engine - Stalls/Hesitates/Long Cranking Times Article No. 93-12-6 06/09/93 ^ HESITATION ON ACCELERATION AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ IDLE - ROUGH - AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ LONG CRANK TIMES - 2.3L, 2.3L OHC, 3.8L NA ^ STALL AT IDLE AND UPON GEAR ENGAGEMENT AFTER COLD START - 2.3L, 2.3L OHC, 3.8L NA ^ STALL AT IDLE AND UPON GEAR ENGAGEMENT AFTER COLD START - 2.3L, 2.3L OHC. 3.8L NA ^ ENGINE - INTAKE VALVE CLEANING PROCEDURE - 2.3L, 2.3L OHC, 3.8L NATURALLY ASPIRATED FORD: 1988-92 MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1988-92 CONTINENTAL, COUGAR, SABLE, TOPAZ LIGHT TRUCK: 1988-92 RANGER This TSB Article is being republished in its entirety to update the Intake Valve Deposit (IVD) inspection/cleaning procedure and to provide technical service tips for the 2.3L OHC engine. ISSUE: Vehicles with excessive intake valve deposit (IVD) may exhibit the following driveability concerns after a cold start. These drive concerns may also result from the use of fuels that have low volatility, such as high octane, "premium" fuels. ^ Long crank times ^ Idle stall after initial cold start ^ Stall upon gear engagement ^ Rough idle after cold start ^ Hesitation on acceleration after cold start ^ Hesitation/Stall on initial acceleration (3.8L N/A applications) When these deposits are dry, they act like sponges which absorb engine fuel. This may result in a lean engine run condition after an initial cold start. The drive conditions normally occur at ambient temperatures of 40~ F (4~ C) to 70~ F (21~ C). ACTION: An IVD inspection and cleaning procedure has been developed using the Rotunda 014-00975 Carbon Blaster Kit. If service is required, use the following procedure to correct the stated driveability concerns. NOTE: MANY FLUIDS ARE AVAILABLE TO CLEAN FUEL INJECTORS. SOME INJECTOR CLEANING FLUIDS ALSO CLAIM TO REMOVE INTAKE VALVE DEPOSITS (IVD). ENGINEERING EVALUATION OF THESE FLUIDS INDICATES NO ABILITY TO REMOVE THE IVD CAUSING THE STATED DRIVEABILITY CONCERNS. IF DRIVEABILITY CONCERNS HAVE BEEN AFFECTED BY INJECTOR CLEANING FLUIDS, IT IS MOST LIKELY DUE TO CLEAN-UP OF PORT FUEL INJECTOR DEPOSITS. IVD IS MORE DIFFICULT TO REMOVE THAN PORT FUEL INJECTOR DEPOSITS. IVD MUST BE COMPLETELY REMOVED AS OUTLINED IN THIS TSB ARTICLE TO RESTORE COLD-START DRIVEABILITY PERFORMANCE. THE OVERUSE OF THESE FLUIDS MAY CAUSE ENGINE DAMAGE NOT COVERED UNDER WARRANTY. 1. Perform underhood inspection of vacuum lines and wiring. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tape Player: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 7625 2. Perform normal Engine Emissions Diagnostics. Refer to the Engine/Emissions Diagnostics Shop Manual or the Powertrain Control/Emissions Diagnosis Manual. 3. If normal Engine/Emissions Diagnostics have not resolved the driveability concerns, proceed with the following IVD inspection. INTAKE VALVE DEPOSIT INSPECTION PROCEDURE 1. Remove any two (2) spark plugs. Use a remote starter switch to bump the engine over until the intake valve is fully open in the cylinder to be inspected. 2. Using the 014-00975 Automotive Borescope or equivalent, inspect the backside of the intake valves through the spark plug holes for the presence of carbon deposits. CAUTION: DO NOT BUMP THE ENGINE WITH THE BORESCOPE IN THE SPARK PLUG HOLE OR ATTEMPT TO VIEW THE VALVE WHILE ROTATING THE ENGINE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. CAUTION: DO NOT POWER THE BORESCOPE LIGHT SOURCE FROM A CAR BATTERY WHILE IT IS UNDER CHARGE. FOR EXAMPLE, IF THE ENGINE IS RUNNING, THE LAMP MAY FAIL. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tape Player: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 7626 3. Compare the deposits with the Intake Valve Deposit Rating System Chart, Figure 1. a. If either of the intake valves appear to have a carbon deposit level of 7 or less (lower number rating), intake valve cleaning is required. b. Proceed to the IVD Cleaning Procedure. 4. If no carbon deposits are seen or the deposit level is 8 or cleaner, the drive concern may be the result of low volatility fuel. Refer to TSB 91-8-13 and proceed to Fuel Recommendation. CLEANING PROCEDURE NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tape Player: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 7627 BEFORE BEGINNING THE IVD CLEANING PROCEDURE, USE THE FOLLOWING CARBON BLASTER TIPS: ^ Be sure that compressed shop air is dry. Drain compressor of water regularly. ^ remove any in-line equipment oilers from the air line to be used with the carbon blaster ^ Be sure to store walnut shells in a water tight container with the lid on. ^ Remove unused walnut shells from the carbon blaster when IVD procedure is completed. Do not store walnut shells in carbon blaster. 1. Remove the upper intake manifold assembly, fuel rail and injectors. Refer to the instructions in the appropriate Service Manual. 2. Insert the Rotunda 014-00975 Automotive Borescope or equivalent through the fuel injector holes into the lower intake manifold to determine which intake valves are in the closed position. CAUTION: DO NOT ROTATE THE ENGINE WITH THE BORESCOPE IN THE FUEL INJECTOR HOLE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. 3. Perform the intake valve carbon cleaning procedure, using the Rotunda Tool 014-00975 Carbon Blaster and Automotive Borescope Kit, or equivalent, on the intake valves that are in the closed position. NOTE: DETAILED WRITTEN INSTRUCTIONS AND A PROCEDURAL VIDEO TAPE ARE INCLUDED WITH THE ROTUNDA CARBON BLASTER AND AUTOMOTIVE BORESCOPE KIT. TECHNICAL TIP - 2.3L OHC ENGINE When IVD cleaning is performed on the 2.3L OHC dual plug engine, the vacuum should be connected to the lower intake manifold as follows: ^ Remove flex hose and manifold adapter from the hand held vacuum. ^ Insert tapered end of vacuum hose into intake port of manifold using a twisting motion to ensure a tight fit. ^ Proceed with the IVD cleaning process. (CLEANING PROCEDURE CONTINUED) When the cleaning procedure is complete, the backside of the intake valve and cylinder port area surrounding the valve will be free of deposits. Confirm complete deposit removal by borescope inspection. (Normal IVD cleaning time is 1 to 1-1/2 minutes per valve.) 4. Bump the engine until the remaining intake valves to be cleaned are in the closed position. Repeat Cleaning Procedure Step # 3. 5. Inspect all intake valves to verify complete carbon deposit removal. 6. Install the fuel rail, fuel injectors, and upper intake manifold using a new intake manifold gasket. Refer to the Dealer Master Parts Catalog for correct part number. 7. Proceed to FUEL RECOMMENDATION. FUEL RECOMMENDATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tape Player: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 7628 Fuels that do not contain the proper detergent additives may result in the formation of intake system deposits, including clogged port fuel injectors and intake valve deposits. To assist the customer in selecting the proper fuel, provide the customer with a copy of the "Clean Gasoline" Flyer, Figure 2. Refer to OASIS special service messages 9000 through 9023 to identify appropriate brands of fuel. To access these messages, enter the vehicle VIN and Service Code 404000. The fuel list will be updated periodically. Gasolines on this list are advertised as having intake system deposit control detergents. Regular use of these fuels should minimize or eliminate accumulation of intake system deposits. NOTE: IF A HIGH QUALITY FUEL IS CONTINUOUSLY USED WHICH CONTAINS INTAKE SYSTEM DEPOSIT CONTROL DETERGENTS AND OTHER ADDITIVES, AFTERMARKET ADDITIVES SHOULD NEVER NEED TO BE ADDED TO THE FUEL TANK. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tape Player: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 7629 Fuels that vaporize poorly may cause similar symptoms or may contribute to symptoms related to intake system deposits. Refer to TSB 91-8-13 for additional information. OTHER APPLICABLE ARTICLES: 91-10-9, 91-11-4, 91-8-13 SUPERSEDES: 92-19-3 WARRANTY STATUS: Eligible Under Basic Warranty Coverage and Powertrain For 1991 And Prior Cars And Light Trucks (Excluding Lincolns), Eligible For Bumper To Bumper For 1991 Lincolns And All 1992 Cars And Light Trucks OPERATION DESCRIPTION TIME 931206A Perform Engine Emission 0.5 Hr. Test And Underhood Inspection 931206B Perform Engine Emission 1.0 Hr. Test, Underhood Inspection And Intake Valve Inspection 931206C Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Ranger 931206D Perform Engine Emission 3.3 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Tempo/Topaz 931206E Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Mustang 931206F Perform Engine Emission 4.1 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Taurus/Sable And Continental 931206G Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Thunderbird/Cougar DEALER CODING BASIC PART NO. CONDITION CODE 6507 49 OASIS CODES: 499000, 602300, 607000, 607400, 608000, 608400, 609000, 609400, 611000, 611500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tape Player: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 7635 2. Perform normal Engine Emissions Diagnostics. Refer to the Engine/Emissions Diagnostics Shop Manual or the Powertrain Control/Emissions Diagnosis Manual. 3. If normal Engine/Emissions Diagnostics have not resolved the driveability concerns, proceed with the following IVD inspection. INTAKE VALVE DEPOSIT INSPECTION PROCEDURE 1. Remove any two (2) spark plugs. Use a remote starter switch to bump the engine over until the intake valve is fully open in the cylinder to be inspected. 2. Using the 014-00975 Automotive Borescope or equivalent, inspect the backside of the intake valves through the spark plug holes for the presence of carbon deposits. CAUTION: DO NOT BUMP THE ENGINE WITH THE BORESCOPE IN THE SPARK PLUG HOLE OR ATTEMPT TO VIEW THE VALVE WHILE ROTATING THE ENGINE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. CAUTION: DO NOT POWER THE BORESCOPE LIGHT SOURCE FROM A CAR BATTERY WHILE IT IS UNDER CHARGE. FOR EXAMPLE, IF THE ENGINE IS RUNNING, THE LAMP MAY FAIL. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tape Player: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 7636 3. Compare the deposits with the Intake Valve Deposit Rating System Chart, Figure 1. a. If either of the intake valves appear to have a carbon deposit level of 7 or less (lower number rating), intake valve cleaning is required. b. Proceed to the IVD Cleaning Procedure. 4. If no carbon deposits are seen or the deposit level is 8 or cleaner, the drive concern may be the result of low volatility fuel. Refer to TSB 91-8-13 and proceed to Fuel Recommendation. CLEANING PROCEDURE NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tape Player: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 7637 BEFORE BEGINNING THE IVD CLEANING PROCEDURE, USE THE FOLLOWING CARBON BLASTER TIPS: ^ Be sure that compressed shop air is dry. Drain compressor of water regularly. ^ remove any in-line equipment oilers from the air line to be used with the carbon blaster ^ Be sure to store walnut shells in a water tight container with the lid on. ^ Remove unused walnut shells from the carbon blaster when IVD procedure is completed. Do not store walnut shells in carbon blaster. 1. Remove the upper intake manifold assembly, fuel rail and injectors. Refer to the instructions in the appropriate Service Manual. 2. Insert the Rotunda 014-00975 Automotive Borescope or equivalent through the fuel injector holes into the lower intake manifold to determine which intake valves are in the closed position. CAUTION: DO NOT ROTATE THE ENGINE WITH THE BORESCOPE IN THE FUEL INJECTOR HOLE. THIS MAY RESULT IN BORESCOPE OR ENGINE DAMAGE. 3. Perform the intake valve carbon cleaning procedure, using the Rotunda Tool 014-00975 Carbon Blaster and Automotive Borescope Kit, or equivalent, on the intake valves that are in the closed position. NOTE: DETAILED WRITTEN INSTRUCTIONS AND A PROCEDURAL VIDEO TAPE ARE INCLUDED WITH THE ROTUNDA CARBON BLASTER AND AUTOMOTIVE BORESCOPE KIT. TECHNICAL TIP - 2.3L OHC ENGINE When IVD cleaning is performed on the 2.3L OHC dual plug engine, the vacuum should be connected to the lower intake manifold as follows: ^ Remove flex hose and manifold adapter from the hand held vacuum. ^ Insert tapered end of vacuum hose into intake port of manifold using a twisting motion to ensure a tight fit. ^ Proceed with the IVD cleaning process. (CLEANING PROCEDURE CONTINUED) When the cleaning procedure is complete, the backside of the intake valve and cylinder port area surrounding the valve will be free of deposits. Confirm complete deposit removal by borescope inspection. (Normal IVD cleaning time is 1 to 1-1/2 minutes per valve.) 4. Bump the engine until the remaining intake valves to be cleaned are in the closed position. Repeat Cleaning Procedure Step # 3. 5. Inspect all intake valves to verify complete carbon deposit removal. 6. Install the fuel rail, fuel injectors, and upper intake manifold using a new intake manifold gasket. Refer to the Dealer Master Parts Catalog for correct part number. 7. Proceed to FUEL RECOMMENDATION. FUEL RECOMMENDATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tape Player: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 7638 Fuels that do not contain the proper detergent additives may result in the formation of intake system deposits, including clogged port fuel injectors and intake valve deposits. To assist the customer in selecting the proper fuel, provide the customer with a copy of the "Clean Gasoline" Flyer, Figure 2. Refer to OASIS special service messages 9000 through 9023 to identify appropriate brands of fuel. To access these messages, enter the vehicle VIN and Service Code 404000. The fuel list will be updated periodically. Gasolines on this list are advertised as having intake system deposit control detergents. Regular use of these fuels should minimize or eliminate accumulation of intake system deposits. NOTE: IF A HIGH QUALITY FUEL IS CONTINUOUSLY USED WHICH CONTAINS INTAKE SYSTEM DEPOSIT CONTROL DETERGENTS AND OTHER ADDITIVES, AFTERMARKET ADDITIVES SHOULD NEVER NEED TO BE ADDED TO THE FUEL TANK. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player > Component Information > Technical Service Bulletins > All Other Service Bulletins for Tape Player: > 93126 > Jun > 93 > Engine - Stalls/Hesitates/Long Cranking Times > Page 7639 Fuels that vaporize poorly may cause similar symptoms or may contribute to symptoms related to intake system deposits. Refer to TSB 91-8-13 for additional information. OTHER APPLICABLE ARTICLES: 91-10-9, 91-11-4, 91-8-13 SUPERSEDES: 92-19-3 WARRANTY STATUS: Eligible Under Basic Warranty Coverage and Powertrain For 1991 And Prior Cars And Light Trucks (Excluding Lincolns), Eligible For Bumper To Bumper For 1991 Lincolns And All 1992 Cars And Light Trucks OPERATION DESCRIPTION TIME 931206A Perform Engine Emission 0.5 Hr. Test And Underhood Inspection 931206B Perform Engine Emission 1.0 Hr. Test, Underhood Inspection And Intake Valve Inspection 931206C Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Ranger 931206D Perform Engine Emission 3.3 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Tempo/Topaz 931206E Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 2.3L Mustang 931206F Perform Engine Emission 4.1 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Taurus/Sable And Continental 931206G Perform Engine Emission 3.8 Hr. Test, Underhood Inspection, Intake Valve Inspection And Cleaning Of Intake Valves - 1988-1992 3.8L N/A Thunderbird/Cougar DEALER CODING BASIC PART NO. CONDITION CODE 6507 49 OASIS CODES: 499000, 602300, 607000, 607400, 608000, 608400, 609000, 609400, 611000, 611500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Horn Relay > Component Information > Locations Alarm Horn Relay: Locations Body & Chassis Components LH Side Of Trunk, Behind Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Alarm Module, (Vehicle Antitheft) > Component Information > Locations Alarm Module: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Antitheft Relay > Component Information > Locations Antitheft Relay: Locations Body & Chassis Components LH Side Of Trunk, Near Anti-Theft Module Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional Equipment > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Antenna Switch, Power > Component Information > Locations Antenna Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional Equipment > Antitheft Mode Switch > Component Information > Locations Antitheft Mode Switch: Locations Body & Chassis Components LH Side Of Trunk, Near Anti-Theft Relay Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest: > 9192 > May > 91 > Paint - Paint Blistering or Peeling Off Bumper Covers Front Bumper Cover / Fascia: Customer Interest Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. 6. Blow off the area with compressed air to remove any dirt and sanding residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest: > 9192 > May > 91 > Paint - Paint Blistering or Peeling Off Bumper Covers > Page 7671 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. 13. Apply top coat (body color) where necessary. 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update Front Bumper Cover / Fascia: All Technical Service Bulletins Bumper Cover - Repair Materials Update Article No. 93-24-1 11/24/93 ^ BUMPERS/BUMPER COVERS - IMPROVED REPAIR MATERIALS ^ SERVICE MANUALS - 1984/94 - BUMPER AND FLEXIBLE PART REPAIR MATERIAL UPDATE FORD: 1979-94 MUSTANG 1980-94 THUNDERBIRD 1984-90 ESCORT 1986-94 TAURUS, TEMPO 1991-94 ESCORT 1992-94 CROWN VICTORIA LINCOLN-MERCURY: 1979-86 CAPRI 1980-94 COUGAR 1984-87 LYNX 1986-94 SABLE, TOPAZ 1988-94 CONTINENTAL 1990-94 TOWN CAR 1991-94 CAPRI, TRACER 1992-94 GRAND MARQUIS 1993-94 MARK VIII LIGHT TRUCK: 1986-94 AEROSTAR ISSUE: The current 3M Flexible Parts Repair Material (3M part # 05900 and # 05901) called out in Service Manuals, TSB'S, Collision Repair Manuals and Shop Tips has been discontinued. This material is being replaced by a new and improved product. The change took place on approximately October 1, 1993. ACTION: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update > Page 7677 Refer to Figures 1 and 2 for manufacturer's information on the new 3M P.R.O. Fill EZ-Sand, Part # 05895 and # 05896 and P.R.O. Fill Automix, Part # 05897. This new material should be used wherever the the discontinued material is called out. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update > Page 7678 OASIS CODES: 106000, 108000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > 9192 > May > 91 > Paint - Paint Blistering or Peeling Off Bumper Covers Front Bumper Cover / Fascia: All Technical Service Bulletins Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. 6. Blow off the area with compressed air to remove any dirt and sanding residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Bumper Cover / Fascia: > 9192 > May > 91 > Paint - Paint Blistering or Peeling Off Bumper Covers > Page 7683 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. 13. Apply top coat (body color) where necessary. 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update Front Bumper Cover / Fascia: All Technical Service Bulletins Bumper Cover - Repair Materials Update Article No. 93-24-1 11/24/93 ^ BUMPERS/BUMPER COVERS - IMPROVED REPAIR MATERIALS ^ SERVICE MANUALS - 1984/94 - BUMPER AND FLEXIBLE PART REPAIR MATERIAL UPDATE FORD: 1979-94 MUSTANG 1980-94 THUNDERBIRD 1984-90 ESCORT 1986-94 TAURUS, TEMPO 1991-94 ESCORT 1992-94 CROWN VICTORIA LINCOLN-MERCURY: 1979-86 CAPRI 1980-94 COUGAR 1984-87 LYNX 1986-94 SABLE, TOPAZ 1988-94 CONTINENTAL 1990-94 TOWN CAR 1991-94 CAPRI, TRACER 1992-94 GRAND MARQUIS 1993-94 MARK VIII LIGHT TRUCK: 1986-94 AEROSTAR ISSUE: The current 3M Flexible Parts Repair Material (3M part # 05900 and # 05901) called out in Service Manuals, TSB'S, Collision Repair Manuals and Shop Tips has been discontinued. This material is being replaced by a new and improved product. The change took place on approximately October 1, 1993. ACTION: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update > Page 7689 Refer to Figures 1 and 2 for manufacturer's information on the new 3M P.R.O. Fill EZ-Sand, Part # 05895 and # 05896 and P.R.O. Fill Automix, Part # 05897. This new material should be used wherever the the discontinued material is called out. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update > Page 7690 OASIS CODES: 106000, 108000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 7691 Front Bumper Cover / Fascia: By Symptom Technical Service Bulletin # 9192 Date: 910501 Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 7692 6. Blow off the area with compressed air to remove any dirt and sanding residue. 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. 13. Apply top coat (body color) where necessary. 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Technical Service Bulletin # 9192 Date: 910501 Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 7693 LINCOLN-MERCURY: 1989-91 COUGAR This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. 6. Blow off the area with compressed air to remove any dirt and sanding residue. 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Front Bumper > Front Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Front Bumper Cover / Fascia: > Page 7694 13. Apply top coat (body color) where necessary. 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest: > 9192 > May > 91 > Paint - Paint Blistering or Peeling Off Bumper Covers Rear Bumper Cover / Fascia: Customer Interest Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. 6. Blow off the area with compressed air to remove any dirt and sanding residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > Customer Interest: > 9192 > May > 91 > Paint - Paint Blistering or Peeling Off Bumper Covers > Page 7704 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. 13. Apply top coat (body color) where necessary. 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update Rear Bumper Cover / Fascia: All Technical Service Bulletins Bumper Cover - Repair Materials Update Article No. 93-24-1 11/24/93 ^ BUMPERS/BUMPER COVERS - IMPROVED REPAIR MATERIALS ^ SERVICE MANUALS - 1984/94 - BUMPER AND FLEXIBLE PART REPAIR MATERIAL UPDATE FORD: 1979-94 MUSTANG 1980-94 THUNDERBIRD 1984-90 ESCORT 1986-94 TAURUS, TEMPO 1991-94 ESCORT 1992-94 CROWN VICTORIA LINCOLN-MERCURY: 1979-86 CAPRI 1980-94 COUGAR 1984-87 LYNX 1986-94 SABLE, TOPAZ 1988-94 CONTINENTAL 1990-94 TOWN CAR 1991-94 CAPRI, TRACER 1992-94 GRAND MARQUIS 1993-94 MARK VIII LIGHT TRUCK: 1986-94 AEROSTAR ISSUE: The current 3M Flexible Parts Repair Material (3M part # 05900 and # 05901) called out in Service Manuals, TSB'S, Collision Repair Manuals and Shop Tips has been discontinued. This material is being replaced by a new and improved product. The change took place on approximately October 1, 1993. ACTION: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update > Page 7710 Refer to Figures 1 and 2 for manufacturer's information on the new 3M P.R.O. Fill EZ-Sand, Part # 05895 and # 05896 and P.R.O. Fill Automix, Part # 05897. This new material should be used wherever the the discontinued material is called out. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update > Page 7711 OASIS CODES: 106000, 108000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Bumper Cover / Fascia: > 9192 > May > 91 > Paint Paint Blistering or Peeling Off Bumper Covers Rear Bumper Cover / Fascia: All Technical Service Bulletins Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. 6. Blow off the area with compressed air to remove any dirt and sanding residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Technical Service Bulletins for Rear Bumper Cover / Fascia: > 9192 > May > 91 > Paint Paint Blistering or Peeling Off Bumper Covers > Page 7716 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. 13. Apply top coat (body color) where necessary. 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update Rear Bumper Cover / Fascia: All Technical Service Bulletins Bumper Cover - Repair Materials Update Article No. 93-24-1 11/24/93 ^ BUMPERS/BUMPER COVERS - IMPROVED REPAIR MATERIALS ^ SERVICE MANUALS - 1984/94 - BUMPER AND FLEXIBLE PART REPAIR MATERIAL UPDATE FORD: 1979-94 MUSTANG 1980-94 THUNDERBIRD 1984-90 ESCORT 1986-94 TAURUS, TEMPO 1991-94 ESCORT 1992-94 CROWN VICTORIA LINCOLN-MERCURY: 1979-86 CAPRI 1980-94 COUGAR 1984-87 LYNX 1986-94 SABLE, TOPAZ 1988-94 CONTINENTAL 1990-94 TOWN CAR 1991-94 CAPRI, TRACER 1992-94 GRAND MARQUIS 1993-94 MARK VIII LIGHT TRUCK: 1986-94 AEROSTAR ISSUE: The current 3M Flexible Parts Repair Material (3M part # 05900 and # 05901) called out in Service Manuals, TSB'S, Collision Repair Manuals and Shop Tips has been discontinued. This material is being replaced by a new and improved product. The change took place on approximately October 1, 1993. ACTION: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update > Page 7722 Refer to Figures 1 and 2 for manufacturer's information on the new 3M P.R.O. Fill EZ-Sand, Part # 05895 and # 05896 and P.R.O. Fill Automix, Part # 05897. This new material should be used wherever the the discontinued material is called out. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > 93241 > Nov > 93 > Bumper Cover - Repair Materials Update > Page 7723 OASIS CODES: 106000, 108000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > Page 7724 Rear Bumper Cover / Fascia: By Symptom Technical Service Bulletin # 9192 Date: 910501 Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > Page 7725 6. Blow off the area with compressed air to remove any dirt and sanding residue. 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. 13. Apply top coat (body color) where necessary. 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Technical Service Bulletin # 9192 Date: 910501 Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > Page 7726 LINCOLN-MERCURY: 1989-91 COUGAR This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. 6. Blow off the area with compressed air to remove any dirt and sanding residue. 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Bumper > Rear Bumper > Rear Bumper Cover / Fascia > System Information > Technical Service Bulletins > All Other Service Bulletins for Rear Bumper Cover / Fascia: > Page 7727 13. Apply top coat (body color) where necessary. 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor Cowl: Customer Interest Cowl - Water Leaks On Passenger Side Front Floor Article No. 91-15-1 07/24/91 LEAK - WATER - PASSENGER SIDE FRONT FLOOR FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: Water leaks may occur on the passenger side front floor area. This usually happens during heavy rain, with the car parked nose up or during high blower operation while driving. Water enters the right hand cowl top air vent because of inadequate sealing around the air intake collar. Figure 1 ACTION: Install an extension assembly - cowl vent deflector and a screen assembly - cowl vent right hand side. Refer to the following procedure for service details. 1. Open the hood and remove the right and left hand windshield wiper arms. 2. Remove the engine compartment seal from the front edge of the cowl top leaf screen, Figure 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor > Page 7736 Figure 2 3. Remove ten (10) screws holding the cowl top leaf screens, Figure 2. Carefully position the left hand screen on the windshield out of the way. NOTE: IT IS NOT NECESSARY TO DISCONNECT THE WASHER HOSES ON THE LEFT HAND SIDE. 4. Remove and throw away the right hand screen. 5. Apply black silicone rubber sealer (D6AZ-19562-BA) to the upper cowl body seam behind the A/C air inlet. a. A continuous bead of sealer must be applied to the rear cowl body seam around the right corner and up the right seam to the cowl drain, near the edge of the hood hinge. b. Inspect the seal between the air inlet and cowl surface. Apply sealer as required to assure a water tight seal. Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor > Page 7737 Figure 4 6. Install the extension assembly - cowl vent deflector (F1SZ-63021B26-A) as shown in Figures 3 and 4. a. Snap the extension assembly on top of the existing collar. b. Be sure that the higher vertical wall is facing the front of the car. NOTE: PLACE BOTH HANDS OVER THE ENDS OF THE PART AND EXERT AN EQUAL AMOUNT OF FORCE TO FASTEN THE SNAPS. 7. Install the new screen assembly - cowl vent right hand (F1SZ-63018A16-A) onto the right hand side of the vehicle. 8. Reinstall all removed parts on the car. PART NUMBER PART NAME CLASS F1SZ-63021B26-A Extension Assembly - Cowl BG Vent Deflector F1SZ-83018A16-A Screen Assembly - Cowl Vent B (RH) D6AZ-19562-BA Silicone Rubber - Black B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-23-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911501A Install Deflector And Screen 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7001934 35 OASIS CODES: 110000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor Cowl: All Technical Service Bulletins Cowl - Water Leaks On Passenger Side Front Floor Article No. 91-15-1 07/24/91 LEAK - WATER - PASSENGER SIDE FRONT FLOOR FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: Water leaks may occur on the passenger side front floor area. This usually happens during heavy rain, with the car parked nose up or during high blower operation while driving. Water enters the right hand cowl top air vent because of inadequate sealing around the air intake collar. Figure 1 ACTION: Install an extension assembly - cowl vent deflector and a screen assembly - cowl vent right hand side. Refer to the following procedure for service details. 1. Open the hood and remove the right and left hand windshield wiper arms. 2. Remove the engine compartment seal from the front edge of the cowl top leaf screen, Figure 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor > Page 7743 Figure 2 3. Remove ten (10) screws holding the cowl top leaf screens, Figure 2. Carefully position the left hand screen on the windshield out of the way. NOTE: IT IS NOT NECESSARY TO DISCONNECT THE WASHER HOSES ON THE LEFT HAND SIDE. 4. Remove and throw away the right hand screen. 5. Apply black silicone rubber sealer (D6AZ-19562-BA) to the upper cowl body seam behind the A/C air inlet. a. A continuous bead of sealer must be applied to the rear cowl body seam around the right corner and up the right seam to the cowl drain, near the edge of the hood hinge. b. Inspect the seal between the air inlet and cowl surface. Apply sealer as required to assure a water tight seal. Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor > Page 7744 Figure 4 6. Install the extension assembly - cowl vent deflector (F1SZ-63021B26-A) as shown in Figures 3 and 4. a. Snap the extension assembly on top of the existing collar. b. Be sure that the higher vertical wall is facing the front of the car. NOTE: PLACE BOTH HANDS OVER THE ENDS OF THE PART AND EXERT AN EQUAL AMOUNT OF FORCE TO FASTEN THE SNAPS. 7. Install the new screen assembly - cowl vent right hand (F1SZ-63018A16-A) onto the right hand side of the vehicle. 8. Reinstall all removed parts on the car. PART NUMBER PART NAME CLASS F1SZ-63021B26-A Extension Assembly - Cowl BG Vent Deflector F1SZ-83018A16-A Screen Assembly - Cowl Vent B (RH) D6AZ-19562-BA Silicone Rubber - Black B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-23-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911501A Install Deflector And Screen 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7001934 35 OASIS CODES: 110000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > Customer Interest for Front Door Interior Handle: > 90194 > Sep > 90 > Interior Door Handles - Pinch Fingers Front Door Interior Handle: Customer Interest Interior Door Handles - Pinch Fingers Article No. 90-19-4 HANDLE - DOOR - INTERIOR - PINCHES OCCUPANT'S FINGERS FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The inside door handies, in some instances, may pinch the occupant's finger(s) between the handle and the door trim cup when they are operated. This occurs because of the design of the door handles. ACTION: Install revised inside door handle cups and door latch remote control assemblies. Refer to the foilowing procedure for service details. 1. Remove the existing door inside handle cups and door latch remote control assemblies from both doors. Refer to the 1989 or 1990 Thunderbird/Cougar Shop Manual, pages 44-16-4 & 45-03-2, for removal information. 2. Install two (2) revised door inside handle cups and two (2) door latch remote control assemblies. ^ Refer to the two previously mentioned Shop Manual pages for installation details. ^ Refer to the parts block for the correct service parts. 3. Check the operation of the door handles to be certain that the new assemblies are functioning correctly. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901904A Install Door Handle - Both 0.3 Hr. Sides DEALER CODING BASIC PART NO. CONDITION CODE 7021818 41 OASIS CODES: 112000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > 90194 > Sep > 90 > Interior Door Handles - Pinch Fingers Front Door Interior Handle: All Technical Service Bulletins Interior Door Handles - Pinch Fingers Article No. 90-19-4 HANDLE - DOOR - INTERIOR - PINCHES OCCUPANT'S FINGERS FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The inside door handies, in some instances, may pinch the occupant's finger(s) between the handle and the door trim cup when they are operated. This occurs because of the design of the door handles. ACTION: Install revised inside door handle cups and door latch remote control assemblies. Refer to the foilowing procedure for service details. 1. Remove the existing door inside handle cups and door latch remote control assemblies from both doors. Refer to the 1989 or 1990 Thunderbird/Cougar Shop Manual, pages 44-16-4 & 45-03-2, for removal information. 2. Install two (2) revised door inside handle cups and two (2) door latch remote control assemblies. ^ Refer to the two previously mentioned Shop Manual pages for installation details. ^ Refer to the parts block for the correct service parts. 3. Check the operation of the door handles to be certain that the new assemblies are functioning correctly. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901904A Install Door Handle - Both 0.3 Hr. Sides DEALER CODING BASIC PART NO. CONDITION CODE 7021818 41 OASIS CODES: 112000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > Page 7762 Front Door Interior Handle: By Symptom Technical Service Bulletin # 90194 Date: 900913 Interior Door Handles - Pinch Fingers Article No. 90-19-4 HANDLE - DOOR - INTERIOR - PINCHES OCCUPANT'S FINGERS FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The inside door handies, in some instances, may pinch the occupant's finger(s) between the handle and the door trim cup when they are operated. This occurs because of the design of the door handles. ACTION: Install revised inside door handle cups and door latch remote control assemblies. Refer to the foilowing procedure for service details. 1. Remove the existing door inside handle cups and door latch remote control assemblies from both doors. Refer to the 1989 or 1990 Thunderbird/Cougar Shop Manual, pages 44-16-4 & 45-03-2, for removal information. 2. Install two (2) revised door inside handle cups and two (2) door latch remote control assemblies. ^ Refer to the two previously mentioned Shop Manual pages for installation details. ^ Refer to the parts block for the correct service parts. 3. Check the operation of the door handles to be certain that the new assemblies are functioning correctly. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901904A Install Door Handle - Both 0.3 Hr. Sides DEALER CODING BASIC PART NO. CONDITION CODE 7021818 41 OASIS CODES: 112000 Technical Service Bulletin # 90194 Date: 900913 Interior Door Handles - Pinch Fingers Article No. 90-19-4 HANDLE - DOOR - INTERIOR - PINCHES OCCUPANT'S FINGERS FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The inside door handies, in some instances, may pinch the occupant's finger(s) between the handle and the door trim cup when they are operated. This occurs because of the design of the door handles. ACTION: Install revised inside door handle cups and door latch remote control assemblies. Refer to the foilowing procedure for service details. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front Door Interior Handle > System Information > Technical Service Bulletins > All Technical Service Bulletins for Front Door Interior Handle: > Page 7763 1. Remove the existing door inside handle cups and door latch remote control assemblies from both doors. Refer to the 1989 or 1990 Thunderbird/Cougar Shop Manual, pages 44-16-4 & 45-03-2, for removal information. 2. Install two (2) revised door inside handle cups and two (2) door latch remote control assemblies. ^ Refer to the two previously mentioned Shop Manual pages for installation details. ^ Refer to the parts block for the correct service parts. 3. Check the operation of the door handles to be certain that the new assemblies are functioning correctly. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901904A Install Door Handle - Both 0.3 Hr. Sides DEALER CODING BASIC PART NO. CONDITION CODE 7021818 41 OASIS CODES: 112000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Latch > System Information > Technical Service Bulletins > Door Latches - Adjustment/Modification Prohibition Front Door Latch: Technical Service Bulletins Door Latches - Adjustment/Modification Prohibition Article No. 91-8-4 04/17/91 LATCHES - DOOR - REPLACEMENT REQUIRED FORD: 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK:1985-90 C SERIES 1985-91 CL-9000, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: Rework of door latches has been reported from Service Investigation Reports. This is unacceptable as it may affect proper latch function. ACTION: Replace latches which function improperly and can not be adjusted. WARNING: NEVER REWORK OR MODIFY A LATCH ASSEMBLY, ALWAYS REPLACE THE LATCH ASSEMBLY. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Panel > System Information > Service and Repair Front Door Panel: Service and Repair Removal 1. Remove window regulator switch housing. See: Sensors and Switches/Sensors and Switches Windows and Glass/Power Window Switch/Service and Repair 2. Remove door inside handle cup (snaps out). 3. Remove self-tapping screw retaining door trim panel upper front extension assembly. Remove extension assembly. 4. Remove two self-tapping screws retaining door trim panel to door inner panel. 5. Lift door trim panel upward and snap out trim panel. 6. Disconnect wire harness for courtesy lamp. Installation 1. Connect courtesy lamp connector. 2. Install door trim panel (lower portion first). Push in until it snaps in place. 3. Install two self-tapping screws retaining trim panel to inner panel. 4. Position extension assembly. Install self-tapping screw. 5. Snap in door inside handle cup. 6. Install window regulator switch housing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Removal WARNING: IF THE REGULATOR COUNTERBALANCE SPRING MUST BE REMOVED OR REPLACED FOR ANY REASON, ENSURE THAT THE REGULATOR ARMS ARE IN A FIXED POSITION PRIOR TO REMOVAL TO PREVENT POSSIBLE INJURY DURING C-SPRING UNWIND. 1. Remove door trim panel and watershield. See: 2. Lower glass to access holes in door inner panel. Remove two nut and washer assemblies retaining glass to glass bracket. 3. Prop the glass in the full-up position. 4. Disconnect the electric motor wiring. 5. Remove two nut and washer assemblies retaining regulator equalizer bracket. 6. Remove the four rivets attaching regulator to door inner panel as follows: - Remove the center pin from each rivet with a drift punch. - Using a 6mm drill, drill out the remaining of the rivet using care not to enlarge the sheet metal retaining holes. 7. Remove regulator through door access hole. Installation 1. With glass in full-up position, install window regulator through access hole in door inner panel. 2. Position regulator base plate to door inner panel and install four rivets. 3. Install regulator equalizer bracket to regulator and loosely assemble with two nut and washer assemblies. 4. Install regulator glass bracket drive channel to glass and secure with two nut and washer assemblies. Tighten nut and washer assemblies to 9-14 N-m (7-10 lb-ft). 5. Connect electric motor wiring. 6. Lower door glass approximately 75mm (3 inch) from full-up position. 7. With door open, place hands on each side of glass and pull glass fully into door glass run assembly at B-pillar. 8. Apply a downward pressure on the equalizer bracket and tighten two nuts and washer assemblies. Tighten to 9-14 N-m (7-10 lb-ft). 9. Cycle door glass to ensure proper operation. 10. Install door trim panel and watershield. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Rear Door > Rear Door Latch > System Information > Technical Service Bulletins > Door Latches - Adjustment/Modification Prohibition Rear Door Latch: Technical Service Bulletins Door Latches - Adjustment/Modification Prohibition Article No. 91-8-4 04/17/91 LATCHES - DOOR - REPLACEMENT REQUIRED FORD: 1985-88 EXP 1985-91 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986 LTD 1986-91 TAURUS 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1985-87 LYNX 1985-91 CAPRI, CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-91 SABLE 1987-91 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1989-91 F SUPER DUTY 1991 EXPLORER MEDIUM/HEAVY TRUCK:1985-90 C SERIES 1985-91 CL-9000, F & B SERIES, L SERIES 1986-91 CARGO SERIES ISSUE: Rework of door latches has been reported from Service Investigation Reports. This is unacceptable as it may affect proper latch function. ACTION: Replace latches which function improperly and can not be adjusted. WARNING: NEVER REWORK OR MODIFY A LATCH ASSEMBLY, ALWAYS REPLACE THE LATCH ASSEMBLY. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock > Component Information > Diagrams > Diagram Information and Instructions Fuel Door Lock: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 7784 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 7785 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Lock > Component Information > Diagrams > Diagram Information and Instructions > Page 7786 Fuel Filler Door Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Release Actuator > Component Information > Locations Fuel Door Release Actuator: Locations Body & Chassis Components RH Rear Corner Of Cargo Compartment Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Fuel Door Switch > Component Information > Locations Fuel Door Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > Customer Interest: > 9031 > Jan > 90 > Hood Lift Retainers - Loose/Broken Hood Shock / Support: Customer Interest Hood Lift Retainers - Loose/Broken HOOD LIFT - LOOSE OR BROKEN RETAINERS - SERVICE PROCEDURE Article No. 90-3-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: Loose or broken hood lift retainers on the hood side or the body side may be repaired with a new released service procedure. ACTION: Use the following service procedure to secure or replace the hood lift retainer on the hood side or the body side. HOOD LIFT RETAINER - HOOD SIDE 1. Support the hood in the open position. 2. Remove the hood insulator. Refer to the Thunderbird/Cougar Shop Manual, Section 44-08 for service details. 3. After the engine has cooled, cover it with a cloth to protect it from sparks and/or debris. Figure 1 4. If the retainer is loose at the base or flange, weld (fusion, wire or mig) the loose retainer as shown in Figure 1. Then proceed to Step # 10. CAUTION: DO NOT APPLY TOO MUCH HEAT TO THE HOOD OUTER PANEL. 5. If the retainer is broken, grind the broken retainer to a smooth surface. 6. Punch in the remaining part of the retainer with an appropriate tool to produce a hole in the bracket. 7. Remove the remaining part of the broken retainer from the hood and throw it away. 8. Remove and clean out any burrs around the hole. 9. Install a new hood lift retainer in the hole of the bracket assembly. 10. Weld (fusion, wire or mig) the new retainer as shown in Figure 1. CAUTION: DO NOT APPLY TOO MUCH HEAT TO THE HOOD OUTER PANEL. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > Customer Interest: > 9031 > Jan > 90 > Hood Lift Retainers - Loose/Broken > Page 7802 11. After the hood is cooled off and before reinstalling the hood insulator, clean, prime and apply paint body color to the hood repair area where the paint has been burned. 12. Remove the cloth covering the engine compartment. 13. Re-install the hood insulator and the hood lift assembly to the hood. HOOD LIFT RETAINER - BODY SIDE 1. Support the hood in the open position. 2. After the engine has cooled, cover it with a cloth to protect it from sparks and/or debris. 3. If the retainer is loose at the base or flange, weld (fusion, wire or mig) the loose retainer. Figure 1 shows typical location of the welds on the retainer. 4. If the retainer is broken, grind the broken retainer off from the back side. 5. Remove and clean out any burrs around the hole. 6. Install a new hood lift retainer in the hole of the bracket assembly. 7. Weld (fusion, wire or mig) the new retainer as shown in Figure 1 with 3/8" welds on the ball stud side of the retainer. 8. Clean, prime and apply paint body color to the repair area where the paint has been burned. 9. Remove the cloth covering the engine compartment. NOTE: USE ACTUAL TIME TO PERFORM THE REPAIR. PART NUMBER PART NAME CLASS FOSZ-16B730-A Hood Lift Retainer Kit C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION M Time DEALER CODING BASIC PART NO. CONDITION CODE 16B730 01 OASIS CODES: 1200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Shock / Support: > 9031 > Jan > 90 > Hood Lift Retainers - Loose/Broken Hood Shock / Support: All Technical Service Bulletins Hood Lift Retainers - Loose/Broken HOOD LIFT - LOOSE OR BROKEN RETAINERS - SERVICE PROCEDURE Article No. 90-3-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: Loose or broken hood lift retainers on the hood side or the body side may be repaired with a new released service procedure. ACTION: Use the following service procedure to secure or replace the hood lift retainer on the hood side or the body side. HOOD LIFT RETAINER - HOOD SIDE 1. Support the hood in the open position. 2. Remove the hood insulator. Refer to the Thunderbird/Cougar Shop Manual, Section 44-08 for service details. 3. After the engine has cooled, cover it with a cloth to protect it from sparks and/or debris. Figure 1 4. If the retainer is loose at the base or flange, weld (fusion, wire or mig) the loose retainer as shown in Figure 1. Then proceed to Step # 10. CAUTION: DO NOT APPLY TOO MUCH HEAT TO THE HOOD OUTER PANEL. 5. If the retainer is broken, grind the broken retainer to a smooth surface. 6. Punch in the remaining part of the retainer with an appropriate tool to produce a hole in the bracket. 7. Remove the remaining part of the broken retainer from the hood and throw it away. 8. Remove and clean out any burrs around the hole. 9. Install a new hood lift retainer in the hole of the bracket assembly. 10. Weld (fusion, wire or mig) the new retainer as shown in Figure 1. CAUTION: DO NOT APPLY TOO MUCH HEAT TO THE HOOD OUTER PANEL. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Shock / Support: > 9031 > Jan > 90 > Hood Lift Retainers - Loose/Broken > Page 7808 11. After the hood is cooled off and before reinstalling the hood insulator, clean, prime and apply paint body color to the hood repair area where the paint has been burned. 12. Remove the cloth covering the engine compartment. 13. Re-install the hood insulator and the hood lift assembly to the hood. HOOD LIFT RETAINER - BODY SIDE 1. Support the hood in the open position. 2. After the engine has cooled, cover it with a cloth to protect it from sparks and/or debris. 3. If the retainer is loose at the base or flange, weld (fusion, wire or mig) the loose retainer. Figure 1 shows typical location of the welds on the retainer. 4. If the retainer is broken, grind the broken retainer off from the back side. 5. Remove and clean out any burrs around the hole. 6. Install a new hood lift retainer in the hole of the bracket assembly. 7. Weld (fusion, wire or mig) the new retainer as shown in Figure 1 with 3/8" welds on the ball stud side of the retainer. 8. Clean, prime and apply paint body color to the repair area where the paint has been burned. 9. Remove the cloth covering the engine compartment. NOTE: USE ACTUAL TIME TO PERFORM THE REPAIR. PART NUMBER PART NAME CLASS FOSZ-16B730-A Hood Lift Retainer Kit C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION M Time DEALER CODING BASIC PART NO. CONDITION CODE 16B730 01 OASIS CODES: 1200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure Hood Shock / Support: All Technical Service Bulletins Hood Lift - Loose/Broken, New Service Procedure Article No. 89-25A-1 12/15/89 ^ SHOP MANUAL - 1989 - SECTION 44-08 - NEW SERVICE PROCEDURE FOR LOOSE OR BROKEN HOOD LIFT RETAINER ^ SHOP MANUAL - 1990 - SECTION 44-08 - NEW SERVICE PROCEDURE FOR LOOSE OR BROKEN HOOD LIFT RETAINER FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: New service procedures on Loose or Broken Retainer - Hood Lift on Hood for 1989 and 1990 Thunderbird/Cougar vehicles are now available. This information is part of Section 44-08 Hood, Hinge and Latch of the 1989 and 1990 Thunderbird/Cougar Shop Manual. ACTION: Refer to the pages in this TSB article for the new service procedures. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure > Page 7813 Page 44-08-01 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure > Page 7814 Page 44-08-02 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure > Page 7815 Page 44-08-02A Page 44-06-5 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure > Page 7816 Page 44-08-1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure > Page 7817 Page 44-08-4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure Hood Shock / Support: All Technical Service Bulletins Hood Lift - Loose/Broken, New Service Procedure Article No. 89-25A-1 12/15/89 ^ SHOP MANUAL - 1989 - SECTION 44-08 - NEW SERVICE PROCEDURE FOR LOOSE OR BROKEN HOOD LIFT RETAINER ^ SHOP MANUAL - 1990 - SECTION 44-08 - NEW SERVICE PROCEDURE FOR LOOSE OR BROKEN HOOD LIFT RETAINER FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: New service procedures on Loose or Broken Retainer - Hood Lift on Hood for 1989 and 1990 Thunderbird/Cougar vehicles are now available. This information is part of Section 44-08 Hood, Hinge and Latch of the 1989 and 1990 Thunderbird/Cougar Shop Manual. ACTION: Refer to the pages in this TSB article for the new service procedures. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure > Page 7823 Page 44-08-01 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure > Page 7824 Page 44-08-02 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure > Page 7825 Page 44-08-02A Page 44-06-5 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure > Page 7826 Page 44-08-1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Shock / Support > Component Information > Technical Service Bulletins > All Other Service Bulletins for Hood Shock / Support: > 8925A1 > Dec > 89 > Hood Lift - Loose/Broken, New Service Procedure > Page 7827 Page 44-08-4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 7833 OASIS CODES: 201000, 201200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Locations Power Trunk / Liftgate Lock Switch: Locations In Center Rear Of Trunk Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions Power Trunk / Liftgate Lock Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7840 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7841 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7842 Luggage Compartment Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Lock Cylinder: > 92211 > Oct > 92 > Alarm System - False Security Alarm Trunk / Liftgate Lock Cylinder: Customer Interest Alarm System - False Security Alarm Article No. 92-21-1 October 7, 1992 ^ LOCK - TRUNK - BENT CYLINDER TAB FALSELY ACTIVATES ALARM ^ ALARM SYSTEM - ACTIVATED IN ERROR FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1988-91 CONTINENTAL, MARK VII, TOWN CAR 1989-91 COUGAR ISSUE: The anti-theft alarm system may be activated in error because of a bent trunk lock switch tab in the lock cylinder. ACTION: Install a new trunk lock cylinder by using the following service procedure. 1. Remove the trunk lock cylinder from the rear decklid sheet metal. Refer to the appropriate 1991 Service Manual, Section 44-10, for service details. 2. Examine the tab portion of the anti-theft lock switch to see if it is bent. The switch is part of the trunk lock cylinder. Refer to Figure 1 for an example of a bent tab. 3. If the tab is bent, replace the trunk lock and matching glove box lock. On Mark VII's also replace the console stowage lock. Refer to the Parts Block of this article for the correct service part numbers. 4. If the tab is OK, reinstall the trunk lock cylinder and continue as follows: a. Check to see that the tab engages with the trunk sheet metal. b. Check with an ohmmeter that the two terminals on the white connector of the trunk lock cylinder are an "open circuit". (There is no continuity or current between them.) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Lock Cylinder: > 92211 > Oct > 92 > Alarm System - False Security Alarm > Page 7851 c. Replace the trunk lock cylinder and matching glove box lock if current exists between the two terminals. PART INFORMATION OTHER APPLICABLE ARTICLES: None SUPERSEDES: 89-15-2 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1991 Lincolns, Basic Warranty Coverage For 1989-91 Thunderbird/Cougar and 1988-1990 Lincolns OPERATIONDESCRIPTION TIME 922101A Continental 0.8 Hr. 922101A Thunderbird, Cougar 0.6 Hr. 922101A Town Car, Mark VII 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7043507 02 OASIS CODES: 112000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Lock Cylinder: > 89152 > Jul > 89 > Alarm System - False Activation Trunk / Liftgate Lock Cylinder: Customer Interest Alarm System - False Activation ALARM SYSTEM-FALSELY ACTIVATED-VEHICLES BUILT BEFORE 2/20/89 LOCK-TRUNK-BENT CYLINDER TAB FALSELY ACTIVATES ALARM-VEHICLES BUILT BEFORE 2/20/89 Article No. 89-15-2 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1988-89 CONTINENTAL, MARK VII, TOWN CAR 1989 COUGAR Figure 1 ISSUE: The anti-theft alarm system may be falsely activated because of a bent trunk lock switch tab in the lock cylinder. ACTION: Install a new trunk lock cylinder by using the following service procedure. 1. Remove the trunk lock cylinder from the rear decklid sheet metal. Refer to Section 44-10 of the appropriate Shop Manual for service details. 2. Examine the tab portion of the anti-lock switch to see if it is bent. The switch is part of the trunk lock cylinder. Refer to Figure 1 for an example of a bent tab. 3. If the tab is bent, replace the trunk lock and matching glove box lock. On Mark VII's also replace the console stowage lock. Refer to the lock cylinder application chart for the correct service part numbers. 4. If the tab is OK, reinstall the trunk lock cylinder and do the following steps. a. Check to see that the tab engages with the trunk sheet metal. b. Check with an ohmmeter that the two terminals on the white connector of the trunk lock cylinder are an "open circuit". (There is no continuity or current between them.) c. Replace the trunk lock cylinder and matching glove box lock if current exists between the two terminals. LOCK CYLINDER APPLICATION CHART MODEL YEAR CARLINE PART NUMBER Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Trunk / Liftgate Lock Cylinder: > 89152 > Jul > 89 > Alarm System - False Activation > Page 7856 1988/1989 Continental E90Y-5443507-A 1988/1989 Town Car E9VY-5443507-A 1988/1989 Mark VII E9LY-6343507-A 1989 T-Bird/Cougar E9SZ-634507-D PART NUMBER PART NAME CLASS E90Y-5443507-A Lock Cylinder C E9VY-5443507-A Lock Cylinder B E9LY-6343507-A Lock Cylinder B E9SZ-6343507-D Lock Cylinder C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891502A Continental 0.8 Hr. 891502A Thunderbird, Cougar 0.6 Hr. 891502A Town Car, Mark VII 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7043507 02 OASIS CODES: 2900, 1200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 92211 > Oct > 92 > Alarm System - False Security Alarm Trunk / Liftgate Lock Cylinder: All Technical Service Bulletins Alarm System - False Security Alarm Article No. 92-21-1 October 7, 1992 ^ LOCK - TRUNK - BENT CYLINDER TAB FALSELY ACTIVATES ALARM ^ ALARM SYSTEM - ACTIVATED IN ERROR FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1988-91 CONTINENTAL, MARK VII, TOWN CAR 1989-91 COUGAR ISSUE: The anti-theft alarm system may be activated in error because of a bent trunk lock switch tab in the lock cylinder. ACTION: Install a new trunk lock cylinder by using the following service procedure. 1. Remove the trunk lock cylinder from the rear decklid sheet metal. Refer to the appropriate 1991 Service Manual, Section 44-10, for service details. 2. Examine the tab portion of the anti-theft lock switch to see if it is bent. The switch is part of the trunk lock cylinder. Refer to Figure 1 for an example of a bent tab. 3. If the tab is bent, replace the trunk lock and matching glove box lock. On Mark VII's also replace the console stowage lock. Refer to the Parts Block of this article for the correct service part numbers. 4. If the tab is OK, reinstall the trunk lock cylinder and continue as follows: a. Check to see that the tab engages with the trunk sheet metal. b. Check with an ohmmeter that the two terminals on the white connector of the trunk lock cylinder are an "open circuit". (There is no continuity or current between them.) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 92211 > Oct > 92 > Alarm System - False Security Alarm > Page 7862 c. Replace the trunk lock cylinder and matching glove box lock if current exists between the two terminals. PART INFORMATION OTHER APPLICABLE ARTICLES: None SUPERSEDES: 89-15-2 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1991 Lincolns, Basic Warranty Coverage For 1989-91 Thunderbird/Cougar and 1988-1990 Lincolns OPERATIONDESCRIPTION TIME 922101A Continental 0.8 Hr. 922101A Thunderbird, Cougar 0.6 Hr. 922101A Town Car, Mark VII 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7043507 02 OASIS CODES: 112000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 89152 > Jul > 89 > Alarm System - False Activation Trunk / Liftgate Lock Cylinder: All Technical Service Bulletins Alarm System - False Activation ALARM SYSTEM-FALSELY ACTIVATED-VEHICLES BUILT BEFORE 2/20/89 LOCK-TRUNK-BENT CYLINDER TAB FALSELY ACTIVATES ALARM-VEHICLES BUILT BEFORE 2/20/89 Article No. 89-15-2 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1988-89 CONTINENTAL, MARK VII, TOWN CAR 1989 COUGAR Figure 1 ISSUE: The anti-theft alarm system may be falsely activated because of a bent trunk lock switch tab in the lock cylinder. ACTION: Install a new trunk lock cylinder by using the following service procedure. 1. Remove the trunk lock cylinder from the rear decklid sheet metal. Refer to Section 44-10 of the appropriate Shop Manual for service details. 2. Examine the tab portion of the anti-lock switch to see if it is bent. The switch is part of the trunk lock cylinder. Refer to Figure 1 for an example of a bent tab. 3. If the tab is bent, replace the trunk lock and matching glove box lock. On Mark VII's also replace the console stowage lock. Refer to the lock cylinder application chart for the correct service part numbers. 4. If the tab is OK, reinstall the trunk lock cylinder and do the following steps. a. Check to see that the tab engages with the trunk sheet metal. b. Check with an ohmmeter that the two terminals on the white connector of the trunk lock cylinder are an "open circuit". (There is no continuity or current between them.) c. Replace the trunk lock cylinder and matching glove box lock if current exists between the two terminals. LOCK CYLINDER APPLICATION CHART MODEL YEAR CARLINE PART NUMBER Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Trunk / Liftgate Lock Cylinder: > 89152 > Jul > 89 > Alarm System - False Activation > Page 7867 1988/1989 Continental E90Y-5443507-A 1988/1989 Town Car E9VY-5443507-A 1988/1989 Mark VII E9LY-6343507-A 1989 T-Bird/Cougar E9SZ-634507-D PART NUMBER PART NAME CLASS E90Y-5443507-A Lock Cylinder C E9VY-5443507-A Lock Cylinder B E9LY-6343507-A Lock Cylinder B E9SZ-6343507-D Lock Cylinder C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891502A Continental 0.8 Hr. 891502A Thunderbird, Cougar 0.6 Hr. 891502A Town Car, Mark VII 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7043507 02 OASIS CODES: 2900, 1200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Diagram Information and Instructions Trunk / Liftgate Motor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7872 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7873 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 7874 Luggage Compartment Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions Trunk / Liftgate Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7879 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7880 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 7881 Luggage Compartment Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > Customer Interest: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work Trunk / Liftgate Release Lever: Customer Interest Vehicle - No Start Condition/Accessories Don't Work Article No. 89-6-6 ^ NO START - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE ^ POWER ACCESSORIES - INOPERATIVE - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A no start condition or power accessories that do not work may be caused by a loose or disconnected wire at the ground buss connector. The wire leads from the ground buss connectors may be looped under the carpet at the lower edge of the cowl trim panel. This type of routing allows the occupants feet to apply enough downward pressure on the carpet to pull one or more ground terminals from the ground buss connector. Accessories and systems that could be affected are in the 1989 Electrical Vacuum Troubleshooting Manual (EVTM), pages 16 through 19. A partial list of these accessories and systems are: ^ Power door locks ^ Power windows ^ Power seats ^ Keyless entry ^ Luggage compartment remote release ^ Interior courtesy lamps ^ Passive restraints ACTION: Inspect the driver's side ground buss connector (G-300) and the passenger's side ground buss connector (G-301) for loose or disconnected ground wires. Refer to the following procedure for service details. FIGURE 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > Customer Interest: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work > Page 7890 FIGURE 2 1. Using the 1989 Thunderbird/Cougar EVTM, pages 16 through 19, determine which ground buss connector (G-300 or G-301) requires service, Figure 1 and 2. 2. Remove the cowl trim panel. 3. Detach the ground buss connector from the cowl. 4. Inspect each terminal for a proper connection. NOTE: THE TERMINALS ARE EASILY SEEN THROUGH THE WHITE PLASTIC COVER OF THE GROUND BUSS CONNECTOR. 5. If a wire(s) is loose or pulled out of a terminal(s), remove the terminal(s) from the ground buss connector and solder the wire(s) to the terminal(s). 6. Reinstall the repaired terminal(s) in the ground buss connector. 7. Reposition the ground buss connector. Rotate the ground buss connector either forward or rearward to allow the ground wire leads to be as close to the cowl as possible. 8. Install a 4-6 inch piece of body tape on the wire harness to hold it to the cowl panel, Figures 1 and 2. 9. Reinstall the cowl trim panel. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 890606A Inspect & Repair Ground 0.6 Hr. Buss (one side) 890606B Inspect & repair Ground 1.0 Hr. Buss (both sides) DEALER CODING BASIC PART NO. CONDITION CODE 14A488 44 OASIS CODES: 2100, 2150, 2700, 2770, 2900, 610200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work Trunk / Liftgate Release Lever: All Technical Service Bulletins Vehicle - No Start Condition/Accessories Don't Work Article No. 89-6-6 ^ NO START - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE ^ POWER ACCESSORIES - INOPERATIVE - GROUND TERMINALS AT THE GROUND BUSS CONNECTOR LOOSE FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A no start condition or power accessories that do not work may be caused by a loose or disconnected wire at the ground buss connector. The wire leads from the ground buss connectors may be looped under the carpet at the lower edge of the cowl trim panel. This type of routing allows the occupants feet to apply enough downward pressure on the carpet to pull one or more ground terminals from the ground buss connector. Accessories and systems that could be affected are in the 1989 Electrical Vacuum Troubleshooting Manual (EVTM), pages 16 through 19. A partial list of these accessories and systems are: ^ Power door locks ^ Power windows ^ Power seats ^ Keyless entry ^ Luggage compartment remote release ^ Interior courtesy lamps ^ Passive restraints ACTION: Inspect the driver's side ground buss connector (G-300) and the passenger's side ground buss connector (G-301) for loose or disconnected ground wires. Refer to the following procedure for service details. FIGURE 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 8966 > Mar > 89 > Vehicle - No Start Condition/Accessories Don't Work > Page 7896 FIGURE 2 1. Using the 1989 Thunderbird/Cougar EVTM, pages 16 through 19, determine which ground buss connector (G-300 or G-301) requires service, Figure 1 and 2. 2. Remove the cowl trim panel. 3. Detach the ground buss connector from the cowl. 4. Inspect each terminal for a proper connection. NOTE: THE TERMINALS ARE EASILY SEEN THROUGH THE WHITE PLASTIC COVER OF THE GROUND BUSS CONNECTOR. 5. If a wire(s) is loose or pulled out of a terminal(s), remove the terminal(s) from the ground buss connector and solder the wire(s) to the terminal(s). 6. Reinstall the repaired terminal(s) in the ground buss connector. 7. Reposition the ground buss connector. Rotate the ground buss connector either forward or rearward to allow the ground wire leads to be as close to the cowl as possible. 8. Install a 4-6 inch piece of body tape on the wire harness to hold it to the cowl panel, Figures 1 and 2. 9. Reinstall the cowl trim panel. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 890606A Inspect & Repair Ground 0.6 Hr. Buss (one side) 890606B Inspect & repair Ground 1.0 Hr. Buss (both sides) DEALER CODING BASIC PART NO. CONDITION CODE 14A488 44 OASIS CODES: 2100, 2150, 2700, 2770, 2900, 610200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Release Lever: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Wheel Hub: All Technical Service Bulletins Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Release Lever: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 7902 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Release Lever: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 7903 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Release Lever: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Release Lever: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 7913 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Release Lever > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Release Lever: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 7914 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Locations Trunk / Liftgate Solenoid: Locations In Rear Of Trunk Lid Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Diagrams > Diagram Information and Instructions Trunk / Liftgate Solenoid: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7924 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7925 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Solenoid > Component Information > Diagrams > Diagram Information and Instructions > Page 7926 Luggage Compartment Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions Trunk / Liftgate Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7932 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7933 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Trunk / Liftgate > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 7934 Luggage Compartment Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > Exterior Roof Ditch Moulding - Shop Manual Update Upper Side Moulding / Trim: Technical Service Bulletins Exterior Roof Ditch Moulding - Shop Manual Update TRIM - EXTERIOR-ROOFDITCHMOULDING REMOVAL - SHOP MANUAL UPDATE Article No. 88-23-3 FORD: 1989 THUNDERBIRD ISSUE: The roof ditch moulding, located rearward of the door opening, cannot be removed unless an attaching nut inside of the vehicle is removed first. This information was omitted from the 1989 Car Shop Manual, Volume B, Section 42-11. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > Exterior Roof Ditch Moulding - Shop Manual Update > Page 7940 FIGURE 3 ACTION: If service is required, gain access to the nut by removing a plug button from the interior quarter trim panel as shown in Figure 3. Refer to the 1989 Thunderbird Shop Manual, Section 42-11 for additional removal and installation instructions. This information should also be inserted in your 1989 Thunderbird Shop Manual, Section 42-11 for future reference. NOTE: THE PLUG BUTTON IS SERVICED IF REPLACEMENT IS REQUIRED. THE PLUG BUTTON IS SERVICED IN MATCHING INTERIOR COLORS. PART NUMBER PART NAME CLASS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Exterior Moulding / Trim > Upper Side Moulding / Trim > Component Information > Technical Service Bulletins > Exterior Roof Ditch Moulding - Shop Manual Update > Page 7941 E9SZ-63312A28-BEK Plug Button - Blue C E9SZ-63312A28-BJH Plug Button - Titanium C E9SZ-63312A28-BP2 Plug Button - Currant C E9SZ-63312A28-BS2 Plug Button - Sandle C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 1050, 1052, 1200, 1800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Fender > Component Information > Technical Service Bulletins > Body Collision Repair Manual Revision Fender: Technical Service Bulletins Body - Collision Repair Manual Revision Article No. 93-19B-6 09/29/93 BODY COLLISION REPAIR MANUAL - 1989 AND FORWARD - PAGE 16 - FRONT APRON/SIDEMEMBER AND FENDER REINFORCEMENT - FIGURE 1-9 REVISED FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR 1993 MARK VIII ISSUE: Front Apron/Sidemember and Fender Reinforcement Figure 1-9 requires revision to include configurations for 1993 Thunderbird/Cougar and 1993 Mark VIII vehicle applications. Page 16 of the Thunderbird/Cougar Body Collision Repair Manual (the manual is applicable to 1989 and newer model vehicles) is affected. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Fender > Component Information > Technical Service Bulletins > Body Collision Repair Manual Revision > Page 7946 ACTION: Refer to the page in this TSB article for the updated illustration. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 8921 > Jan > 89 > Driveshaft - Vibration Cross-Member: Customer Interest Driveshaft - Vibration ^ CROSSMEMBER - CENTER SUPPORT BRACKET INSTALLATION - VEHICLES BUILT BEFORE 2/01/89 ^ VIBRATION - CENTER SUPPORT BRACKET CONTACTS DRIVESHAFT - VEHICLES BUILT BEFORE 2/01/89 Article No. 89-2-1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A driveline vibration between 5-10 MPH (8-16 Km/h) may be caused by the driveshaft contacting the crossmember center support bracket. The crossmember center support bracket may have been initially installed backwards. ACTION: Inspect the position of the crossmember center support bracket to determine if service is required. Refer to the following procedure for service details. FIGURE 1 1. Remove the four (4) bolts holding the body reinforcement, Figure 1. 2. Remove the two (2) bolts and one (1) nut retaining the heat shield. 3. Position the heat shield aside. 4. Make sure the arrow on the center support bracket is pointing toward the rear of the vehicle, Figure 1. If not proceed to Step 5. If okay proceed to Step 8. 5. Remove the two (2) bolts that hold the center support bracket to the body reinforcement, Figure 1. 6. Rotate the center support bracket 180 degrees so the arrow on the bracket points toward the rear of the vehicle. 7. Install the two (2) bolts that hold the center support bracket to the body reinforcement. 8. Reposition the heat shield. 9. Reinstall the two (2) bolts and one (1) nut that retains the heat shield. 10. Reinstall the four (4) bolts that retain the body reinforcement, Figure 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION : 890201A - Inspect TIME: 0.4 Hr. OPERATION: 890201B - Inspect and Correct TIME: 0.5 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > Customer Interest for Cross-Member: > 8921 > Jan > 89 > Driveshaft - Vibration > Page 7956 DLR. CODING: Basic Part No. 5A041 Condition Code: 79 OASIS CODES: 5950, 7210, 7211, 7212, 7213 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 8921 > Jan > 89 > Driveshaft - Vibration Cross-Member: All Technical Service Bulletins Driveshaft - Vibration ^ CROSSMEMBER - CENTER SUPPORT BRACKET INSTALLATION - VEHICLES BUILT BEFORE 2/01/89 ^ VIBRATION - CENTER SUPPORT BRACKET CONTACTS DRIVESHAFT - VEHICLES BUILT BEFORE 2/01/89 Article No. 89-2-1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A driveline vibration between 5-10 MPH (8-16 Km/h) may be caused by the driveshaft contacting the crossmember center support bracket. The crossmember center support bracket may have been initially installed backwards. ACTION: Inspect the position of the crossmember center support bracket to determine if service is required. Refer to the following procedure for service details. FIGURE 1 1. Remove the four (4) bolts holding the body reinforcement, Figure 1. 2. Remove the two (2) bolts and one (1) nut retaining the heat shield. 3. Position the heat shield aside. 4. Make sure the arrow on the center support bracket is pointing toward the rear of the vehicle, Figure 1. If not proceed to Step 5. If okay proceed to Step 8. 5. Remove the two (2) bolts that hold the center support bracket to the body reinforcement, Figure 1. 6. Rotate the center support bracket 180 degrees so the arrow on the bracket points toward the rear of the vehicle. 7. Install the two (2) bolts that hold the center support bracket to the body reinforcement. 8. Reposition the heat shield. 9. Reinstall the two (2) bolts and one (1) nut that retains the heat shield. 10. Reinstall the four (4) bolts that retain the body reinforcement, Figure 1. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION : 890201A - Inspect TIME: 0.4 Hr. OPERATION: 890201B - Inspect and Correct TIME: 0.5 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cross-Member: > 8921 > Jan > 89 > Driveshaft - Vibration > Page 7962 DLR. CODING: Basic Part No. 5A041 Condition Code: 79 OASIS CODES: 5950, 7210, 7211, 7212, 7213 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications > Tightening Specifications Fig. 15 Tightening Specifications Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications > Tightening Specifications > Page 7965 Cross-Member: Specifications Crossmember Bolt 12-17 ft.lb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Frame > Frame Extension > Component Information > Technical Service Bulletins > Body - Collision Repair Manual Revision Frame Extension: Technical Service Bulletins Body - Collision Repair Manual Revision Article No. 93-19B-6 09/29/93 BODY COLLISION REPAIR MANUAL - 1989 AND FORWARD - PAGE 16 - FRONT APRON/SIDEMEMBER AND FENDER REINFORCEMENT - FIGURE 1-9 REVISED FORD: 1989-93 THUNDERBIRD LINCOLN-MERCURY: 1989-93 COUGAR 1993 MARK VIII ISSUE: Front Apron/Sidemember and Fender Reinforcement Figure 1-9 requires revision to include configurations for 1993 Thunderbird/Cougar and 1993 Mark VIII vehicle applications. Page 16 of the Thunderbird/Cougar Body Collision Repair Manual (the manual is applicable to 1989 and newer model vehicles) is affected. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Frame > Frame Extension > Component Information > Technical Service Bulletins > Body - Collision Repair Manual Revision > Page 7970 ACTION: Refer to the page in this TSB article for the updated illustration. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Component Information > Service and Repair Dashboard / Instrument Panel: Service and Repair Fig. 15 Steering Column Lower Trim Cover Removal, 1989 Cougar & Thunderbird. Fig. 16 Steering Column Opening Reinforcement Removal, 1989 Cougar & Thunderbird. Fig. 17 Steering Column Wiring Connectors, 1989 Cougar & Thunderbird. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Component Information > Service and Repair > Page 7975 Fig. 18 Removing Cowl Trim Panel, 1989 Cougar & Thunderbird. Fig. 19 Removing Floor Console, 1989 Cougar & Thunderbird. Fig. 12 Removing I/P Retaining Screws. Cougar & Thunderbird Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Component Information > Service and Repair > Page 7976 Fig. 21 Removing Upper Finish Panels, 1989 Cougar & Thunderbird. Fig. 22 Removing I/P From Cowl, 1989 Cougar & Thunderbird. 1. Disconnect battery ground cable. 2. Disconnect all underhood wiring connectors from main wiring harness. Remove rubber grommet seal from dash panel and push wiring hamess and connectors into passenger compartment. Fig. 15. 3. Remove steering column lower trim cover, Fig. 15. 4. Remove six steering column lower opening reinforcement retaining screws, Fig. 16. 5. Remove steering column upper and lower shrouds. 6. Disconnect steering column wiring connectors, Fig. 17. 7. Remove shift interlock switch. 8. Disconnect steering column lower universal joint. 9. Support steering column and remove four nuts retaining column to support. Remove column from vehicle. 10. Remove one screw retaining left side of instrument panel to parking brake bracket. 11. Install lower steering column lower opening reinforcement, Fig. 16. Reinforcement prevents instrument panel from twisting when being removed from vehicle. 12. Remove right and left side cowl trim panels, Fig. 18. 13. Open floor console door and remove container and mat to gain access to two console to floorpan retaining screws. Remove screws, Fig. 19. 14. On models with 5 speed manual transmission, remove gear shift knob. 15. On all models, remove two rear finish panel retaining screws. 16. Tilt finish panel forward and disconnect electrical connectors, then remove finish panel. 17. Remove two front console to instrument panel retaining screws and remove console. 18. Remove two nuts retaining center of instrument panel to floor. 19. Open glove compartment, squeeze sides of bin and lower to full open position. 20. From underneath instrument panel and through glove compartment opening, disconnect wiring and heater-A/C vacuum lines and control cables. 21. Remove two retaining screws from both the left and right sides of the instrument panel, Fig. 20. 22. Remove right and left side upper finish panels by pulling up to disengage snap-in retainers, Fig. 21. 23. Remove four screws retaining instrument panel to cowl top, Fig. 22. 24. Remove right and left roof rail trim panel panel, then remove door frame weather strip. 25. Carefully pull instrument panel away from cowl and disconnect any remaining wiring or controls. 26. Remove instrument panel from the vehicle. 27. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service and Repair Trim Panel: Service and Repair Removal 1. Remove window regulator switch housing. See: Sensors and Switches/Sensors and Switches Windows and Glass/Power Window Switch/Service and Repair 2. Remove door inside handle cup (snaps out). 3. Remove self-tapping screw retaining door trim panel upper front extension assembly. Remove extension assembly. 4. Remove two self-tapping screws retaining door trim panel to door inner panel. 5. Lift door trim panel upward and snap out trim panel. 6. Disconnect wire harness for courtesy lamp. Installation 1. Connect courtesy lamp connector. 2. Install door trim panel (lower portion first). Push in until it snaps in place. 3. Install two self-tapping screws retaining trim panel to inner panel. 4. Position extension assembly. Install self-tapping screw. 5. Snap in door inside handle cup. 6. Install window regulator switch housing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry Key-Pad: > 94103 > May > 94 > Keyless Entry - Key Pad Illumination Non Functional Keyless Entry Key-Pad: Customer Interest Keyless Entry - Key Pad Illumination Non Functional Article No. 94-10-3 05/18/94 ^ DOOR LOCKS - KEYLESS ENTRY SYSTEM - KEYPAD ILLUMINATION DOES NOT FUNCTION ^ KEYLESS ENTRY SYSTEM - KEYPAD ILLUMINATION DOES NOT FUNCTION FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR 1990-92 CONTINENTAL, TOWN CAR This TSB article is being republished in its entirety to request dealers to sort and return the older inventory to the facing PDC'S. See Attention Parts Manager Page of this TSB for information about handling obsolete parts. ISSUE: Keyless entry system keypad illumination may not be functional. This may be due to water entry into the keypad. ACTION: Replace the keypad assembly with an improved design keypad having a date code of 2D01 or later (1992 APRIL 01). Refer to the appropriate Service Manual, Section 01-14B, for removal and installation instructions. NOTE: DATE CODES MAY BE IN EITHER OF TWO CONFIGURATIONS, i.e. "2D01" OR "2DA." THE DATE CODE OF 2DO1 IS "1992/APRIL/01;" THE DATE CODE OF 2EA IS "1992/MAY/1ST WEEK;" SIMILARLY, THE DATE CODE OF 2DB IS "1992/APRIL/2ND WEEK." Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-6-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 941003A Remove And Replace The 0.8 Hr. Keypad Actuator - Town Car 941003B Remove And Replace The 0.6 Hr. Keypad Actuator - Thunderbird/Cougar/Continental DEALER CODING BASIC PART NO. CONDITION CODE 14A626 49 OASIS CODES: 112000, 203000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless Entry Key-Pad: > 94103 > May > 94 > Keyless Entry - Key Pad Illumination Non Functional Keyless Entry Key-Pad: All Technical Service Bulletins Keyless Entry - Key Pad Illumination Non Functional Article No. 94-10-3 05/18/94 ^ DOOR LOCKS - KEYLESS ENTRY SYSTEM - KEYPAD ILLUMINATION DOES NOT FUNCTION ^ KEYLESS ENTRY SYSTEM - KEYPAD ILLUMINATION DOES NOT FUNCTION FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR 1990-92 CONTINENTAL, TOWN CAR This TSB article is being republished in its entirety to request dealers to sort and return the older inventory to the facing PDC'S. See Attention Parts Manager Page of this TSB for information about handling obsolete parts. ISSUE: Keyless entry system keypad illumination may not be functional. This may be due to water entry into the keypad. ACTION: Replace the keypad assembly with an improved design keypad having a date code of 2D01 or later (1992 APRIL 01). Refer to the appropriate Service Manual, Section 01-14B, for removal and installation instructions. NOTE: DATE CODES MAY BE IN EITHER OF TWO CONFIGURATIONS, i.e. "2D01" OR "2DA." THE DATE CODE OF 2DO1 IS "1992/APRIL/01;" THE DATE CODE OF 2EA IS "1992/MAY/1ST WEEK;" SIMILARLY, THE DATE CODE OF 2DB IS "1992/APRIL/2ND WEEK." Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-6-2 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992 Models And 1991 Lincolns, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 941003A Remove And Replace The 0.8 Hr. Keypad Actuator - Town Car 941003B Remove And Replace The 0.6 Hr. Keypad Actuator - Thunderbird/Cougar/Continental DEALER CODING BASIC PART NO. CONDITION CODE 14A626 49 OASIS CODES: 112000, 203000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Key-Pad > Component Information > Technical Service Bulletins > Page 7995 Keyless Entry Key-Pad: Locations Body & Chassis Components Lower Rear Of LH Door Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 9322 > Jan > 93 > Power Door Lock Inoperative Power Door Lock Actuator: Customer Interest Power Door Lock - Inoperative Article No. 93-2-2 01/18/93 LOCKS - POWER DOOR - INOPERATIVE - ACTUATOR DISENGAGES FROM BRACKET FORD: 1989-93 TAURUS, THUNDERBIRD 1992-93 CROWN VICTORIA LINCOLN-MERCURY: 1988-93 CONTINENTAL 1989-93 COUGAR, SABLE 1990-93 TOWN CAR 1992-93 GRAND MARQUIS LIGHT TRUCK: 1991-93 EXPLORER 1992-93 BRONCO, ECONOLINE, F-150-350 SERIES 1993 AEROSTAR ISSUE: The power door lock actuator may disengage from the bracket when the door is closed. This occurs because the actuator assembly is not properly secured to the bracket. ACTION: Install a tie wrap on the actuator assembly. Refer to the following procedure for service details. 1. Remove the old actuator bracket from the door. Refer to the appropriate 1988-93 Car or Light Truck Service Manual, Sections 01-14 04 01-14A, for service details. CAUTION: DO NOT SIMPLY SNAP THE ACTUATOR INTO THE OLD BRACKET. THE RETENTION FORCE MAY HAVE DETERIORATED DUE TO BUSHING DAMAGE. 2. Replace the actuator assembly. Refer to the appropriate 1988-93 Car or Light Truck Service Manual, Sections 01-14 04 01-14A, for installation details. Refer to the Dealer Master Parts Catalog For correct parts usage. 3. Check the replacement part for the presence of a tie wrap strap as shown in Figure 1. If the tie strap is present, install the actuator. (Go to Step 5.) If the tie strap is not present, install a tie wrap strap (95874-S) before installing the actuator. See Step 4. 4. Obtain a tie wrap (95874-S). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 9322 > Jan > 93 > Power Door Lock Inoperative > Page 8008 a. Install the tie wrap strap through the existing holes in the bracket, Figure 1. b. Wrap the strap around the actuator over the rubber watershield. c. Pull the strap tight enough to remove any slack in the strap (about 2 lbs. pull). d. Cut off the excess strap. NOTE: THE TIE WRAP STRAP KNOT MUST BE LOCATED AWAY FROM THE BRACKET HOLES SO THE RETAINER PUSH PIN CAN BE INSTALLED INTO THE BRACKET HOLE. 5. Install the revised assembly on the door per the Service Manual procedure. PART NUMBER PART NAME CLASS 95874-S Tie Wrap Strap (Pk/10) AG OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage. For 1992/93 Model Year Vehicles And 1991 Lincolns. Eligible Under Basic Warranty Coverage For All Other Model Year Vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 9322 > Jan > 93 > Power Door Lock Inoperative > Page 8009 Operation/Description/Time Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 9322 > Jan > 93 > Power Door Lock - Inoperative Power Door Lock Actuator: All Technical Service Bulletins Power Door Lock - Inoperative Article No. 93-2-2 01/18/93 LOCKS - POWER DOOR - INOPERATIVE - ACTUATOR DISENGAGES FROM BRACKET FORD: 1989-93 TAURUS, THUNDERBIRD 1992-93 CROWN VICTORIA LINCOLN-MERCURY: 1988-93 CONTINENTAL 1989-93 COUGAR, SABLE 1990-93 TOWN CAR 1992-93 GRAND MARQUIS LIGHT TRUCK: 1991-93 EXPLORER 1992-93 BRONCO, ECONOLINE, F-150-350 SERIES 1993 AEROSTAR ISSUE: The power door lock actuator may disengage from the bracket when the door is closed. This occurs because the actuator assembly is not properly secured to the bracket. ACTION: Install a tie wrap on the actuator assembly. Refer to the following procedure for service details. 1. Remove the old actuator bracket from the door. Refer to the appropriate 1988-93 Car or Light Truck Service Manual, Sections 01-14 04 01-14A, for service details. CAUTION: DO NOT SIMPLY SNAP THE ACTUATOR INTO THE OLD BRACKET. THE RETENTION FORCE MAY HAVE DETERIORATED DUE TO BUSHING DAMAGE. 2. Replace the actuator assembly. Refer to the appropriate 1988-93 Car or Light Truck Service Manual, Sections 01-14 04 01-14A, for installation details. Refer to the Dealer Master Parts Catalog For correct parts usage. 3. Check the replacement part for the presence of a tie wrap strap as shown in Figure 1. If the tie strap is present, install the actuator. (Go to Step 5.) If the tie strap is not present, install a tie wrap strap (95874-S) before installing the actuator. See Step 4. 4. Obtain a tie wrap (95874-S). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 9322 > Jan > 93 > Power Door Lock - Inoperative > Page 8015 a. Install the tie wrap strap through the existing holes in the bracket, Figure 1. b. Wrap the strap around the actuator over the rubber watershield. c. Pull the strap tight enough to remove any slack in the strap (about 2 lbs. pull). d. Cut off the excess strap. NOTE: THE TIE WRAP STRAP KNOT MUST BE LOCATED AWAY FROM THE BRACKET HOLES SO THE RETAINER PUSH PIN CAN BE INSTALLED INTO THE BRACKET HOLE. 5. Install the revised assembly on the door per the Service Manual procedure. PART NUMBER PART NAME CLASS 95874-S Tie Wrap Strap (Pk/10) AG OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Bumper To Bumper Warranty Coverage. For 1992/93 Model Year Vehicles And 1991 Lincolns. Eligible Under Basic Warranty Coverage For All Other Model Year Vehicles. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 9322 > Jan > 93 > Power Door Lock - Inoperative > Page 8016 Operation/Description/Time Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Technical Service Bulletins > Page 8017 Power Door Lock Actuator: Locations Circuit Location Amp Cigar Lighter Fuse Panel 20 Power Door Locks Fuse Panel 20 Power Moon Roof Fuse Panel 20 Power Seats Fuse Panel 20 Power Windows Fuse Panel 20 Windshield Wiper Fuse Panel 8.25 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Actuator: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 8020 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 8021 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 8022 Power Door Lock Actuator: Electrical Diagrams Power Door Locks (Except Keyless Entry) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 8023 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 8024 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 8025 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component Information > Diagrams > Diagram Information and Instructions > Page 8026 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8031 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8032 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8033 Power Door Lock Relay: Electrical Diagrams Power Door Locks (Except Keyless Entry) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8034 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8035 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8036 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8037 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8042 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8043 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8044 Power Door Lock Switch: Electrical Diagrams Power Door Locks (Except Keyless Entry) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8045 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8046 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8047 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8048 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 92211 > Oct > 92 > Alarm System - False Security Alarm Trunk / Liftgate Lock Cylinder: Customer Interest Alarm System - False Security Alarm Article No. 92-21-1 October 7, 1992 ^ LOCK - TRUNK - BENT CYLINDER TAB FALSELY ACTIVATES ALARM ^ ALARM SYSTEM - ACTIVATED IN ERROR FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1988-91 CONTINENTAL, MARK VII, TOWN CAR 1989-91 COUGAR ISSUE: The anti-theft alarm system may be activated in error because of a bent trunk lock switch tab in the lock cylinder. ACTION: Install a new trunk lock cylinder by using the following service procedure. 1. Remove the trunk lock cylinder from the rear decklid sheet metal. Refer to the appropriate 1991 Service Manual, Section 44-10, for service details. 2. Examine the tab portion of the anti-theft lock switch to see if it is bent. The switch is part of the trunk lock cylinder. Refer to Figure 1 for an example of a bent tab. 3. If the tab is bent, replace the trunk lock and matching glove box lock. On Mark VII's also replace the console stowage lock. Refer to the Parts Block of this article for the correct service part numbers. 4. If the tab is OK, reinstall the trunk lock cylinder and continue as follows: a. Check to see that the tab engages with the trunk sheet metal. b. Check with an ohmmeter that the two terminals on the white connector of the trunk lock cylinder are an "open circuit". (There is no continuity or current between them.) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 92211 > Oct > 92 > Alarm System - False Security Alarm > Page 8057 c. Replace the trunk lock cylinder and matching glove box lock if current exists between the two terminals. PART INFORMATION OTHER APPLICABLE ARTICLES: None SUPERSEDES: 89-15-2 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1991 Lincolns, Basic Warranty Coverage For 1989-91 Thunderbird/Cougar and 1988-1990 Lincolns OPERATIONDESCRIPTION TIME 922101A Continental 0.8 Hr. 922101A Thunderbird, Cougar 0.6 Hr. 922101A Town Car, Mark VII 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7043507 02 OASIS CODES: 112000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 89152 > Jul > 89 > Alarm System - False Activation Trunk / Liftgate Lock Cylinder: Customer Interest Alarm System - False Activation ALARM SYSTEM-FALSELY ACTIVATED-VEHICLES BUILT BEFORE 2/20/89 LOCK-TRUNK-BENT CYLINDER TAB FALSELY ACTIVATES ALARM-VEHICLES BUILT BEFORE 2/20/89 Article No. 89-15-2 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1988-89 CONTINENTAL, MARK VII, TOWN CAR 1989 COUGAR Figure 1 ISSUE: The anti-theft alarm system may be falsely activated because of a bent trunk lock switch tab in the lock cylinder. ACTION: Install a new trunk lock cylinder by using the following service procedure. 1. Remove the trunk lock cylinder from the rear decklid sheet metal. Refer to Section 44-10 of the appropriate Shop Manual for service details. 2. Examine the tab portion of the anti-lock switch to see if it is bent. The switch is part of the trunk lock cylinder. Refer to Figure 1 for an example of a bent tab. 3. If the tab is bent, replace the trunk lock and matching glove box lock. On Mark VII's also replace the console stowage lock. Refer to the lock cylinder application chart for the correct service part numbers. 4. If the tab is OK, reinstall the trunk lock cylinder and do the following steps. a. Check to see that the tab engages with the trunk sheet metal. b. Check with an ohmmeter that the two terminals on the white connector of the trunk lock cylinder are an "open circuit". (There is no continuity or current between them.) c. Replace the trunk lock cylinder and matching glove box lock if current exists between the two terminals. LOCK CYLINDER APPLICATION CHART MODEL YEAR CARLINE PART NUMBER Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest: > 89152 > Jul > 89 > Alarm System - False Activation > Page 8062 1988/1989 Continental E90Y-5443507-A 1988/1989 Town Car E9VY-5443507-A 1988/1989 Mark VII E9LY-6343507-A 1989 T-Bird/Cougar E9SZ-634507-D PART NUMBER PART NAME CLASS E90Y-5443507-A Lock Cylinder C E9VY-5443507-A Lock Cylinder B E9LY-6343507-A Lock Cylinder B E9SZ-6343507-D Lock Cylinder C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891502A Continental 0.8 Hr. 891502A Thunderbird, Cougar 0.6 Hr. 891502A Town Car, Mark VII 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7043507 02 OASIS CODES: 2900, 1200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92211 > Oct > 92 > Alarm System - False Security Alarm Trunk / Liftgate Lock Cylinder: All Technical Service Bulletins Alarm System - False Security Alarm Article No. 92-21-1 October 7, 1992 ^ LOCK - TRUNK - BENT CYLINDER TAB FALSELY ACTIVATES ALARM ^ ALARM SYSTEM - ACTIVATED IN ERROR FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1988-91 CONTINENTAL, MARK VII, TOWN CAR 1989-91 COUGAR ISSUE: The anti-theft alarm system may be activated in error because of a bent trunk lock switch tab in the lock cylinder. ACTION: Install a new trunk lock cylinder by using the following service procedure. 1. Remove the trunk lock cylinder from the rear decklid sheet metal. Refer to the appropriate 1991 Service Manual, Section 44-10, for service details. 2. Examine the tab portion of the anti-theft lock switch to see if it is bent. The switch is part of the trunk lock cylinder. Refer to Figure 1 for an example of a bent tab. 3. If the tab is bent, replace the trunk lock and matching glove box lock. On Mark VII's also replace the console stowage lock. Refer to the Parts Block of this article for the correct service part numbers. 4. If the tab is OK, reinstall the trunk lock cylinder and continue as follows: a. Check to see that the tab engages with the trunk sheet metal. b. Check with an ohmmeter that the two terminals on the white connector of the trunk lock cylinder are an "open circuit". (There is no continuity or current between them.) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92211 > Oct > 92 > Alarm System - False Security Alarm > Page 8068 c. Replace the trunk lock cylinder and matching glove box lock if current exists between the two terminals. PART INFORMATION OTHER APPLICABLE ARTICLES: None SUPERSEDES: 89-15-2 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1991 Lincolns, Basic Warranty Coverage For 1989-91 Thunderbird/Cougar and 1988-1990 Lincolns OPERATIONDESCRIPTION TIME 922101A Continental 0.8 Hr. 922101A Thunderbird, Cougar 0.6 Hr. 922101A Town Car, Mark VII 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7043507 02 OASIS CODES: 112000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89152 > Jul > 89 > Alarm System - False Activation Trunk / Liftgate Lock Cylinder: All Technical Service Bulletins Alarm System - False Activation ALARM SYSTEM-FALSELY ACTIVATED-VEHICLES BUILT BEFORE 2/20/89 LOCK-TRUNK-BENT CYLINDER TAB FALSELY ACTIVATES ALARM-VEHICLES BUILT BEFORE 2/20/89 Article No. 89-15-2 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1988-89 CONTINENTAL, MARK VII, TOWN CAR 1989 COUGAR Figure 1 ISSUE: The anti-theft alarm system may be falsely activated because of a bent trunk lock switch tab in the lock cylinder. ACTION: Install a new trunk lock cylinder by using the following service procedure. 1. Remove the trunk lock cylinder from the rear decklid sheet metal. Refer to Section 44-10 of the appropriate Shop Manual for service details. 2. Examine the tab portion of the anti-lock switch to see if it is bent. The switch is part of the trunk lock cylinder. Refer to Figure 1 for an example of a bent tab. 3. If the tab is bent, replace the trunk lock and matching glove box lock. On Mark VII's also replace the console stowage lock. Refer to the lock cylinder application chart for the correct service part numbers. 4. If the tab is OK, reinstall the trunk lock cylinder and do the following steps. a. Check to see that the tab engages with the trunk sheet metal. b. Check with an ohmmeter that the two terminals on the white connector of the trunk lock cylinder are an "open circuit". (There is no continuity or current between them.) c. Replace the trunk lock cylinder and matching glove box lock if current exists between the two terminals. LOCK CYLINDER APPLICATION CHART MODEL YEAR CARLINE PART NUMBER Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89152 > Jul > 89 > Alarm System - False Activation > Page 8073 1988/1989 Continental E90Y-5443507-A 1988/1989 Town Car E9VY-5443507-A 1988/1989 Mark VII E9LY-6343507-A 1989 T-Bird/Cougar E9SZ-634507-D PART NUMBER PART NAME CLASS E90Y-5443507-A Lock Cylinder C E9VY-5443507-A Lock Cylinder B E9LY-6343507-A Lock Cylinder B E9SZ-6343507-D Lock Cylinder C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891502A Continental 0.8 Hr. 891502A Thunderbird, Cougar 0.6 Hr. 891502A Town Car, Mark VII 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7043507 02 OASIS CODES: 2900, 1200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 97811 > Apr > 97 > Rear Axle Whining/Howling Noise Ring Gear: All Technical Service Bulletins Rear Axle - Whining/Howling Noise Article No. 97-8-11 04/14/97 ^ NOISE - "WHINING/HOWLING" FROM REAR AXLE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION ^ REAR AXLE - "WHINING/HOWLING" NOISE DURING LIGHT THROTTLE AT SPEEDS BETWEEN 56-72 KM/H (35-45 MPH) OR AT HIGHWAY SPEEDS DURING ACCELERATION OR DECELERATION FORD: 1989-96 THUNDERBIRD LINCOLN-MERCURY: 1989-96 COUGAR ISSUE: Some vehicles may exhibit a rear axle "whining" or "howling" noise. This noise may be audible during light throttle at speeds between 56-72 km/h (35-45 mph) or at highway speeds during acceleration or deceleration. This may be due to the ring and pinion gear set. ACTION: Select the appropriate ring and pinion set from the Parts Block listed below and replace the ring and pinion set. The revised ring and pinion should reduce the possibility of noise. Refer to the appropriate year Thunderbird/cougar Service Manual and the following text for removal and installation procedures. REAR AXLE ASSEMBLY IDENTIFICATION Refer to the metal service identification tag for the rear axle ring gear size, ratio and differential type (Traction-Lok or conventional). The identification tag is attached to the rear axle cover by a cover bolt. CAUTION: SHEET MOLDING COMPOSITE (SMC) PLASTIC REAR AXLE COVERS CANNOT BE REUSED AFTER REMOVAL. A NEW COVER SHOULD BE ORDERED AS SOON AS POSSIBLE TO COMPLETE THE REPAIR ON A TIMELY BASIS. CAUTION: BE SURE TO MARK THE DRIVESHAFT IN RELATION TO THE COMPANION FLANGE SO IT MAY BE REINSTALLED IN ITS ORIGINAL POSITION. CAUTION: DIFFERENTIAL BEARING CAPS MUST BE INSTALLED IN THEIR ORIGINAL POSITIONS AND LOCATIONS AT ASSEMBLY TIME. CAUTION: IF LOOSENED, REMOVED OR DAMAGED, THE SPEED SENSOR RING CANNOT BE REUSED AND MUST BE REPLACED. NOTE: BE SURE TO FILL THE AXLE WITH MOTORCRAFT SAE 80W90 PREMIUM REAR AXLE LUBRICANT (XY-80W90-QL) TO THE LEVEL SPECIFIED IN THE SERVICE MANUAL. FOR TRACTION-LOK DIFFERENTIALS, ADD 118 mL (4 OZ) OF ADDITIVE FRICTION MODIFIER (C8AZ-19B546-A). ROAD TEST THE VEHICLE. Parts Block OTHER APPLICABLE ARTICLES: NONE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 97811 > Apr > 97 > Rear Axle Whining/Howling Noise > Page 8079 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Powertrain Warranty Coverage For 1989-91 Vehicles OPERATION DESCRIPTION TIME 970811A Install New Gear Set 2.5 Hrs. (Includes Drain And Refill DEALER CODING CONDITION BASIC PART NO. CODE 4209 56 OASIS CODES: 509000, 597997, 702200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Locks > Trunk / Liftgate Lock Cylinder > Component Information > Technical Service Bulletins > All Other Service Bulletins for Trunk / Liftgate Lock Cylinder: > 97811 > Apr > 97 > Rear Axle Whining/Howling Noise > Page 8085 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-96 Model Year Vehicles, Powertrain Warranty Coverage For 1989-91 Vehicles OPERATION DESCRIPTION TIME 970811A Install New Gear Set 2.5 Hrs. (Includes Drain And Refill DEALER CODING CONDITION BASIC PART NO. CODE 4209 56 OASIS CODES: 509000, 597997, 702200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Diagrams > Diagram Information and Instructions Power Mirror Motor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8091 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8092 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 8093 Power Mirrors Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Body & Chassis Components Lower Rear Of LH Door Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions Power Mirror Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8099 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8100 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8101 Power Mirrors Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 9384 > Apr > 93 > Exterior Clearcoat - Cracking/Eroding/Peeling Off Paint: Customer Interest Exterior Clearcoat - Cracking/Eroding/Peeling Off Article No. 93-8-4 April 14, 1993 PAINT - EXTERIOR CLEARCOAT "MICROCHECKING", HAZING OR PEELING FORD: 1983-93 THUNDERBIRD 1984-93 TEMPO 1985-93 ESCORT 1986 LTD 1986-93 TAURUS 1989-93 CROWN VICTORIA, MUSTANG, PROBE LINCOLN-MERCURY: 1983-93 COUGAR 1984-92 MARK VII 1984-93 TOPAZ 1985-89 TRACER 1986 MARQUIS 1986-93 SABLE 1988-93 CONTINENTAL, TOWN CAR 1989-93 GRAND MARQUIS 1991-93 TRACER 1993 MARK VIII LIGHT TRUCK: 1983-93 RANGER 1986-93 AEROSTAR 1987-90 BRONCO II 1988-93 F SUPER DUTY, F-47 1991-93 ECONOLINE, EXPLORER 1992-93 F-150-350 SERIES 1993 VILLAGER ISSUE: The clearcoat layer of the basecoat/clearcoat paint system may "microcheck" (crack and erode), turn white, flake or peel off the vehicle. This condition is noticeable on the horizontal surfaces only. ACTION: Inspect the vehicle and if repair is necessary, refer to the following procedure for service details. This is a wet on wet procedure. Sanding is not required after the seal coat is applied. NOTE: READ THE ENTIRE SERVICE REPAIR PROCEDURE BEFORE STARTING REPAIRS. REPAIR PROCEDURE WARNING: ALWAYS WEAR A NIOSH/OSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT. 1. Wash the vehicle with soap and water. 2. Verify clearcoat to basecoat or primer adhesion by applying a 2" wide masking tape strip on all horizontal body panels. a. Pull the tape up quickly b. Inspect the adhesive side for paint removal. NOTE: IF PAINT WAS REMOVED DURING TAPE TEST, THE ENTIRE CLEARCOAT AND BASECOAT SHOULD BE REMOVED FROM THE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 9384 > Apr > 93 > Exterior Clearcoat - Cracking/Eroding/Peeling Off > Page 8111 PANEL. 3. Wipe down the areas to be repainted with wax and grease remover. ^ BASF product # 900 PreKleano or equivalent 4. Sand the affected surface with 150/240 grit sand paper. Remove only clearcoat and colorcoat, featheredge areas with 320 grit paper. NOTE: DO NOT REMOVE SPRAY PRIMER OR E-COAT. 5. Blow off the area to remove loose dust or debris. 6. Wipe the sanded surface with wax or grease remover. ^ BASF product # 901 Prekleano or equivalent 7. Tack off area. 8. Mix and apply one coat of epoxy primer for adhesion and let dry per manufacturer's label instruction (20 - 30 minutes). ^ BASF product # DE 15, PA16, PR80 or equivalent NOTE: DO NOT SAND THE NEWLY PRIMED AREAS. 9. Mix and apply two coats of the appropriate colored primer surface sealer. ^ BASF product # DP 21, Solo Color 1:1, then 2 parts of mixture 1 part DH 60, 30% PR80 or equivalent. 10. Mix and apply 2 coats or until hiding of basecoat per manufacturer's label instructions. Apply first coat to repair area only. Apply second coat over entire area. Allow a minimum of 15 minutes flash time before applying the clearcoat. ^ BASF # Diamont Basecoat Color and Diamont Reducer 1:1 or equivalent. 11. Mix and apply 2 coats of urethane clearcoat per manufacturer's label instructions. ^ BASF product # DC90 Diamond Clear, LH50 Diamond Hardener 2:1 or equivalent. 12. Polish if necessary. 13. Clean and detail the vehicle and return it to the customer. WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 9192 > May > 91 > Paint - Paint Blistering or Peeling Off Bumper Covers Paint: Customer Interest Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. 6. Blow off the area with compressed air to remove any dirt and sanding residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > Customer Interest: > 9192 > May > 91 > Paint - Paint Blistering or Peeling Off Bumper Covers > Page 8116 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. 13. Apply top coat (body color) where necessary. 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal Paint: All Technical Service Bulletins Paint - Iron Particle Removal Article No. 95-6-1 03/27/95 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, combustion engines, jet engines, body shops, etc. These particles mechanically/magnetically bond to vehicles' painted surfaces. Moisture and temperature combine with the particles to create a chemical reaction. The reaction causes the particles to corrode and enter into the physical paint film. ACTION: To remove these particles/contaminants, USE ONLY the following procedure. The procedure must be performed before any buffing, polishing, color sanding or refinishing is attempted. The materials in this procedure are alkaline, acidic and neutral. They must be used in the specified order. CAUTION: ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR AND MAY RESULT IN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8122 POSSIBLE DAMAGE TO THE PAINTED SURFACES AND TRIM. WARNING: THE TECHNICIAN MUST WEAR PROTECTIVE CLOTHING AND EYE PROTECTION TO PREVENT SKIN IRRITATION. CAUTION: THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM, FLEXIBLE PAINTED SURFACES OR OTHER PAINTED SURFACES. FOLLOW DIRECTIONS EXACTLY AND RINSE THOROUGHLY AFTER EACH STEP. NOTE: THIS DECONTAMINATION PROCEDURE IS DESIGNED TO REMOVE SURFACE CONTAMINANTS FROM THE PAINT ON VEHICLES THAT HAVE BEEN CONTAMINATED UP TO 120 DAYS. VEHICLES WHICH HAVE EXPERIENCED THE CONDITION LONGER THAN THIS PERIOD MAY REQUIRE AN ADDITIONAL TREATMENT TO REMOVE FERROUS METAL CONTAMINANTS. IDENTIFICATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8123 For ease of identifying, the Radio Shack Model 63-851, 30X, lighted, magnifier is recommended. 1. Ferrous Metal ^ Light colored vehicles: Small rust orange dots with black in center of stain. ^ Dark colored vehicles: Small white or silver dots with a "rainbow hue" around the particle. The surface will also feel rough to the touch. 2. Industrial Fallout ^ The surface feels rough to the touch and may exhibit crystalline deposits. ^ Usually ferrous metal is present, as well as water spots. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8124 3. Acid Rain ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles will show cloudy or greying spots where the acids have started to etch away the paint. NOTE: IN EXTREME CASES ETCHING OF THE SURFACE WILL BE VISIBLE OR FELT. DECONTAMINATION Use Finish Kare Inc. products 1119/883/11850 to decontaminate the paint surface. Follow the manufacturer's recommended procedures. NOTE: FORD DOES NOT RECOMMEND THE USE OF OXALIC ACIDS OR OTHER "FALLOUT REMOVERS". 1. Rinse off dust and debris with cold water. Be sure to start at the bottom and work up. 2. Prepare product "1119" by mixing one (1) part "1119" with four (4) parts cold water. 3. Use clean wash mitt and apply mixture to entire car, starting at the bottom and working up to the top surface. Keep car wet with the solution for 5 to 10 minutes. Do not allow product to dry on the car, and do not allow it to streak down the sides. Rewipe with mitt if necessary to avoid streaks. 4. Rinse car with cold water. 5. Dry the flat surfaces of the vehicle hood, roof and deck lid. 6. Apply product "883" directly to the contaminated surfaces using a clean dry sponge, wash mitt, or soft truck brush ("883" is ready to use from the bottle, with no mixing involved). Keep the areas wet with the "883" for 5 to 7 minutes. Do not allow to dry on the car. Wipe down to the body line on the sides. 7. Prepare product "118SC" by mixing 1 oz (0.03 L) with 1 gal (3.785 L) of water. 8. Shampoo the vehicle with "118SC" shampoo mixture using a clean wash mitt and then rinse with cold water. NOTE: DO NOT USE "1185C" MITT WITH "1119" OR "883" SOLUTIONS. USE SEPARATE MITTS AND ALWAYS KEEP THEM SEPARATE. 9. Inspect paint surface to see if rust particles have been removed. If rust particles have been on the vehicle for a long time, it may be necessary to repeat each of the above steps. NOTE: THE NEUTRALIZER CONCENTRATE IS A HEAVY DUTY SHAMPOO AND CAN BE USED IN AN AUTOMATIC CAR WASH SYSTEM. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8125 CORRECTION OF SURFACE FOLLOWING DECONTAMINATION: 1. Visually inspect surface for evidence of removal of ferrous metal particles, crystalline deposits and water spots. Acid rain discoloring or etching will require either buffing, color sanding or refinishing if etching is visible. 2. Use the buffing products from only one (1) manufacturer. Do not intermix products. 3. Always follow the manufacturer's product sequence. Use appropriate pads with each product as recommended by the manufacturer. NOTE: DO NOT REMOVE MORE THAN 0.3 OF A MIL OF PAINT MATERIAL, OR REPAINTING WILL BE REQUIRED. 4. Use a dual action sander (D/A Sander) with a velcro-mount backing plate and appropriate foam pad for final polishing swirl removal. 5. Use an alcohol and water mixture (1:4 ratio) to clean buffed areas to verify removal of scratches and swirls before application of final protective glaze. NOTE: FREQUENT WASHING OF VEHICLES IS IMPORTANT. CONTAMINANTS SETTLE ONTO THE VEHICLE EVERY DAY. USE CLEAN WATER (DEIONIZED, REVERSE OSMOSIS, ETC.) TWICE WEEKLY TO REMOVE HEAVY DUST, AND PARTICULATES. THE USE OF A NEUTRAL pH CAR WASH SOAP EVERY TWO (2) WEEKS IS RECOMMENDED TO NEUTRALIZE VEHICLE CONTAMINATION. Parts Block NOTE: DEALERS SHOULD USE PROGRAM CODE R-23 AND CONDITION CODES C5 AND C6. REFER TO W & P MANUAL, SECTION 5-1, PAGE 3. OTHER APPLICABLE ARTICLES: 91-18-1, 92-6-4 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 950601A Decontaminate And Surface 0.6 Hr. Correction - Aspire 950601B Decontaminate And Surface 0.6 Hr. Correction - Escort/Tracer 950601C Decontaminate And Surface 0.6 Hr. Correction - Probe Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8126 950601D Decontaminate And Surface 0.6 Hr. Correction - Contour/Mystique 950601E Decontaminate And Surface 0.6 Hr. Correction - Mustang 950601F Decontaminate And Surface 0.7 Hr. Correction - Taurus/Sable 950601G Decontaminate And Surface 0.7 Hr. Correction - Thunderbird/Cougar 950601H Decontaminate And Surface 0.7 Hr. Correction - Crown Victoria/Grand Marquis 950601I Decontaminate And Surface 0.7 Hr. Correction - Mark VIII 950601J Decontaminate And Surface 0.7 Hr. Correction - Continental 950601K Decontaminate And Surface 0.6 Hr. Correction - Capri 950601L Decontaminate And Surface 0.8 Hr. Correction - Town Car 950601M Decontaminate And Surface 0.7 Hr. Correction - Villager 950601N Decontaminate And Surface 0.6 Hr. Correction - Windstar 9506010 Decontaminate And Surface 0.7 Hr. Correction - Aerostar 950601P Decontaminate And Surface 0.6 Hr. Correction - Bronco 9506010 Decontaminate And Surface 1.1 Hrs. Correction - Econoline 950601R Decontaminate And Surface 0.9 Hr. Correction - F-Series 950601S Decontaminate And Surface 0.6 Hr. Correction - Explorer 950601T Decontaminate And Surface 0.7 Hr. Correction - Ranger 950601U Decontaminate And Surface 0.5 Hr. Correction - F-Super Duty 950601V Decontaminate And Surface 0.7 Hr. Correction - F/B-Series 950601W Decontaminate And Surface 0.7 Hr. Correction - L-Series 950601X Decontaminate And Surface 0.5 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8127 Correction - Cargo 950601Y Decontaminate And Surface 0.6 Hr. Correction - Tempo/Topaz DEALER CODING BASIC PART NO. CONDITION CODE ENTRE C5 OR C6 OASIS CODES: 106000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information Paint: All Technical Service Bulletins Paint - Preparation Procedure And MSDS Information Article No. 94-23-4 11/14/94 PAINT - PRIMED SHEET METAL - PREP PROCEDURE AND MSDS INFORMATION FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984 and after TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984 and after TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1993 and after MARK VIII MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: This procedure is being published to advise all body and paint technicians about proper procedures for preparation of sheet metal parts coated with electrodeposition primer (E-Coat). ACTION: When prepping a replacement body panel for installation, it is mandatory to leave the E-Coat intact. DO NOT SAND OFF THE E-COAT. Improper preparation with excessive sanding of the E-Coat to bare metal will jeopardize the sheet metal warranty and overall customer satisfaction. In particular, the E-Coat is necessary to protect the parts from rust. Light scuff sanding using a Scotch Brite pad or wet 320 grit sand paper is recommended for minor flaws. If a minor flaw exists, wet sand or scuff out the flaw and prime the repair area. Again, do not remove all of the E-Coat from the panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 8132 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 8133 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 8134 WARNING: LEAD CONTAMINATION POTENTIAL: THE ELECTRODEPOSITION PRIMER USED BY FORD MOTOR COMPANY OVER BASE METAL ON SERVICE REPLACEMENT PARTS OR COMPLETED VEHICLES CONTAINS SMALL AMOUNTS OF LEAD FOR CORROSION PROTECTION OF STEEL. EXCESSIVE DUSTS GENERATED BY UNNECESSARY AND IMPROPER SANDING MAY CONTAIN AIRBORNE LEAD CONTAMINATION IN EXCESS OF OSHA STANDARDS. INFORMATION REGARDING THE HAZARDS OF LEAD CAN BE FOUND IN THE CHEMICAL FACT SHEETS IN THE FIGURES IN THIS ARTICLE. NOTE: READ ALL INFORMATION IN THIS TECHNICAL SERVICE BULLETIN CAREFULLY AND FORWARD TO ALL EMPLOYEES PERFORMING PAINT PREPPING OPERATIONS. DEALERS SHOULD CONTACT LEGAL COUNSEL AND/OR LOCAL OSHA Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 8135 AUTHORITIES FOR DIRECTION REGARDING OSHA LEAD STANDARD REQUIREMENTS. If a replacement body panel contains more than a minor flaw in the E-coat, it should be returned. Contact your Customer Service representative for instructions. If more extensive sanding, other than that described above, is necessary, (e.g., refinishing original vehicle sheet metal) follow the procedures outlined below: ALTERNATIVE SANDING PROCEDURES WHEN EXTENSIVE SANDING IS REQUIRED The following procedures for sheet metal preparation by sanding or media blasting are based on tests conducted by Ford Motor Company in accordance with requirements set forth in the Federal OSHA Inorganic Lead Standard 29 CFR 1910.1025. SANDING PROCEDURE 1. Each technician performing the sanding operation MUST wear an approved respirator with high efficiency particulate filter (HEPA). 2. Technicians should use dual action sander with vacuum collection. 3. The vacuum equipment MUST be equipped with a HEPA filter on the air exhaust. Dealers are cautioned not to exhaust vacuum air into the atmosphere. Operators are cautioned to follow the manufacturer's guidelines for maintenance and the replacement of filters. MEDIA BLASTING PROCEDURE 1. Testing has shown that plastic media blasting meets OSHA lead standard requirements and is efficient when the manufacturer's published procedures are followed. 2. The operator must wear an air supplied hood using compressed air free from carbon monoxide, oil, water, and other contamination when performing this operation. Specifics of the media blasting procedure for whole body paint removal have been previously published. NOTE: PLEASE READ THE CHEMICAL FACT SHEETS IN THE FIGURES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9384 > Apr > 93 > Exterior Clearcoat - Cracking/Eroding/Peeling Off Paint: All Technical Service Bulletins Exterior Clearcoat - Cracking/Eroding/Peeling Off Article No. 93-8-4 April 14, 1993 PAINT - EXTERIOR CLEARCOAT "MICROCHECKING", HAZING OR PEELING FORD: 1983-93 THUNDERBIRD 1984-93 TEMPO 1985-93 ESCORT 1986 LTD 1986-93 TAURUS 1989-93 CROWN VICTORIA, MUSTANG, PROBE LINCOLN-MERCURY: 1983-93 COUGAR 1984-92 MARK VII 1984-93 TOPAZ 1985-89 TRACER 1986 MARQUIS 1986-93 SABLE 1988-93 CONTINENTAL, TOWN CAR 1989-93 GRAND MARQUIS 1991-93 TRACER 1993 MARK VIII LIGHT TRUCK: 1983-93 RANGER 1986-93 AEROSTAR 1987-90 BRONCO II 1988-93 F SUPER DUTY, F-47 1991-93 ECONOLINE, EXPLORER 1992-93 F-150-350 SERIES 1993 VILLAGER ISSUE: The clearcoat layer of the basecoat/clearcoat paint system may "microcheck" (crack and erode), turn white, flake or peel off the vehicle. This condition is noticeable on the horizontal surfaces only. ACTION: Inspect the vehicle and if repair is necessary, refer to the following procedure for service details. This is a wet on wet procedure. Sanding is not required after the seal coat is applied. NOTE: READ THE ENTIRE SERVICE REPAIR PROCEDURE BEFORE STARTING REPAIRS. REPAIR PROCEDURE WARNING: ALWAYS WEAR A NIOSH/OSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT. 1. Wash the vehicle with soap and water. 2. Verify clearcoat to basecoat or primer adhesion by applying a 2" wide masking tape strip on all horizontal body panels. a. Pull the tape up quickly b. Inspect the adhesive side for paint removal. NOTE: IF PAINT WAS REMOVED DURING TAPE TEST, THE ENTIRE CLEARCOAT AND BASECOAT SHOULD BE REMOVED FROM THE Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9384 > Apr > 93 > Exterior Clearcoat - Cracking/Eroding/Peeling Off > Page 8140 PANEL. 3. Wipe down the areas to be repainted with wax and grease remover. ^ BASF product # 900 PreKleano or equivalent 4. Sand the affected surface with 150/240 grit sand paper. Remove only clearcoat and colorcoat, featheredge areas with 320 grit paper. NOTE: DO NOT REMOVE SPRAY PRIMER OR E-COAT. 5. Blow off the area to remove loose dust or debris. 6. Wipe the sanded surface with wax or grease remover. ^ BASF product # 901 Prekleano or equivalent 7. Tack off area. 8. Mix and apply one coat of epoxy primer for adhesion and let dry per manufacturer's label instruction (20 - 30 minutes). ^ BASF product # DE 15, PA16, PR80 or equivalent NOTE: DO NOT SAND THE NEWLY PRIMED AREAS. 9. Mix and apply two coats of the appropriate colored primer surface sealer. ^ BASF product # DP 21, Solo Color 1:1, then 2 parts of mixture 1 part DH 60, 30% PR80 or equivalent. 10. Mix and apply 2 coats or until hiding of basecoat per manufacturer's label instructions. Apply first coat to repair area only. Apply second coat over entire area. Allow a minimum of 15 minutes flash time before applying the clearcoat. ^ BASF # Diamont Basecoat Color and Diamont Reducer 1:1 or equivalent. 11. Mix and apply 2 coats of urethane clearcoat per manufacturer's label instructions. ^ BASF product # DC90 Diamond Clear, LH50 Diamond Hardener 2:1 or equivalent. 12. Polish if necessary. 13. Clean and detail the vehicle and return it to the customer. WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures Technical Service Bulletin # 91181 Date: 910905 Exterior Paint - Comprehensive Repair Procedures Article No. 91-18-1 09/05/91 PAINT-EXTERIOR-COMPREHENSIVE REPAIR PROCEDURES FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-92 TAURUS 1988-92 FESTIVA 1989-92 PROBE LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1988-92 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-92 AEROSTAR 1991 EXPLORER ISSUE: A comprehensive paint repair procedure TSB has been developed for service use. It includes the following paint repair topics: Section (A) has been superseded by TSB # 9264, dated 3/92. (B) Exterior Color Peeling From Ultra Violet Light (C) Lower Body Stone Protection Repair Tips (D) Procedures For PVC Body Side Moldings (E) Lower Body-Side Stone Chip Protection Program (F) Surface Defect Removal Without Repainting (G) 1991 Color Matched/Compatible Spray Primer Chart (H) Repair For Tinted Clearcoat (I) Frequently Used And Paintable Plastics (J) 1992 Paint Codes ACTION: If paint repair is required, refer to the following procedures for paint restoration. Section A Has Been Superseded By TSB # 9264, Dated 3/92. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS PROCEDURE # 2 FINISH KARE FORMULA # 1119 AND # 883 (Buffered solution not as harsh on aluminum parts) WARNING: FOR YOUR SAFETY, USE RUBBER GLOVES, GOGGLES AND PROTECTIVE CLOTHING WHEN HANDLING THESE PRODUCTS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8145 1. Apply hot diluted solution with soft mitt. 2. Agitate to create suds. Suds hold the acid solution in suspension and to the surface creating greater and extended activity. 3. Allow 3 to 5 minutes dwell time. 4. Rinse with COLD WATER. 5. Apply # 883 per label instructions. LIQUID NEUTRALIZER CONCENTRATE 1. Using a mitt, thoroughly go over the entire surface with the diluted solution (50-1) of water and # 118 Liquid Neutralizer Concentrate. Then wipe dry. 2. If the iron particles are not totally removed after 2 washings, use one or both of the following service actions. a. Sand with micro fine sandpaper (1500 Grid or greater) in localized areas. b. Buff with very light compound and polish with wax in localized areas. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'S) OR EXCESS MATERIALS. (B) Paint Exterior Color Peeling From Ultra Violet Light Paint may be damaged because of ultra violet light absorption through the color coat. This damage will cause the top coat to peel to the E-coat primer. If service is required, use the following procedure to correct the concerns. NOTE: READ THE ENTIRE SERVICE PROCEDURE BEFORE STARTING REPAIRS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT. 1. Wash the vehicle with soap and water. 2. Verify topcoat adhesion by applying a 2 inch wide masking tape strip on all body panels above and below the beltline on each panel. a. Pull the tape up quickly. b. Inspect the adhesive side of the tape for paint removal. NOTE: IF PAINT WAS REMOVED DURING THE TAPE TEST, THE ENTIRE PANEL SHOULD BE STRIPPED AND REFINISHED AS NECESSARY. 3. Remove all trim (mouldings, name plates, striping, etc.) from the areas which will be repainted. NOTE: ALL REQUIRED REPLACEMENT MOULDINGS AND STRIPES SHOULD BE ORDERED AND RECEIVED PRIOR TO REPAIRING THE CUSTOMER'S VEHICLE. 4. Wipe the entire vehicle with wax and grease remover. ^ BASF Product # 900 Prekleano ^ PPG Product # DX300 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mask off all areas on the vehicle which are not going to be painted or will be affected by overspray (engine compartment, wheels, etc.). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8146 6. Remove the paint to bare metal from all the areas of the vehicle which are going to be repainted. Use one of the following methods. SAND THE AFFECTED AREAS TO BARE METAL USING 40 GRIT 3M GREEN CORPS SANDING DISCS OR EQUIVALENT AND A SOFT PAD ON A 1700 RPM POLISHER. KEEP THE POLISHER MOVING TO AVOID DEVELOPING HOT SPOTS ON THE METAL. NOTE: CHEMICAL STRIPPING IS NOT RECOMMENDED. NOTE: IF AVAILABLE, PAINT MAY BE REMOVED USING A PLASTIC MEDIA BLAST SYSTEM. IF THIS PROCESS IS USED, EXTRA CARE MUST BE TAKEN DURING THE MASKING PROCESS TO PREVENT DAMAGE TO GLASS, MOULDING, ETC. 7. Blow off the entire vehicle to remove loose dust and debris. NOTE: IF RUST IS PRESENT, USE APPROPRIATE METAL CLEANER AND CONDITIONER (PHOSPHATE COATING) OVER BARE METAL AREAS. 8. Wipe all affected areas with a fast dry enamel reducer solvent, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. NOTE: THIS STEP WILL REDUCE THE POSSIBILITY OF FLASH RUST. ^ BASF Product # BR 50 ^ PPG Product # DX 300 ^ S-W Product # R7 K156 ^ DuPont Product # 3812 S ^ Sikkens Product # 123 FAST 9. Apply two medium wet coats (1.0 mil total) of self-etching, anti-corrosion primer using the manufacturer's recommendations and flash times. ^ BASF Product # DE-17 ^ PPG Product # DP EPOXY PRIMER ^ S-W Product # E2-6980 ^ DuPont Product # VARIPRIME ^ Sikkens Product # WASH FILLER 580 10. Apply three medium wet coats (2.0 mils total) of acrylic urethane primer surfacer following the manufacturer's recommended procedures. ^ BASF Product # DP-20 PRIMER/SUFACER ^ PPG Product # K-36 ^ S-W Product # P6-M49 OR P6-A48 ^ DuPont Product # URO PRIMERFILLER ^ Sikkens Product # AUTOCRYL 3+1 FILLER 11. Sand the vehicle using one of the following methods: ^ Wet-sand by hand using 400 grit or finer sandpaper. ^ Dry-sand by hand using 320 grit or finer sandpaper. 12. Blow the entire vehicle off to remove loose dust and debris. 13. Demask (remove all paper and tape) as necessary to remove the primer and dirt buildup on the paper and tape. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8147 14. Wipe the entire vehicle with wax and grease remover, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. ^ BASF Product # 901 PRE-PAINT CLEANER ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3812 S ^ Sikkens Product # M 600 15. Mask all areas on the vehicle which are not to be painted or will be affected by paint overspray (engine compartment, wheels, etc.). NOTE: APPLY BASECOAT/CLEAR COAT ONLY TO SURFACES WHICH ORIGINALLY HAD BASECOAT/CLEAR COAT 16. Apply three medium wet coats (enough material to hide primer) of acrylic enamel base coat or acrylic urethane monocoat following the manufacturer's recommended procedure. ^ BASF Product # DIAMONT BASECOAT/Solo ^ PPG Product # DELTRON BASECOAT DBC/Deltron ^ S-W Product # ULTRA BASE/Ultra One Stage ^ DuPont Product # CHROMABASE/Cronar ^ Sikkens Product # AUTO BASE/Autocryl 17. Apply two medium wet coats of 2K acrylic urethane enamel clear coat, following manufacturer's recommended procedure. ^ BASF Product # DIAMONT CLEAR 88/89 ^ PPG Product # CONCEPT 2001 DCU ^ S-W Product # CC-650 OR CC-640 ^ DuPont Product # 1080 S URO CLEAR ^ Sikkens Product # AUTO CLEAR 18. After the paint is dry, demask the entire vehicle and clean up any areas which have overspray. 19. Polish the vehicle as necessary to remove any defects in the paint which may create a customer concern. CAUTION: USE LOW SPEED (1700 RPM MAXIMUM) POLISHER. 20. Install all trim (mouldings, name plates, striping, etc.) on the vehicle which were removed prior to repainting. 21. Clean the exterior and interior of the vehicle thoroughly, including air ducts and other areas which are prone to accumulating dust. This step is essential to ensure customer satisfaction. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8148 Figure 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8149 Figure 2 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8150 Figure 3 STRIP AND REFINISH CLAIMING METHODOLOGY The claiming instructions shown in Figure 1 are applicable to the repair of the EXTERIOR COLOR PEELING FROM ULTRA VIOLET LIGHT concern covered in this TSB only. See the SAMPLE CLAIMS, Figures 2 and 3, for examples. (C) Lower Body Stone Protection Repair Tips Ford has introduced a vinyl anti-stone abrasion material for the lower exterior body surfaces of selected passenger vehicles and light trucks. The anti-stone abrasion material is applied to the lower fenders, rocker panels, lower doors, quarter panel dogleg, and lower rear of quarter panel behind the wheel. The anti-stone abrasion material will usually end at a body character line. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8151 While primarily for servicing of factory-applied protective coating, the following provides installation information. If the vehicle has experienced body damage in the factory-applied material protective area, the sheet metal damage must be serviced prior to the application of the new protective coating. SMALL AREAS - MINOR DEFECTS (VEHICLES WITH FACTORY SPRAYED-ON VINYL) A small dent in the sheet metal that did not mar the vinyl surface, can possibly be corrected with proper bumping tools without damage to the vinyl coating. However, noticeable scratches or gouges (not over 1/2 inch in diameter) or dings and dents that when "ironed out" show vinyl damage, can be satisfactorily serviced with the following procedure: 1. Solvent-wipe the damaged area with "Silicone and Wax Remover." 2. Using a heat gun or lamp, soften the vinyl coating of the damaged area until it can be scraped off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The spray-on vinyl protective coatings may not be suitable for "spot" application. See Manufacturer's label for instructions.) 3. Perform necessary servicing to correct the sheet metal damage. 4. Using white bodyfiller, fill the damaged area. Follow the instructions on the label and blend the bodyfiller with the surrounding sheet metal. 5. Allow the bodyfiller to completely cure and then carefully sand the area smooth, removing any high spots. 6. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. LARGE DAMAGED AREAS - VEHICLE WITH FACTORY SPRAYED ON VINYL Peeling or damage over a large area will necessitate removal of the factory sprayed-on vinyl coating. The following procedure is suggested. NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR, OR QUARTER PANEL REPLACEMENT IS REQUIRED (OR IN AN INITIAL INSTALLATION), DISREGARD STEPS NO. 1 AND NO. 2. 1. Using a heat gun or lamp, soften the vinyl coating until it is pliable. Scrape coating off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The vinyl material, abrasion resistant coating may not be suitable for "spot" applications. See manufacturer's label for instructions.) 2. Perform necessary servicing to correct the sheet metal damage. 3. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. COATING APPLICATIONS Approximately two quarts will be required for an initial installation on a passenger car or F-Series. Slightly more will be required for an Econoline. The specified dry film thickness of 15 to 20 mils (.015 to .020 inch) will require at least three, possibly four, applications of coating material, with "flash off" time between coats. Spray coat complete panels only. The coating must be applied with commercial equipment by an experienced automotive painter. The coating must be thoroughly agitated before application. The material is heavy bodied. A pressure cup spray gun or "Rocker Schutz Gun" is recommended. COATING PREPARATION - MASKING VEHICLE Install suitable covers over the wheels. NOTE: IF THE VEHICLE HAS LOWER BODY SIDE MOULDINGS (12-14 INCHES ABOVE THE "TURN UNDER" OF THE ROCKER PANEL), THE MOULDING CAN SERVE AS THE UPPER MARGIN OF THE AREA TO BE COATED. IF THE VEHICLE DOES NOT HAVE SUITABLE MOULDINGS, A SCULPTURE OR BREAK LINE IN THE SHEET METAL CAN BE UTILIZED. THIS LINE SHOULD BE SELECTED TO ENSURE ADEQUATE PROTECTION OF THE PAINTED SURFACES. VEHICLES WITH BODY SIDE MOULDINGS 1. Masking tape should be positioned so that the moulding lower edge is also covered. The adjoining sheet metal should be left uncovered too so anti-stone, abrasion vinyl can be applied. VEHICLES WITHOUT BODY SIDE MOULDINGS 2. If the contour of the body side has a break line, the upper coating margin must be masked off using 3M "Fine Line" Tape. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8152 a. The normal masking tape and paper protection for the body side should be applied first and positioned about a quarter inch above the margin line. b. The "Fine Line" tape should then be applied over the regular masking tape with the lower edge at the upper coating margin line. Extend this "Fine Line" tape into the wheel opening, in the absence of wheel opening mouldings, allowing the flange to be coated. c. The anti-stone abrasion coating does not adhere well to flexible plastic parts. If left exposed, they must be masked off. d. It is not necessary to mask off the body door openings in the coating area, as they will be uniformly coated where the door margins allow the coating to enter. NOTE: DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE. COATING PREPARATION - SHEET METAL REPAIRED SHEETMETAL 1. Scuff sand (No. 180 Grit Paper) the glossy surface of the painted areas to be coated. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and lint-free tack cloth. NEW SHEET METAL 1. Sand off (No. 180 Grit Paper) the prime paint in the area to be coated. 2. Using a lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. NEW INSTALLATION 1. The glossy surface of the paint in the coating area must be sanded with a D/A sander. A 220/240 Grit Disc does a good, fast job. DO NOT sand through the primer. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. SPRAY PROCEDURE The lower exposed painted fender, rocker, and quarter panel down flanges should be protected. The vehicle must be elevated high enough so that the painter can spray this area effectively. When an initial installation is to be made, a remote two-quart capacity pressure cup makes a much more efficient tool, as the spray gun can be used closer to the floor. The spray gun, fluid hose and/or cup must be cleaned immediately after use. Refer to manufacturer's recommended cleaning procedure. Lacquer thinner can be used when the suggested clean up material is unavailable. WARNING: WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EOUIPMENT. 1. After preparing the new or damaged area(s), mix either Epoxy primer or Self-etch prime, per manufacturer's label instructions, and spray bare metal areas. ^ BASF DE15 or DE17 ^ Sikkens Metalflex CR Primer (1 coat only) ^ DuPont Variprime ^ S-W E2G 980 GBP Etching Filler ^ PPG DP 40 (only) 2. Apply 1-2 light prime coats over the bare metal areas. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8153 3. Allow the material to dry for 15-20 minutes before applying the anti-stone abrasion material. 4. Mix and apply anti-stone abrasion material per manufacturer's label instructions over the primed area. NOTE: AN ORANGE PEELED FINISH IS NORMAL WITH THESE PRODUCTS. ^ BASF Glassohyd 1109-1240/6 ^ Sikkens 0TO Bodycoat ^ DuPont 123-5 Vinyl ^ S-W G/W 295 Vinyl Gravel Guard ^ PPG DX 54 Roadguard ^ 3M Rocker Schutz NOTE: SOME ANTI-STONE ABRASION MATERIAL MAY REQUIRE A SLIGHTLY DIFFERENT MIXING PREPARATION, PROCEDURE AND APPLICATION. SOME ANTI-STONE ABRASION MATERIALS CAN NOT BE USED FOR SPOT REPAIR. CHECK WITH THE PAINT MANUFACTURER FOR RECOMMENDATIONS ABOUT THEIR PRODUCT. 5. Allow the stone abrasion material to dry. Heat can be used to accelerate the drying time. Check the manufacturer's instructions. COLOR COAT The complete coated area, as well as the upper raw edge, must be covered with color coat. Mask off the upper margin line using "Fine Line" tape positioned 1/16 inch above the coating edge. Using appropriate service paint and application procedures, the protective coating area can now be finish painted with monocoat or a basecoat/clearcoat urethane system. NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA, NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Figure 4 Refer to the Lower Body Stone Protection Chart, Figure 4, for the material and labor hours involved. (D) Procedure For PVC Body Side Moldings If replacement of the body side molding is necessary, some dealer service kits will be supplied "paint to match." Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8154 The painting procedures in the following instructions (also included with the part) address materials from five (5) major aftermarket paint suppliers. Use the paint system materials you are the most familiar with. NOTE: CAREFULLY READ ALL LABEL WARNINGS BEFORE APPLYING THESE PRODUCTS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SIKKENS PRODUCTS PREPARATION 1. Degrease with M600 wax and grease remover. 2. Scuff with # 320 dry paper or Scotchbrite 7447 (red). 3. Repeat degreasing step. 4. Spray two medium coats of Plastoflex primer. Allow 5 to 10 minutes flash between coats. 5. Allow 20 minutes flash-off at 70~ F before topcoating. TOPCOATING 1. Mix Autocryl color with Elast-O-Actif 50:50 by volume. 2. Mix this material with 1.2.3 hardner and 1.2.3 reducer (use correct reducer for temperature) 100:50:30 by volume. 3. Apply three medium coats, allowing enough flash off to dry to a light touch. 4. Dry one hour at 140~F after 10 minutes flash off or dry 24 hours at 75~F. PPG PRODUCTS PPG MONO-COAT SYSTEMS 1. Solvent wipe with DX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron topcoat color with DX-369 Flexative per label instructions. 2. Use 40-50 PSI at the gun. PPG BASECOAT/CLEARCOAT SYSTEMS PREPARATION 1. Solvent wipe with SX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron basecoat color (DBU), with the recommended reducer for the temperature, per label instructions. 2. Mix and apply clearcoat material DBU-88 or DCU-2001, with DX-369 Flexative, per label instructions. SHERWIN-WILLIAMS PRODUCTS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8155 Ultrabase 7 Basecoat/Clearcoat or Ultra One Stage Acrylic Urethane Enamel PREPARATION 1. Wash the material with a mild detergent and wipe dry. 2. Solvent wash with R7 K 156 and wipe dry. 3. Clean with a tack cloth. 4. Apply desired system with correct amount of Multi-flex, V6 V 299. TOPCOATING Prepare topcoating as follows: ^ S-W Ultra One Stage: (Mono-coat) 4 Parts Color 3 Parts SSR 650 Reducer 1 Part V6 V 440 or SSH 520 2 Parts V6 V 299 ^ S-W UB7 Basecoat: 8 Parts Basecoat Color 8 Parts Stabilizer 1 Part V6 V 299 ^ S-W UB7 Clearcoat: 4 Parts T1 C 650 Clearcoat 2 Parts T1 C 650 Reducer 1 Part CCH 690 1 Part V6 V 299 ^ S-W Ultra One Stage: (Mono-coat) Apply 2-3 medium wet coats at 50 PSI ^ UB7 Basecoat: Apply 2-3 medium coats at 45 PSI ^ UB7 Clearcoat: Apply 2-3 medium coats at 50 PSI DUPONT PRODUCTS DUPONT CRONAR POLYOXITHANE MONOCOAT SYSTEM PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING 1. Add 8 parts of Cronar single stage enamel. 2. Add 1 part Cronar initiator 9404S. 3. Add two parts of (9475S, 9485S, or 9495S,) depending on shop temperature. 4. Add 2 parts flex-additive 9250S. 5. Mix thoroughly. 6. Spray at 45-55 PSI at the gun, 2-3 medium wet coats or until hiding. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8156 7. If a clear coat is applied, use 9500S. DUPONT CENTARI MONO-COAT ENAMEL SYSTEMS PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING (Follow Manufacturer's Recommendation) 1. Add 8 parts of Centari enamel color and 1 part 793S hardener. 2. Add 4 parts of (8022S, 8093S, or 8096S) reducer, depending on shop temperature. 3. Add 355S flex additive per label instructions. 4. Mix thoroughly. 5. Spray 2-3 wet coats, with 5 minutes flash time, at 50-65 PSI. BASF PRODUCTS The following procedure is applicable to 4 paint systems in the BASF paint line. Read individual "system" instructions carefully. PREPARATION 1. Solvent wipe the molding with RM Pre-klean-o 900. 2. Sand with 400 grit sand paper and rinse with 901 pre-paint cleaner. TOPCOATING BASECOAT ^ "Glasurit" 54-line color 2 vol. parts ^ 54-line reducer 1 vol. part ^ "Diamont" basecoat color 2 vol. parts ^ B R Diamont reducer 2 vol. parts ^ "Miracryl" basecoat color 2 vol. parts ^ BCR reducer 2 vol. parts ^ "Supreme Gold" basecoat color 2 vol. parts ^ LBR reducer 2 vol. parts Apply basecoat color until hiding is achieved. Allow 3-5 minutes flash time between coats. NOTE: USE APPROPRIATE REDUCER FOR SHOP CONDITIONS. ALLOW 15 MINUTES FLASH-OFF BEFORE SPRAYING CLEARCOAT. TOPCOATING Apply clearcoat per manufacturer's label instructions: CLEARCOAT REDUCTIONS ^ DC-88 Diamont Clear 4 Vol. Parts ^ DH-44 Diamont Hardener 1 Vol. Part ^ MC-1000 Clear 4 Vol. Parts ^ 894 Hardener 1 Vol. Part ^ LC-1300 Supreme Gold Clear 4 Vol. Parts ^ LH-1301 Hardener 1 Vol. Part Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8157 ^ 92354 Glasurit Clear 100 Parts ^ 521-111 Elastifier 20 Parts ^ 929-29 Hardener 60 Parts Apply 2 wet coats with 5 to 10 minutes flash time between coats. Overnight dry or force dry at 140~F for 30 minutes. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. (E) Lower Body-Side Stone Chip Protection Program Ford Motor Company has recently initiated a program to provide improved stone-chip protection on some vehicles and to increase the corrosion protection on cars and trucks. Some customers are unaware of body side anti-stone chip protection which appears as wavy orange peel texture on the lower body areas. Ford is increasing the use of PVC (poly vinyl chloride) material which is applied in a thicker coating on the lower body-side. This material has been in use on vehicles destined for the Canadian market for many years. This PVC material is now applied at the following plants on ALL vehicles. ^ Edison - Ranger ^ Hermosillo - Escort/Tracer ^ Louisville - Ranger and Explorer ^ Ohio Truck - Econoline ^ Wayne - Escort/Tracer This process is also planned for Kansas City, Oakville, Twin Cities and Wixom. This material can be identified by the "orange peel" appearance and a visible "break-line" between protected and unprotected areas in the lower body areas. CAUTION: THIS PROTECTION MUST NOT BE REMOVED IF VEHICLE IS EXPECTED TO MAINTAIN THE CORROSION PROTECTION. Some customers have expressed concerns due to the appearance of the treated areas. These customers did not know about the extra protection this material provides their vehicle. Once explained, customers were pleased with the added protection and accepted the orange peel finish. NOTE: DEALERS SHOULD ADVISE THEIR SALES PEOPLE, SERVICE PEOPLE, AND CUSTOMERS, OF THE REASONS AND BENEFITS OF THIS PROTECTION. CANADIAN DEALERS STRESS THIS AS A SELLING POINT WITH THEIR SALES PEOPLE. IT IS CONSIDERED A COMPETITIVE ADVANTAGE. (F) Surface Defect Removal Without Repainting Exterior paint surface damage or imperfections, where the primer coat does not show through, should be restored without repainting. The restoration of gloss and luster, after the condition has been repaired, is possible with new techniques and improved materials. The following procedure is applicable to surface conditions such as dirt particles, orange peel, runs, sags, industrial fallout stains, swirl marks, light scratches and other minor surface imperfections. For dirt particles or scratches in several localized areas, the entire panel should be refinished to maintain a uniform appearance. PREPARATION To repair the affected surface it must be clean and dry. Mask off adjacent panels, mouldings, stripe and character lines as required. CAUTION: EYE PROTECTION, AND FACE MASK SHOULD BE WORN. RINGS, BRACELETS, WATCHES AND BELT BUCKLES MUST BE REMOVED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH. SERVICE PROCEDURE 1. Remove sanding marks with rubbing compound. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8158 2. Swirl marks, evident after buffing, are removed by polishing. 3. Remove light scratches and small dirt particles with a power buffer and medium buffing compound followed with polishing. 4. Remove deeper scratches and heavy dirt particles or orange peel, by wet sanding. 5. Buff with compound to remove the sanding marks and then polish to remove the swirl marks from the buffing operation. NOTE: PERFORM A TRIAL REPAIR WITH A SMALL AREA. FIRST, TRY POLISHING; IF THIS IS NOT SUCCESSFUL, TRY BUFFING AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE MOST EFFECTIVE TECHNIQUE ON REMAINDER OF AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE AND REQUIRED MATERIALS FOLLOWS. POLISHING - VERY MINOR SCRATCHES OR SWIRL MARKS AND/OR RESTORING A DULL FINISH 1. Apply a small amount of Meguiar's Mirror Glaze, or equivalent, to the affected panel (or pad). 2. Use a suitable electric or air powered polish/buffing wheel (1750 max. RPM) and a Meguiar's Finesse Polishing Pad, or equivalent, to polish the affected area until all swirl marks are gone and desired luster is obtained. 3. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the buffer is sufficient. CAUTION: DO NOT MIX PRODUCTS! USE A SEPARATE, DEDICATED BUFFING PAD FOR EACH PRODUCT TO ACHIEVE DESIRED RESULTS. Variable speed buffers are available in a variety of buffing speeds. The recommended speed range is 1200-1750 RPM. COMPOUNDING - LIGHT SCRATCHES, SMALL DIRT PARTICLES, MINOR GRIND MARKS, AND SANDING MARKS 1. Apply Meguiar's Rubbing Compound (medium) or equivalent to the panel with a clean compound pad on the wheel. 2. Spread the compound evenly and continue buffing until the condition is removed. 3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes. 4. Periodically check the finish and add compound as required. 5. When buffing is complete, polish the panel as described previously. Twisted wool cutting pads are the most effective compounding pads to use with Glaze Machine Cleaner for removing paint defects and heavy oxidation. Following the use of a wool compounding pad, it may be necessary to polish the finish with No. 2 Mirror Glaze Hi-Tech Cleaner using a Mirror Glaze Finesse Polishing Pad to remove the deep swirl marks. GENERAL TECHNIQUES AND HINTS ^ "Foam" buffing pads create added gloss and depth of color on all types of paint finishes without creating buffer swirl marks. ^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material, slower buffing motion and added downward pressure to increase cutting action. ^ Always apply cleaner to buffing pad, not directly on the oxidized paint surface. Dry paint absorbs material into pores upon contact. ^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat. ^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage and allows both material and buffer to perform at maximum efficiency. ^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint burn through. It is best to buff up to them from each side. ^ Always use a "wet buff" technique on a basecoat/clearcoat finish. This is a precaution against buffer swirls. Stop buffing just after the product begins to break down and before an overall dry, glossy finish appears. After "wet buffing", use a towel to wipe off the excess material. ^ Always use a "dry buff" technique on light colored, conventional paint finishes. Continue buffing until the material breaks down and only a slight film remains for final wipe off. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8159 ^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish. Confine your buffing strokes to the immediate area of the blemish while applying additional downward pressure and keeping the pad flat. NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EXCESSIVE HEAT BUILD-UP AND POSSIBLE BURN THROUGH. STOP IMMEDIATELY IF THE SURFACE BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT. NOTE: HEAT BUILD-UP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE SURFACE BEING BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME BUFFING ... AT A LOWER RPM IF POSSIBLE. NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON PAINTED FIBERGLASS/PLASTIC SURFACE BEING BUFFED, THE MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO REMEDY, GROUND THE SURFACE BEING BUFFED TO METAL. WET SANDING Paint defects and sanding marks must be completely removed without using compounds and abrasive cleaners that scar the finish. Mirror Glaze Hi-Tech Finesse Sanding Papers provide uniformity in grit particle size and distribution. Using these precision made sanding papers, water sanding marks can be removed with Meguiar's cleaner and finesse polishing pads. ^ Typical paint defects that are repaired with this system include: dirt-in paint, solvent pop, cratering, orange peel, drips, scratches, water spots, and acid rain. ^ Always use the least abrasive (highest grit) sanding products possible to do this job. The following wet sanding procedure utilizes light grit sand paper or sanding blocks for removal of surface damage. These materials cut quickly leaving a uniform finish requiring a minimum of buffing to restore gloss. PROCEDURE 1. Squeeze water to flush the area to be sanded. Continue to flush water to the surface during sanding for maximum lubrication. 2. Use small circular motions to contain the abrasion to the immediate area of the defect. Keep the blocks in water when not in use. 3. If the sanding block is cutting too slow, switch to a lower grade block and resume sanding. When 90% of the defect is removed, switch to a 2000 grade Finesse Sanding Paper or Sanding Block to finish smoothing and prepare the surface for buffing. 4. Finesse Sanding Blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for shaping. 5. When using Finesse Sanding Papers, wrap the paper tightly around a E-7200 Backing Pad. This pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform sanding pattern. 6. Plan your strokes to limit the abrasion to the smallest area possible. NOTE: ALWAYS SAND IN ONE DIRECTION AND KEEP YOUR STROKES STRAIGHT. 7. Always finish sanding with 2000 Grit Finesse Sanding Paper. This eliminates the need for compounding. 8. Buff out sanding marks by applying Meguiar's Cleaner with a Finesse "Foam" Polishing Pad. Follow with a Mirror Glaze Polish for swirl-free gloss. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS RUNS AND SAGS REMOVAL This procedure consists of shaving the run or sag flush with a commercial single edge razor blade, shaving file or sanding with a hard block and then compounding. NOTE: IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT PANEL FINISH. MEGUIAR'S PRODUCTS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8160 PART NUMBER GRADE PART NAME S-1005 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Half Sheets S-1205 1200 S-1505 1600 S-2005 2000 S-1000 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Full Sheets 8-1200 1200 8-1500 1500 S-2000 2000 E-7200 - Mirror Glaze Hi-Tech Finesse Backing Pad E-2000 - Mirror Glaze Hi-Tech Tach Sponge K-400 400 Mirror Glaze Hi-Tech Finesse Sanding Blocks K-1000 1000 K-1500 1500 K-2000 2000 K-3000 3000 Other Applicable Articles: 82-3-3 (G) Color Compatible Spray Primer Chart Ford has released color compatible spray primers for exterior and some interior surfaces. Colored sprayed primers are being used by our "Best-in-Class" competition and are now being implemented at Ford in order to improve process capability and to help in minimizing unsightly paint chipping from stone abrasion. Color keyed (matched) spray primer for exterior body colors is being used in an effort to help in the elimination of unsightly paint chipping from stone abrasion. As with "Best-In-Class" competition, the engine compartment will be left with color compatible primer only and not be topcoated as per past practice. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8161 Figure 5 When any paint repair is required, remember that the vehicle may have a colored primer. Refer to the Spray Primer Chart, Figure 5. This information may be of help in correction of exterior paint color match concerns. (H) Paint Repair For Tinted Clear Coat Ford introduced (Early Spring, 1991) a new paint color using a tinted clearcoat. The first color to use this new system is Rio Red. If a paint repair is necessary, refer to the following procedure for repair instructions. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8162 BACKGROUND The Probe production paint system for Rio Red includes a Medium Green E-Coat primer, a Light Gray spray primer, bright Rio Red (E4) basecoat and a slightly Red tinted clearcoat topcoat. NOTE: BEFORE ANY REPAIRS ARE BEGUN, IT IS CRITICAL THAT PRIMER, RED BASECOAT AND TINTED CLEARCOAT BE SPRAYED ON A TEST PANEL. THE COLOR MATCH IN EACH STEP IS VERY IMPORTANT FOR A SUCCESSFUL REPAIR. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SMALL SPOT REPAIR PROCEDURE 1 Wash the vehicle with detergent soap and water. 2 Wipe the vehicle down with wax and grease remover. 3. Sand the spot using 400 grit paper. Do not sand through the E-coat. 4. Wipe the sanded surface again with wax and grease remover/pre-cleaner. ^ BASF Product # 90 Pre-Kleano ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mix and apply tintable (Light Gray) self-etching or epoxy primer per manufacturer's label instructions. NOTE: COLOR MATCH OF PRIME COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. ^ BASF Product # DE 17 ^ PPG Product # DP 40 ^ S-W Product # E2-G973 ^ DuPont Product # 615S ^ Sikkens Product # 1016 6. Mix and apply bright Rio Red base coat material per manufacturer's label instructions. NOTE: COLOR MATCH OF BASE CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. 7. Mix and apply red tinted clearcoat material per manufacturer's label instructions. NOTE: COLOR MATCH OF TINTED CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. FULL PANEL REPAIR PROCEDURE 1. Wash the vehicle with detergent soap and water. 2. Wipe the vehicle down with wax and grease remover. 3. Sand the complete panel and feather edge into the next panel using 400 grit paper. Do not sand through the E-Coat primer. 4. Wipe the sanded surface with wax and grease remover. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8163 5. Mix and apply tintable (light gray) primer per manufacturer's label instructions. 6. Mix and apply Rio Red basecoat per manufacturer's label instructions. 7. Mix and apply Red tinted clearcoat per manufacturer's label instructions. 8. Mix and apply one coat of non-tinted clearcoat per manufacturer's label instructions. NOTE: COLOR MATCH OF EACH COAT ARE KEY TO COLOR MATCH OF FINISH REPAIR. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C's) OR EXCESS MATERIALS. (I) Paintable Plastics Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8164 Figure 6 The Paintable Plastics Chart, Figure 6, is a summary of widely used plastics in our industry. The standard symbol should be located on the part for ease of material identification. If painting or repair of these plastics is necessary, the following chart identifies those materials which can be painted. Refer to paint manufacturer for specific paint material recommendations. NOTE: MATERIALS MAY REQUIRE PRIME COAT SEE "YES", UNDER "CAN BE PAINTED" COLUMN. (J) 1992 Paint Color Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8165 Figure 7 The 1992 Paint Color Codes are listed in Figure 7. NOTE: REFER TO THE SERVICE LABOR TIME STANDARDS MANUAL AND THE SPECIFIC PROCEDURE WITHIN THIS BULLETIN FOR REIMBURSEMENT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OASIS CODES: 106000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9192 > May > 91 > Paint - Paint Blistering or Peeling Off Bumper Covers Paint: All Technical Service Bulletins Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. 6. Blow off the area with compressed air to remove any dirt and sanding residue. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 9192 > May > 91 > Paint - Paint Blistering or Peeling Off Bumper Covers > Page 8170 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. 13. Apply top coat (body color) where necessary. 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure Technical Service Bulletin # 90153 Date: 900719 Lower Body Stone Protection - Repair Procedure PAINT - LOWER BODY STONE PROTECTION REPAIR TIPS Article No. 90-15-3 FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS 1988-90 FESTIVA, PROBE LINCOLN-MERCURY: 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE 1987-90 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A service repair procedure has been developed to restore damaged factory-applied lower body stone protection vinyl material. ACTION: If service is required, use the following procedure to restore damaged lower body stone protected areas. This abrasion resistant coating material (D9AZ-19515-A) is primarily for repair of factory-applied protective coatings. However, this material may also be installed on previously unprotected vehicles. If the vehicle has body damage in the area of the factory-applied coating, body damage must be repaired before repairing the protective coating. WARNING: WHENEVER USING PAINT, SOLVENT, REFINISHING OR RECONDITIONING MATERIALS, WEAR A NOSE OR FACE MASK, PLUS HAVE ADEQUATE VENTILATION IN THE WORK AREA. Large Repair Areas A large repair area, resulting from peeling or damage, will require removal of the factory-applied vinyl coating. NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR OR QUARTER PANEL REPLACEMENT IS REQUIRED, (OR IN AN INITIAL INSTALLATION), SKIP STEPS # 1 - 3. 1. Use a heat gun or lamp to soften the vinyl coating until it is pliable. 2. Scrape off the softened vinyl with a putty knife or similar tool. If necessary, sand off any hard-to-remove vinyl coating using an orbital disc sander (# 80 Disc). NOTE: THE REPAIR MATERIAL, ABRASION RESISTANT COATING (D9AZ-19515-A), IS NOT SUITABLE FOR "SPOT" REPAIRS. THE OLD COATING MUST BE REMOVED COMPLETELY FROM EACH DAMAGED PANEL. 3. Make the necessary repairs to the sheet metal. Coating Preparation and Applications: The abrasion resistant coating is available in quart cans. About two quarts will be required for an initial installation on a passenger car similar to a factory-applied system. Slightly more will be required for a larger vehicle such as an Econoline. The specified dry film thickness of 15 to 20 mils (.015 to .020") will require at least three or possibly four applications of coating material, with flash off time allowed between coats. As with painting, spray coat the complete lower panel. The adherence of this coating to properly prepared sheet metal is excellent and it is not necessary to prime the repaired sheet metal. However, adhesion will be adversely affected unless the sheet metal (either repaired or new) is prepared in accordance with the following procedure. Coating Preparation - Masking Car 1. Install covers over the wheels. 2. Determine the area to be coated. ^ If the vehicle has lower body side mouldings (12-14" above the "turn under" of the rocker Panel), the moulding can serve as the upper margin of the area to be coated. ^ If the vehicle does not have suitable mouldings, a sculpture or break line in the sheet metal can be used. ^ The method used in masking off the upper coating margin line will depend on the presence or absence of mouldings in this area. VEHICLES WITH SIDE MOULDINGS 3. Position the masking tape so that the moulding lower side is covered down to, but not on the sheet metal. VEHICLES WITHOUT SIDE MOULDINGS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure > Page 8175 4. If the contour of the body side has a break line, or if an arbitrary line is chosen, mask off the upper coating margin using Scotch "Fine Line" tape. This is available nationally from 3M Company Distributors. a. Apply the normal masking tape and paper protection for the vehicle body side first. Position them about a 1/4" above the margin line. b. Apply the "Fine Line" tape over the regular masking tape with the lower edge at the upper coating margin line. c. Extend this "Fine Line" tape into the wheel opening, in absence of wheel opening mouldings, to allow the flange to be coated. d. Since the protective coating does not adhere well to flexible plastic stone shields, mask off the front of the plastic rear stone shield, if exposed. NOTE: IT IS NOT NECESSARY TO MASK OFF THE BODY DOOR OPENINGS IN THE COATING AREA BECAUSE THEY WILL BE UNIFORMLY COATED WHERE THE DOOR MARGINS ALLOW THE COATING TO ENTER. HOWEVER, THESE DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE. Coating Preparation - Sheet Metal REPAIRED SHEET METAL 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover and allow to flash off. 2. Scuff sand (# 180 Grit Paper) the glossy surface of the painted areas to be coated. 3. Remove sanding dust using a lint-free tack cloth and compressed air. NEW SHEET METAL 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover and allow to flash off. 2. Scuff sand (# 180 Grit Paper) the prime paint in the area to be coated. 3. Remove sanding dust using a lint-free tack cloth and compressed air. INITIAL INSTALLATION 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover. 2. Sand the glossy surface of the paint in the coating area. (A D/A sander, 220/240 Grit Disc does a good fast job.) CAUTION: DO NOT SAND THROUGH THE COLOR COAT INTO THE PRIMER. 3. Remove sanding dust using a lint-free tack cloth and compressed air. Coating Application Coating applications must be applied with care. ^ The coating must be applied with commercial equipment by an experienced automotive painter. ^ The coating must be thoroughly agitated and used without thinning. ^ Since the material is reasonably heavy-bodied, a pressure cup equipped spray gun is recommended. ^ Satisfactory coating appearance (orange peel) will result with gun pressure of approximately 30 P.S.I. and cup pressures of approximately 15 P.S.I. Spray Procedure Since the lower exposed painted fender, rocker and quarter panel down flanges are to be coated, the vehicle should be elevated high enough so that the painter can spray this area effectively. When an initial installation is to be made, a remote, two-quart capacity pressure cup makes a much more efficient tool because the spray gun can be used closer to the floor. The spray gun, fluid hose and cup must be cleaned immediately after use. While lacquer thinner may be used when the suggested clean up material is unavailable, the Ford Vinyl Paint Precleaner (VC-542-A) is quicker and much more efficient. With the spray gun at 30 P.S.I. and pressure feed cup at 15 P.S.I. proceed as follows: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure > Page 8176 1. Apply a wet, sag-free coat. Allow 3 to 5 minutes flash off. 2. Apply a second wet, sag-free coat. Allow 3 to 5 minutes flash off. 3. Apply a third wet, sag-free coat. Allow 3 to 5 minutes flash off. 4. Apply a final wet, sag-free coat. Allow 3 to 5 minutes flash off. Pull off the "Fine Line" tape, exposing the raw upper edge of the coating. 5. Immediately clean the spray equipment using Ford Vinyl Paint Precleaner (VC-542-A) or equivalent. 6. Air drying time depends on the refinishing materials that are used. ^ If you refinish with acrylic lacquer, allow one hour for drying (at 70~F). ^ If you refinish with acrylic enamel, allow two hours for drying (at 70~F). Color Coat In order to paint the entire coated area as well as the upper raw edge, mask off the upper margin line using the "Fine Line" tape. Position the tape 1/16" above the coating edge. The protective coating area can now be finish painted. NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA, NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED. Suggested Equipment ^ DeVilbiss - Spray Gun - Model JGA-502-704-FX or equivalent ^ DeVilbiss - Remote Pressure Cup - Model KB-520 (2 Quarts), Model KB-521 (1 Quart) or equivalent ^ Binks - Spray Gun - Model 62 (# 63 Air Cap, # SS Fluid Tip, # 363 AN Needle) ^ Binks - Attached Pressure Cup - Model 80 (1 Quart, with Air Adjusting Gage) or equivalent. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100, 1800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials Paint: All Technical Service Bulletins Paint - Cosmetic Damage From Airborn Materials PAINT COSMETIC DAMAGE FROM AIRBORN MATERIALS Article No. 89-13-3 FORD: 1989 and prior ALL FORD LINES LINCOLN-MERCURY: 1989 and prior ALL LINCOLN-MERCURY LINES LIGHT TRUCK: 1989 and prior ALL LIGHT TRUCK LINES ISSUE: Paint may be damaged from various sources of airborn materials. The two different types are: ^ Inorganic ^ Organic Sometimes it is hard to identify the type of paint damage and know how to remove it. This TSB article gives detailed information and descriptions of both types of airborn materials. It also outlines the service procedures for treating them. ACTION: If service is required, identify the source of damage involved by referring to the following information. Use the following recommended service procedure to correct concerns. INORGANIC AIRBORN MATERIAL The effects of inorganic airborn materials can be seen as: ^ Dark blotches in the paint where the pigment in the paint surface has been attacked ^ Irregular spots that are cracked or etched around the edges and dull in the centers. ^ Small orange colored spots caused by iron particles may appear on the paint surface. Generally, materials that attack a paint film are either acidic or alkaline in nature. Sulfuric and nitric acids, in general, cause extreme damage to automative paint finishes. Even very small concentrations of the same materials can cause chemical spotting damage. Due to evaporation and condensation, these acids can create severe etching "spots" that may eventually crack or lift the paint film after some time in service. Although some automotive finishes are more resistant than others, none are completely immune to these chemicals. The most resistant paints used today are the urethanes because their resin system is least likely to react with chemicals. Air dry coatings are more susceptible to attack only when they are fresh. The longer the paint dries the more resistant it becomes. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 8181 Metallic colors are more intolerant to chemicals because aluminum flake is fairly reactive with either an acid or alkali. The following chart contains the most common acid materials found on automotive finishes. The chart shows a color, the corresponding damage appearance and also the chemical causal agent. It is not applicable for Basecoat/Clearcoat finishes. * "Caustic" refers to any alkaline substance that may be "harsh" or "corrosive" depending on strength or concentration. The following "pH" chart show the relationship between acidic and alkaline chemicals and their corresponding pH values. This chart is provided for informational reference only. ORGANIC AIRBORN MATERIALS Organic damage is generally easier to identify. Organic damage is mostly due to tree sap, bird and insect droppings, dead insects (Figure 8) and pollen. Tree sap is easily identified by clear raised drops that may be hard or sticky. Bee or bug dropping spots may appear brownish or yellow in color, about an eighth to a quarter inch in diameter. Dead and decomposing insect bodies are readily visible to the eye. Pollen deposits are small yellow clusters. Each of these items is potentially damaging to any currently available paint system. Other noticeable traits of organic damage are spots that are raised (swelling) micro-crazing (cracked) and pitting, due to pollen eating into the paint film. The active ingredients in most organic contaminants are tannic and formic acids . These acids are found in berries and bodily fluids of insects and birds. Investigations completed at dealerships show that the bright lot lights tend to attract insects. The use of "soft lights" for display and storage lot illumination will help reduce damage resulting from decomposing bugs and droppings by decreasing the number of bugs attracted to these lights. Organic damage is accelerated by heat. During very hot weather conditions, it is important to wash vehicles more often. ORGANIC AND INORGANIC REPAIR PROCEDURES FOR MILD DAMAGE Iron dust particles may imbed themselves into the paint film. On some light colored vehicles after some weathering, tiny dots of rust start to appear. They Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 8182 feel rough to the touch and are difficult to remove. The best way to remove these particles is by treating the finish with an oxalic acid-detergent-water wash. Use the following procedure to perform this service repair. NOTE: OXALIC ACID WASH IS ALSO PRE-PACKAGED IN VARIOUS STRENGTHS UNDER VARIOUS BRAND NAMES, IF YOU CHOOSE NOT TO MIX YOUR OWN BATCHES. 1. Wash and degrease the vehicle first, using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent, and a suitable wax and grease remover. If this does not remove all of the iron particles, proceed with the oxalic acid wash. 2. Prepare a quantity of oxalic acid-detergent-water solution as follows: a. Dissolve 6-8 ounces of Oxalic Acid (powder) in one gallon of warm water. b. Add 1-2 tablespoons full of non-alkaline detergent such as Ford Multi Purpose Cleaner. 3. Apply this solution liberally to all affected surfaces of the vehicle with a large sponge. Keep the surface wet until the technician can no longer feel any surface roughness with bare or gloved fingertips. NOTE: IF THIS IS NOT DONE THOROUGHLY, STAINING MAY REDEVELOP IF IRON PARTICLES ARE LEFT BEHIND. 4. Rinse the area with clean water. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS WITH PROLONGED CONTACT. 5. If the iron particles are not totally removed after 2 washings, use one or both of the procedures listed for minor chemical contamination. NOTE: THE USE OF POLISHING (WITH WAX), SANDING WITH MICRO FINE SANDPAPER (1500 GRIT OR GREATER) OR BUFFING WITH VERY LIGHT COMPOUND SHOULD ONLY BE DONE AS A LAST RESORT. CHEMICAL CONTAMINATION Chemical contamination, either acid or alkali, can cause off-color spots and crack the paint film. In the presence of moisture (dew), sulfur contamination will change the color (light/dark) of the paint pigments. (This does not apply to Basecoat/Clearcoat) Since this contamination affects the pigments, lacquers and enamels show no difference in resistance. Production thermal drying and air drying finishes are likely to be spotted. Minor chemical contamination can be removed by using the following step by step procedure. 1. Wash the vehicle first by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent to remove the exterior foreign materials. 2. If the spotting is extensive and on the horizontal surfaces, then machine polish. 3. Apply a light grit polishing compound to the affected surface by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum cutting efficiency. 4. Polish off the spots using a buffer operating at 1700-1800 rpm. Confine polishing to the spotted areas. Repeat as necessary until all spots have been removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all contamination. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 8183 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OR SAND OUT, THEN REFINISHING IS REQUIRED. ORGANIC MATERIAL REPAIR PROCEDURE FOR MILD DAMAGE Minor organic damage can be removed by using the following step by step procedure. 1. Wash and degrease the vehicle thoroughly by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent and a wax and grease remover to remove all organics. 2. Inspect the vehicle horizontal surfaces. If spotting or paint film swelling is extensive, use a buffer to repair. 3. Apply a light grit polishing compound to the affected areas by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum efficiency. 4. Polish off the spots or swelling marks using a buffer that operates between 1700-1800 rpm. Polishing should be confined to the affected areas only. Repeat as necessary until all spots or marks are removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE. Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all organics. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OUT, THEN REFINISHING IS REQUIRED. PAINT RECONDITIONING PROCEDURES FOR SEVERE DAMAGE Acrylic enamel single stage or base/clear paint systems should be painted by using the following procedure. 1. .Wash the vehicle with Ford Multi Purpose Cleaner or equivalent to remove all organic materials. 2. Wash the areas to be painted with wax and grease remover. 3. Prepare the area as follows: a. Neutralize the affected areas with baking soda (sodium bicarbonate) and water. b. Rinse the surface off with plain water. c. Wash the panel with a mild soapy detergent. d. Dry the panel completely. NOTE: IF THE DAMAGE IS THROUGH THE TOP COAT FINISH AND INTO THE PRIMERS, THE PANEL MUST BE SANDED DOWN TO BARE METAL OR PLASTIC AND THEN REFINISHED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 8184 4. Apply a self-etching primer for metal surfaces only. NOTE: A FLEX ADDITIVE MAY BE NECESSARY WHEN WORKING WITH FLEXIBLE PLASTICS Then proceed as follows: a. Let dry per instructions. b. Apply a two component urethane primer surfacer. c. Sand the surface with 400 grit sandpaper to get to proper finish. d. Finish sanding with 600 grit sandpaper. 5. Solvent wash panel with wax and grease remover. Then, tack wipe it. 6. Apply base coat or top coat material per applicable paint system. NOTE: THE USE OF ACRYLIC URETHANE ENAMEL IS HIGHLY RECOMMENDED FOR THIS TYPE OF REPAIR. 7. Apply clear acrylic urethane if you are using a base/clear paint system. WAYS TO MINIMIZE EFFECTS OF AIRBORN MATERIAL DAMAGE During the past year, Ford Motor Company and major paint suppliers have participated in a survey to analyze the effects of airborn materials. This survey was conducted on foreign and domestic vehicles. It resulted in the following interesting conclusions. 1. Keeping the vehicles clean, washing frequently with de-ionized water and drying by hand or mechanical means will help minimize the effects of inorganic and organic materials. 2. Spray washing without rubbing will not totally remove all residue on the surface of the vehicle. Damage could possibly occur over a longer period of time. 3. Care should be taken to not allow any painted vehicle surface to become wet in direct sunlight. (A sprinkler system can cause damage if the vehicles are not dried.) Possible alkaline water or mineral deposit may be the cause. 4. The use of "Soft Lights" for lighting around storage lots and showing areas will minimize the attraction of insects and the possibility of organic damage. 5. Ford Motor Company is piloting a program for a transit/storage coating to be applied on the horizontal surfaces of all vehicles. These coatings have shown good protection to the paint surface. They are clear in color and should be left on the vehicles until they are sold. 6. We are testing many "permanent paint sealants" used by dealers. Until all testing is completed, we cannot give any recommendations for what products to use. Testing has shown that a sealant that allows water to bead up on the vehicle does not help to dissipate the materials on the paint surface. Sheeting of water on the vehicle is highly desirable. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 8912189614 > Jun > 89 > Paint - Codes/Cross References Paint: All Technical Service Bulletins Paint - Codes/Cross References PAINT - 1989 COLOR CHART - AFTERMARKET SUPPLIER CROSS - REFERENCE LIST Article No. 89-12-1 FORD: 1989 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 8912189614 > Jun > 89 > Paint - Codes/Cross References > Page 8189 ISSUE: The following 1989 Ford and Lincoln-Mercury color chart provides all of the supplier paint code numbers for the Ford two-digit paint codes listed on the Vehicle Certification Label. ACTION: Paint should be available in either lacquer or enamel from the manufacturers; however, not all manufacturers provide both mixing types. To get the best color match, either the "Factory Pack" or "Intermix" is okay to use. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Technical Service Bulletins for Paint: > 88225 > Oct > 88 > Wheel Cover - Paint Chiping Paint: All Technical Service Bulletins Wheel Cover - Paint Chiping WHEEL COVERS - TWO PIECE - PAINT CHIPS WHILE PRYING OFF CENTER ORNAMENT Article No. 88-22-5 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The paint on two-piece wheel covers may be chipped if the center ornament is removed with a screw driver or any other tool with sharp edges. The lug wrench supplied with the vehicle has a curved tip with rounded edges to prevent paint chip damage to the cover when prying off the center ornament. ACTION: Use the lug wrench supplied with the vehicle to remove the center ornament from a two-piece wheel cover. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 1100, 3300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal Paint: All Technical Service Bulletins Paint - Iron Particle Removal Article No. 95-6-1 03/27/95 ^ PAINT - IRON PARTICLE REMOVAL - INDUSTRIAL FALLOUT - ACID RAIN NEUTRALIZATION ^ PAINT - ROUGH TEXTURE/FERROUS METAL CONTAMINATION - ACID RAIN DISCOLORATION OR ETCHING FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984-94 TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE 1994-95 ASPIRE 1995 CONTOUR LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984-94 TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1991 and after TRACER 1993 and after MARK VIII 1995 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 and after WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: Ferrous metal particles (hot iron dust) are generated by manufacturing facilities, rail shipments, combustion engines, jet engines, body shops, etc. These particles mechanically/magnetically bond to vehicles' painted surfaces. Moisture and temperature combine with the particles to create a chemical reaction. The reaction causes the particles to corrode and enter into the physical paint film. ACTION: To remove these particles/contaminants, USE ONLY the following procedure. The procedure must be performed before any buffing, polishing, color sanding or refinishing is attempted. The materials in this procedure are alkaline, acidic and neutral. They must be used in the specified order. CAUTION: ANY CHANGES TO THIS PROCEDURE WILL CAUSE AN INCOMPLETE OR UNSATISFACTORY REPAIR AND MAY RESULT IN Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8199 POSSIBLE DAMAGE TO THE PAINTED SURFACES AND TRIM. WARNING: THE TECHNICIAN MUST WEAR PROTECTIVE CLOTHING AND EYE PROTECTION TO PREVENT SKIN IRRITATION. CAUTION: THE USE OF ANY OTHER PRODUCT OR PROCEDURE MAY CAUSE DAMAGE TO ALUMINUM, FLEXIBLE PAINTED SURFACES OR OTHER PAINTED SURFACES. FOLLOW DIRECTIONS EXACTLY AND RINSE THOROUGHLY AFTER EACH STEP. NOTE: THIS DECONTAMINATION PROCEDURE IS DESIGNED TO REMOVE SURFACE CONTAMINANTS FROM THE PAINT ON VEHICLES THAT HAVE BEEN CONTAMINATED UP TO 120 DAYS. VEHICLES WHICH HAVE EXPERIENCED THE CONDITION LONGER THAN THIS PERIOD MAY REQUIRE AN ADDITIONAL TREATMENT TO REMOVE FERROUS METAL CONTAMINANTS. IDENTIFICATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8200 For ease of identifying, the Radio Shack Model 63-851, 30X, lighted, magnifier is recommended. 1. Ferrous Metal ^ Light colored vehicles: Small rust orange dots with black in center of stain. ^ Dark colored vehicles: Small white or silver dots with a "rainbow hue" around the particle. The surface will also feel rough to the touch. 2. Industrial Fallout ^ The surface feels rough to the touch and may exhibit crystalline deposits. ^ Usually ferrous metal is present, as well as water spots. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8201 3. Acid Rain ^ Surface will exhibit irregular discolored spotting. ^ Dark colored vehicles will show cloudy or greying spots where the acids have started to etch away the paint. NOTE: IN EXTREME CASES ETCHING OF THE SURFACE WILL BE VISIBLE OR FELT. DECONTAMINATION Use Finish Kare Inc. products 1119/883/11850 to decontaminate the paint surface. Follow the manufacturer's recommended procedures. NOTE: FORD DOES NOT RECOMMEND THE USE OF OXALIC ACIDS OR OTHER "FALLOUT REMOVERS". 1. Rinse off dust and debris with cold water. Be sure to start at the bottom and work up. 2. Prepare product "1119" by mixing one (1) part "1119" with four (4) parts cold water. 3. Use clean wash mitt and apply mixture to entire car, starting at the bottom and working up to the top surface. Keep car wet with the solution for 5 to 10 minutes. Do not allow product to dry on the car, and do not allow it to streak down the sides. Rewipe with mitt if necessary to avoid streaks. 4. Rinse car with cold water. 5. Dry the flat surfaces of the vehicle hood, roof and deck lid. 6. Apply product "883" directly to the contaminated surfaces using a clean dry sponge, wash mitt, or soft truck brush ("883" is ready to use from the bottle, with no mixing involved). Keep the areas wet with the "883" for 5 to 7 minutes. Do not allow to dry on the car. Wipe down to the body line on the sides. 7. Prepare product "118SC" by mixing 1 oz (0.03 L) with 1 gal (3.785 L) of water. 8. Shampoo the vehicle with "118SC" shampoo mixture using a clean wash mitt and then rinse with cold water. NOTE: DO NOT USE "1185C" MITT WITH "1119" OR "883" SOLUTIONS. USE SEPARATE MITTS AND ALWAYS KEEP THEM SEPARATE. 9. Inspect paint surface to see if rust particles have been removed. If rust particles have been on the vehicle for a long time, it may be necessary to repeat each of the above steps. NOTE: THE NEUTRALIZER CONCENTRATE IS A HEAVY DUTY SHAMPOO AND CAN BE USED IN AN AUTOMATIC CAR WASH SYSTEM. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8202 CORRECTION OF SURFACE FOLLOWING DECONTAMINATION: 1. Visually inspect surface for evidence of removal of ferrous metal particles, crystalline deposits and water spots. Acid rain discoloring or etching will require either buffing, color sanding or refinishing if etching is visible. 2. Use the buffing products from only one (1) manufacturer. Do not intermix products. 3. Always follow the manufacturer's product sequence. Use appropriate pads with each product as recommended by the manufacturer. NOTE: DO NOT REMOVE MORE THAN 0.3 OF A MIL OF PAINT MATERIAL, OR REPAINTING WILL BE REQUIRED. 4. Use a dual action sander (D/A Sander) with a velcro-mount backing plate and appropriate foam pad for final polishing swirl removal. 5. Use an alcohol and water mixture (1:4 ratio) to clean buffed areas to verify removal of scratches and swirls before application of final protective glaze. NOTE: FREQUENT WASHING OF VEHICLES IS IMPORTANT. CONTAMINANTS SETTLE ONTO THE VEHICLE EVERY DAY. USE CLEAN WATER (DEIONIZED, REVERSE OSMOSIS, ETC.) TWICE WEEKLY TO REMOVE HEAVY DUST, AND PARTICULATES. THE USE OF A NEUTRAL pH CAR WASH SOAP EVERY TWO (2) WEEKS IS RECOMMENDED TO NEUTRALIZE VEHICLE CONTAMINATION. Parts Block NOTE: DEALERS SHOULD USE PROGRAM CODE R-23 AND CONDITION CODES C5 AND C6. REFER TO W & P MANUAL, SECTION 5-1, PAGE 3. OTHER APPLICABLE ARTICLES: 91-18-1, 92-6-4 WARRANTY STATUS: Eligible Under The Provisions Of 12 Month/12,000 Mile Basic Warranty Coverage OPERATION DESCRIPTION TIME 950601A Decontaminate And Surface 0.6 Hr. Correction - Aspire 950601B Decontaminate And Surface 0.6 Hr. Correction - Escort/Tracer 950601C Decontaminate And Surface 0.6 Hr. Correction - Probe Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8203 950601D Decontaminate And Surface 0.6 Hr. Correction - Contour/Mystique 950601E Decontaminate And Surface 0.6 Hr. Correction - Mustang 950601F Decontaminate And Surface 0.7 Hr. Correction - Taurus/Sable 950601G Decontaminate And Surface 0.7 Hr. Correction - Thunderbird/Cougar 950601H Decontaminate And Surface 0.7 Hr. Correction - Crown Victoria/Grand Marquis 950601I Decontaminate And Surface 0.7 Hr. Correction - Mark VIII 950601J Decontaminate And Surface 0.7 Hr. Correction - Continental 950601K Decontaminate And Surface 0.6 Hr. Correction - Capri 950601L Decontaminate And Surface 0.8 Hr. Correction - Town Car 950601M Decontaminate And Surface 0.7 Hr. Correction - Villager 950601N Decontaminate And Surface 0.6 Hr. Correction - Windstar 9506010 Decontaminate And Surface 0.7 Hr. Correction - Aerostar 950601P Decontaminate And Surface 0.6 Hr. Correction - Bronco 9506010 Decontaminate And Surface 1.1 Hrs. Correction - Econoline 950601R Decontaminate And Surface 0.9 Hr. Correction - F-Series 950601S Decontaminate And Surface 0.6 Hr. Correction - Explorer 950601T Decontaminate And Surface 0.7 Hr. Correction - Ranger 950601U Decontaminate And Surface 0.5 Hr. Correction - F-Super Duty 950601V Decontaminate And Surface 0.7 Hr. Correction - F/B-Series 950601W Decontaminate And Surface 0.7 Hr. Correction - L-Series 950601X Decontaminate And Surface 0.5 Hr. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 9561 > Mar > 95 > Paint - Iron Particle Removal > Page 8204 Correction - Cargo 950601Y Decontaminate And Surface 0.6 Hr. Correction - Tempo/Topaz DEALER CODING BASIC PART NO. CONDITION CODE ENTRE C5 OR C6 OASIS CODES: 106000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information Paint: All Technical Service Bulletins Paint - Preparation Procedure And MSDS Information Article No. 94-23-4 11/14/94 PAINT - PRIMED SHEET METAL - PREP PROCEDURE AND MSDS INFORMATION FORD: 1980 and after CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1982-88 EXP 1984 and after TEMPO 1986 and after TAURUS 1988-93 FESTIVA 1989 and after PROBE LINCOLN-MERCURY: 1980 and after CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1981-87 LYNX 1984-92 MARK VII 1984 and after TOPAZ 1986 and after SABLE 1987-89 TRACER 1991-94 CAPRI 1993 and after MARK VIII MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1980 and after F-150-350 SERIES 1981 and after ECONOLINE 1982 and after BRONCO 1983 and after RANGER 1984-90 BRONCO II 1986 and after AEROSTAR 1988 and after F SUPER DUTY 1991 and after EXPLORER 1993 and after VILLAGER 1995 WINDSTAR MEDIUM/HEAVY TRUCK: 1980-91 C SERIES, CL-CLT-9000 SERIES 1980 and after F & B SERIES, L SERIES 1986 and after CARGO SERIES ISSUE: This procedure is being published to advise all body and paint technicians about proper procedures for preparation of sheet metal parts coated with electrodeposition primer (E-Coat). ACTION: When prepping a replacement body panel for installation, it is mandatory to leave the E-Coat intact. DO NOT SAND OFF THE E-COAT. Improper preparation with excessive sanding of the E-Coat to bare metal will jeopardize the sheet metal warranty and overall customer satisfaction. In particular, the E-Coat is necessary to protect the parts from rust. Light scuff sanding using a Scotch Brite pad or wet 320 grit sand paper is recommended for minor flaws. If a minor flaw exists, wet sand or scuff out the flaw and prime the repair area. Again, do not remove all of the E-Coat from the panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 8209 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 8210 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 8211 WARNING: LEAD CONTAMINATION POTENTIAL: THE ELECTRODEPOSITION PRIMER USED BY FORD MOTOR COMPANY OVER BASE METAL ON SERVICE REPLACEMENT PARTS OR COMPLETED VEHICLES CONTAINS SMALL AMOUNTS OF LEAD FOR CORROSION PROTECTION OF STEEL. EXCESSIVE DUSTS GENERATED BY UNNECESSARY AND IMPROPER SANDING MAY CONTAIN AIRBORNE LEAD CONTAMINATION IN EXCESS OF OSHA STANDARDS. INFORMATION REGARDING THE HAZARDS OF LEAD CAN BE FOUND IN THE CHEMICAL FACT SHEETS IN THE FIGURES IN THIS ARTICLE. NOTE: READ ALL INFORMATION IN THIS TECHNICAL SERVICE BULLETIN CAREFULLY AND FORWARD TO ALL EMPLOYEES PERFORMING PAINT PREPPING OPERATIONS. DEALERS SHOULD CONTACT LEGAL COUNSEL AND/OR LOCAL OSHA Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 94234 > Nov > 94 > Paint - Preparation Procedure And MSDS Information > Page 8212 AUTHORITIES FOR DIRECTION REGARDING OSHA LEAD STANDARD REQUIREMENTS. If a replacement body panel contains more than a minor flaw in the E-coat, it should be returned. Contact your Customer Service representative for instructions. If more extensive sanding, other than that described above, is necessary, (e.g., refinishing original vehicle sheet metal) follow the procedures outlined below: ALTERNATIVE SANDING PROCEDURES WHEN EXTENSIVE SANDING IS REQUIRED The following procedures for sheet metal preparation by sanding or media blasting are based on tests conducted by Ford Motor Company in accordance with requirements set forth in the Federal OSHA Inorganic Lead Standard 29 CFR 1910.1025. SANDING PROCEDURE 1. Each technician performing the sanding operation MUST wear an approved respirator with high efficiency particulate filter (HEPA). 2. Technicians should use dual action sander with vacuum collection. 3. The vacuum equipment MUST be equipped with a HEPA filter on the air exhaust. Dealers are cautioned not to exhaust vacuum air into the atmosphere. Operators are cautioned to follow the manufacturer's guidelines for maintenance and the replacement of filters. MEDIA BLASTING PROCEDURE 1. Testing has shown that plastic media blasting meets OSHA lead standard requirements and is efficient when the manufacturer's published procedures are followed. 2. The operator must wear an air supplied hood using compressed air free from carbon monoxide, oil, water, and other contamination when performing this operation. Specifics of the media blasting procedure for whole body paint removal have been previously published. NOTE: PLEASE READ THE CHEMICAL FACT SHEETS IN THE FIGURES. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures Technical Service Bulletin # 91181 Date: 910905 Exterior Paint - Comprehensive Repair Procedures Article No. 91-18-1 09/05/91 PAINT-EXTERIOR-COMPREHENSIVE REPAIR PROCEDURES FORD: 1985-86 LTD 1985-92 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-92 TAURUS 1988-92 FESTIVA 1989-92 PROBE LINCOLN-MERCURY: 1985-86 CAPRI, MARQUIS 1985-87 LYNX 1985-92 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-92 SABLE 1988-92 TRACER MERKUR: 1985-89 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1985-90 BRONCO II 1985-92 BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1986-92 AEROSTAR 1991 EXPLORER ISSUE: A comprehensive paint repair procedure TSB has been developed for service use. It includes the following paint repair topics: Section (A) has been superseded by TSB # 9264, dated 3/92. (B) Exterior Color Peeling From Ultra Violet Light (C) Lower Body Stone Protection Repair Tips (D) Procedures For PVC Body Side Moldings (E) Lower Body-Side Stone Chip Protection Program (F) Surface Defect Removal Without Repainting (G) 1991 Color Matched/Compatible Spray Primer Chart (H) Repair For Tinted Clearcoat (I) Frequently Used And Paintable Plastics (J) 1992 Paint Codes ACTION: If paint repair is required, refer to the following procedures for paint restoration. Section A Has Been Superseded By TSB # 9264, Dated 3/92. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS PROCEDURE # 2 FINISH KARE FORMULA # 1119 AND # 883 (Buffered solution not as harsh on aluminum parts) WARNING: FOR YOUR SAFETY, USE RUBBER GLOVES, GOGGLES AND PROTECTIVE CLOTHING WHEN HANDLING THESE PRODUCTS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8217 1. Apply hot diluted solution with soft mitt. 2. Agitate to create suds. Suds hold the acid solution in suspension and to the surface creating greater and extended activity. 3. Allow 3 to 5 minutes dwell time. 4. Rinse with COLD WATER. 5. Apply # 883 per label instructions. LIQUID NEUTRALIZER CONCENTRATE 1. Using a mitt, thoroughly go over the entire surface with the diluted solution (50-1) of water and # 118 Liquid Neutralizer Concentrate. Then wipe dry. 2. If the iron particles are not totally removed after 2 washings, use one or both of the following service actions. a. Sand with micro fine sandpaper (1500 Grid or greater) in localized areas. b. Buff with very light compound and polish with wax in localized areas. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'S) OR EXCESS MATERIALS. (B) Paint Exterior Color Peeling From Ultra Violet Light Paint may be damaged because of ultra violet light absorption through the color coat. This damage will cause the top coat to peel to the E-coat primer. If service is required, use the following procedure to correct the concerns. NOTE: READ THE ENTIRE SERVICE PROCEDURE BEFORE STARTING REPAIRS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT. 1. Wash the vehicle with soap and water. 2. Verify topcoat adhesion by applying a 2 inch wide masking tape strip on all body panels above and below the beltline on each panel. a. Pull the tape up quickly. b. Inspect the adhesive side of the tape for paint removal. NOTE: IF PAINT WAS REMOVED DURING THE TAPE TEST, THE ENTIRE PANEL SHOULD BE STRIPPED AND REFINISHED AS NECESSARY. 3. Remove all trim (mouldings, name plates, striping, etc.) from the areas which will be repainted. NOTE: ALL REQUIRED REPLACEMENT MOULDINGS AND STRIPES SHOULD BE ORDERED AND RECEIVED PRIOR TO REPAIRING THE CUSTOMER'S VEHICLE. 4. Wipe the entire vehicle with wax and grease remover. ^ BASF Product # 900 Prekleano ^ PPG Product # DX300 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mask off all areas on the vehicle which are not going to be painted or will be affected by overspray (engine compartment, wheels, etc.). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8218 6. Remove the paint to bare metal from all the areas of the vehicle which are going to be repainted. Use one of the following methods. SAND THE AFFECTED AREAS TO BARE METAL USING 40 GRIT 3M GREEN CORPS SANDING DISCS OR EQUIVALENT AND A SOFT PAD ON A 1700 RPM POLISHER. KEEP THE POLISHER MOVING TO AVOID DEVELOPING HOT SPOTS ON THE METAL. NOTE: CHEMICAL STRIPPING IS NOT RECOMMENDED. NOTE: IF AVAILABLE, PAINT MAY BE REMOVED USING A PLASTIC MEDIA BLAST SYSTEM. IF THIS PROCESS IS USED, EXTRA CARE MUST BE TAKEN DURING THE MASKING PROCESS TO PREVENT DAMAGE TO GLASS, MOULDING, ETC. 7. Blow off the entire vehicle to remove loose dust and debris. NOTE: IF RUST IS PRESENT, USE APPROPRIATE METAL CLEANER AND CONDITIONER (PHOSPHATE COATING) OVER BARE METAL AREAS. 8. Wipe all affected areas with a fast dry enamel reducer solvent, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. NOTE: THIS STEP WILL REDUCE THE POSSIBILITY OF FLASH RUST. ^ BASF Product # BR 50 ^ PPG Product # DX 300 ^ S-W Product # R7 K156 ^ DuPont Product # 3812 S ^ Sikkens Product # 123 FAST 9. Apply two medium wet coats (1.0 mil total) of self-etching, anti-corrosion primer using the manufacturer's recommendations and flash times. ^ BASF Product # DE-17 ^ PPG Product # DP EPOXY PRIMER ^ S-W Product # E2-6980 ^ DuPont Product # VARIPRIME ^ Sikkens Product # WASH FILLER 580 10. Apply three medium wet coats (2.0 mils total) of acrylic urethane primer surfacer following the manufacturer's recommended procedures. ^ BASF Product # DP-20 PRIMER/SUFACER ^ PPG Product # K-36 ^ S-W Product # P6-M49 OR P6-A48 ^ DuPont Product # URO PRIMERFILLER ^ Sikkens Product # AUTOCRYL 3+1 FILLER 11. Sand the vehicle using one of the following methods: ^ Wet-sand by hand using 400 grit or finer sandpaper. ^ Dry-sand by hand using 320 grit or finer sandpaper. 12. Blow the entire vehicle off to remove loose dust and debris. 13. Demask (remove all paper and tape) as necessary to remove the primer and dirt buildup on the paper and tape. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8219 14. Wipe the entire vehicle with wax and grease remover, followed by a dry wipe using a clean, lint free cloth to remove all residue. CAUTION: KEEP WIPING UNTIL SURFACE IS COMPLETELY DRY. ANY RESIDUE WILL RESULT IN POPPING OF THE COATINGS TO BE APPLIED FOLLOWING THIS STEP. ^ BASF Product # 901 PRE-PAINT CLEANER ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3812 S ^ Sikkens Product # M 600 15. Mask all areas on the vehicle which are not to be painted or will be affected by paint overspray (engine compartment, wheels, etc.). NOTE: APPLY BASECOAT/CLEAR COAT ONLY TO SURFACES WHICH ORIGINALLY HAD BASECOAT/CLEAR COAT 16. Apply three medium wet coats (enough material to hide primer) of acrylic enamel base coat or acrylic urethane monocoat following the manufacturer's recommended procedure. ^ BASF Product # DIAMONT BASECOAT/Solo ^ PPG Product # DELTRON BASECOAT DBC/Deltron ^ S-W Product # ULTRA BASE/Ultra One Stage ^ DuPont Product # CHROMABASE/Cronar ^ Sikkens Product # AUTO BASE/Autocryl 17. Apply two medium wet coats of 2K acrylic urethane enamel clear coat, following manufacturer's recommended procedure. ^ BASF Product # DIAMONT CLEAR 88/89 ^ PPG Product # CONCEPT 2001 DCU ^ S-W Product # CC-650 OR CC-640 ^ DuPont Product # 1080 S URO CLEAR ^ Sikkens Product # AUTO CLEAR 18. After the paint is dry, demask the entire vehicle and clean up any areas which have overspray. 19. Polish the vehicle as necessary to remove any defects in the paint which may create a customer concern. CAUTION: USE LOW SPEED (1700 RPM MAXIMUM) POLISHER. 20. Install all trim (mouldings, name plates, striping, etc.) on the vehicle which were removed prior to repainting. 21. Clean the exterior and interior of the vehicle thoroughly, including air ducts and other areas which are prone to accumulating dust. This step is essential to ensure customer satisfaction. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8220 Figure 1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8221 Figure 2 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8222 Figure 3 STRIP AND REFINISH CLAIMING METHODOLOGY The claiming instructions shown in Figure 1 are applicable to the repair of the EXTERIOR COLOR PEELING FROM ULTRA VIOLET LIGHT concern covered in this TSB only. See the SAMPLE CLAIMS, Figures 2 and 3, for examples. (C) Lower Body Stone Protection Repair Tips Ford has introduced a vinyl anti-stone abrasion material for the lower exterior body surfaces of selected passenger vehicles and light trucks. The anti-stone abrasion material is applied to the lower fenders, rocker panels, lower doors, quarter panel dogleg, and lower rear of quarter panel behind the wheel. The anti-stone abrasion material will usually end at a body character line. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8223 While primarily for servicing of factory-applied protective coating, the following provides installation information. If the vehicle has experienced body damage in the factory-applied material protective area, the sheet metal damage must be serviced prior to the application of the new protective coating. SMALL AREAS - MINOR DEFECTS (VEHICLES WITH FACTORY SPRAYED-ON VINYL) A small dent in the sheet metal that did not mar the vinyl surface, can possibly be corrected with proper bumping tools without damage to the vinyl coating. However, noticeable scratches or gouges (not over 1/2 inch in diameter) or dings and dents that when "ironed out" show vinyl damage, can be satisfactorily serviced with the following procedure: 1. Solvent-wipe the damaged area with "Silicone and Wax Remover." 2. Using a heat gun or lamp, soften the vinyl coating of the damaged area until it can be scraped off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The spray-on vinyl protective coatings may not be suitable for "spot" application. See Manufacturer's label for instructions.) 3. Perform necessary servicing to correct the sheet metal damage. 4. Using white bodyfiller, fill the damaged area. Follow the instructions on the label and blend the bodyfiller with the surrounding sheet metal. 5. Allow the bodyfiller to completely cure and then carefully sand the area smooth, removing any high spots. 6. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. LARGE DAMAGED AREAS - VEHICLE WITH FACTORY SPRAYED ON VINYL Peeling or damage over a large area will necessitate removal of the factory sprayed-on vinyl coating. The following procedure is suggested. NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR, OR QUARTER PANEL REPLACEMENT IS REQUIRED (OR IN AN INITIAL INSTALLATION), DISREGARD STEPS NO. 1 AND NO. 2. 1. Using a heat gun or lamp, soften the vinyl coating until it is pliable. Scrape coating off with a putty knife or a similar tool. If necessary, sand off any hard to remove coating using an orbital disc sander (No. 80 Disc). (The vinyl material, abrasion resistant coating may not be suitable for "spot" applications. See manufacturer's label for instructions.) 2. Perform necessary servicing to correct the sheet metal damage. 3. Refer to "Spray Procedure" for restoration of vinyl anti-stone abrasion material. COATING APPLICATIONS Approximately two quarts will be required for an initial installation on a passenger car or F-Series. Slightly more will be required for an Econoline. The specified dry film thickness of 15 to 20 mils (.015 to .020 inch) will require at least three, possibly four, applications of coating material, with "flash off" time between coats. Spray coat complete panels only. The coating must be applied with commercial equipment by an experienced automotive painter. The coating must be thoroughly agitated before application. The material is heavy bodied. A pressure cup spray gun or "Rocker Schutz Gun" is recommended. COATING PREPARATION - MASKING VEHICLE Install suitable covers over the wheels. NOTE: IF THE VEHICLE HAS LOWER BODY SIDE MOULDINGS (12-14 INCHES ABOVE THE "TURN UNDER" OF THE ROCKER PANEL), THE MOULDING CAN SERVE AS THE UPPER MARGIN OF THE AREA TO BE COATED. IF THE VEHICLE DOES NOT HAVE SUITABLE MOULDINGS, A SCULPTURE OR BREAK LINE IN THE SHEET METAL CAN BE UTILIZED. THIS LINE SHOULD BE SELECTED TO ENSURE ADEQUATE PROTECTION OF THE PAINTED SURFACES. VEHICLES WITH BODY SIDE MOULDINGS 1. Masking tape should be positioned so that the moulding lower edge is also covered. The adjoining sheet metal should be left uncovered too so anti-stone, abrasion vinyl can be applied. VEHICLES WITHOUT BODY SIDE MOULDINGS 2. If the contour of the body side has a break line, the upper coating margin must be masked off using 3M "Fine Line" Tape. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8224 a. The normal masking tape and paper protection for the body side should be applied first and positioned about a quarter inch above the margin line. b. The "Fine Line" tape should then be applied over the regular masking tape with the lower edge at the upper coating margin line. Extend this "Fine Line" tape into the wheel opening, in the absence of wheel opening mouldings, allowing the flange to be coated. c. The anti-stone abrasion coating does not adhere well to flexible plastic parts. If left exposed, they must be masked off. d. It is not necessary to mask off the body door openings in the coating area, as they will be uniformly coated where the door margins allow the coating to enter. NOTE: DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE. COATING PREPARATION - SHEET METAL REPAIRED SHEETMETAL 1. Scuff sand (No. 180 Grit Paper) the glossy surface of the painted areas to be coated. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and lint-free tack cloth. NEW SHEET METAL 1. Sand off (No. 180 Grit Paper) the prime paint in the area to be coated. 2. Using a lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. NEW INSTALLATION 1. The glossy surface of the paint in the coating area must be sanded with a D/A sander. A 220/240 Grit Disc does a good, fast job. DO NOT sand through the primer. 2. Using a clean, lint-free cloth, solvent wipe the area to be coated with wax and grease remover. 3. Remove sanding dust using compressed air and a lint-free tack cloth. SPRAY PROCEDURE The lower exposed painted fender, rocker, and quarter panel down flanges should be protected. The vehicle must be elevated high enough so that the painter can spray this area effectively. When an initial installation is to be made, a remote two-quart capacity pressure cup makes a much more efficient tool, as the spray gun can be used closer to the floor. The spray gun, fluid hose and/or cup must be cleaned immediately after use. Refer to manufacturer's recommended cleaning procedure. Lacquer thinner can be used when the suggested clean up material is unavailable. WARNING: WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EOUIPMENT. 1. After preparing the new or damaged area(s), mix either Epoxy primer or Self-etch prime, per manufacturer's label instructions, and spray bare metal areas. ^ BASF DE15 or DE17 ^ Sikkens Metalflex CR Primer (1 coat only) ^ DuPont Variprime ^ S-W E2G 980 GBP Etching Filler ^ PPG DP 40 (only) 2. Apply 1-2 light prime coats over the bare metal areas. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8225 3. Allow the material to dry for 15-20 minutes before applying the anti-stone abrasion material. 4. Mix and apply anti-stone abrasion material per manufacturer's label instructions over the primed area. NOTE: AN ORANGE PEELED FINISH IS NORMAL WITH THESE PRODUCTS. ^ BASF Glassohyd 1109-1240/6 ^ Sikkens 0TO Bodycoat ^ DuPont 123-5 Vinyl ^ S-W G/W 295 Vinyl Gravel Guard ^ PPG DX 54 Roadguard ^ 3M Rocker Schutz NOTE: SOME ANTI-STONE ABRASION MATERIAL MAY REQUIRE A SLIGHTLY DIFFERENT MIXING PREPARATION, PROCEDURE AND APPLICATION. SOME ANTI-STONE ABRASION MATERIALS CAN NOT BE USED FOR SPOT REPAIR. CHECK WITH THE PAINT MANUFACTURER FOR RECOMMENDATIONS ABOUT THEIR PRODUCT. 5. Allow the stone abrasion material to dry. Heat can be used to accelerate the drying time. Check the manufacturer's instructions. COLOR COAT The complete coated area, as well as the upper raw edge, must be covered with color coat. Mask off the upper margin line using "Fine Line" tape positioned 1/16 inch above the coating edge. Using appropriate service paint and application procedures, the protective coating area can now be finish painted with monocoat or a basecoat/clearcoat urethane system. NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA, NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. Figure 4 Refer to the Lower Body Stone Protection Chart, Figure 4, for the material and labor hours involved. (D) Procedure For PVC Body Side Moldings If replacement of the body side molding is necessary, some dealer service kits will be supplied "paint to match." Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8226 The painting procedures in the following instructions (also included with the part) address materials from five (5) major aftermarket paint suppliers. Use the paint system materials you are the most familiar with. NOTE: CAREFULLY READ ALL LABEL WARNINGS BEFORE APPLYING THESE PRODUCTS. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SIKKENS PRODUCTS PREPARATION 1. Degrease with M600 wax and grease remover. 2. Scuff with # 320 dry paper or Scotchbrite 7447 (red). 3. Repeat degreasing step. 4. Spray two medium coats of Plastoflex primer. Allow 5 to 10 minutes flash between coats. 5. Allow 20 minutes flash-off at 70~ F before topcoating. TOPCOATING 1. Mix Autocryl color with Elast-O-Actif 50:50 by volume. 2. Mix this material with 1.2.3 hardner and 1.2.3 reducer (use correct reducer for temperature) 100:50:30 by volume. 3. Apply three medium coats, allowing enough flash off to dry to a light touch. 4. Dry one hour at 140~F after 10 minutes flash off or dry 24 hours at 75~F. PPG PRODUCTS PPG MONO-COAT SYSTEMS 1. Solvent wipe with DX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron topcoat color with DX-369 Flexative per label instructions. 2. Use 40-50 PSI at the gun. PPG BASECOAT/CLEARCOAT SYSTEMS PREPARATION 1. Solvent wipe with SX330 Acryli-clean. 2. Scuff with red Scotchbrite pad. 3. Repeat solvent wipe. TOPCOATING 1. Mix and apply Deltron basecoat color (DBU), with the recommended reducer for the temperature, per label instructions. 2. Mix and apply clearcoat material DBU-88 or DCU-2001, with DX-369 Flexative, per label instructions. SHERWIN-WILLIAMS PRODUCTS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8227 Ultrabase 7 Basecoat/Clearcoat or Ultra One Stage Acrylic Urethane Enamel PREPARATION 1. Wash the material with a mild detergent and wipe dry. 2. Solvent wash with R7 K 156 and wipe dry. 3. Clean with a tack cloth. 4. Apply desired system with correct amount of Multi-flex, V6 V 299. TOPCOATING Prepare topcoating as follows: ^ S-W Ultra One Stage: (Mono-coat) 4 Parts Color 3 Parts SSR 650 Reducer 1 Part V6 V 440 or SSH 520 2 Parts V6 V 299 ^ S-W UB7 Basecoat: 8 Parts Basecoat Color 8 Parts Stabilizer 1 Part V6 V 299 ^ S-W UB7 Clearcoat: 4 Parts T1 C 650 Clearcoat 2 Parts T1 C 650 Reducer 1 Part CCH 690 1 Part V6 V 299 ^ S-W Ultra One Stage: (Mono-coat) Apply 2-3 medium wet coats at 50 PSI ^ UB7 Basecoat: Apply 2-3 medium coats at 45 PSI ^ UB7 Clearcoat: Apply 2-3 medium coats at 50 PSI DUPONT PRODUCTS DUPONT CRONAR POLYOXITHANE MONOCOAT SYSTEM PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING 1. Add 8 parts of Cronar single stage enamel. 2. Add 1 part Cronar initiator 9404S. 3. Add two parts of (9475S, 9485S, or 9495S,) depending on shop temperature. 4. Add 2 parts flex-additive 9250S. 5. Mix thoroughly. 6. Spray at 45-55 PSI at the gun, 2-3 medium wet coats or until hiding. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8228 7. If a clear coat is applied, use 9500S. DUPONT CENTARI MONO-COAT ENAMEL SYSTEMS PREPARATION 1. Wash the surface thoroughly with a mild detergent. 2. Clean with Prep Sol. TOPCOATING (Follow Manufacturer's Recommendation) 1. Add 8 parts of Centari enamel color and 1 part 793S hardener. 2. Add 4 parts of (8022S, 8093S, or 8096S) reducer, depending on shop temperature. 3. Add 355S flex additive per label instructions. 4. Mix thoroughly. 5. Spray 2-3 wet coats, with 5 minutes flash time, at 50-65 PSI. BASF PRODUCTS The following procedure is applicable to 4 paint systems in the BASF paint line. Read individual "system" instructions carefully. PREPARATION 1. Solvent wipe the molding with RM Pre-klean-o 900. 2. Sand with 400 grit sand paper and rinse with 901 pre-paint cleaner. TOPCOATING BASECOAT ^ "Glasurit" 54-line color 2 vol. parts ^ 54-line reducer 1 vol. part ^ "Diamont" basecoat color 2 vol. parts ^ B R Diamont reducer 2 vol. parts ^ "Miracryl" basecoat color 2 vol. parts ^ BCR reducer 2 vol. parts ^ "Supreme Gold" basecoat color 2 vol. parts ^ LBR reducer 2 vol. parts Apply basecoat color until hiding is achieved. Allow 3-5 minutes flash time between coats. NOTE: USE APPROPRIATE REDUCER FOR SHOP CONDITIONS. ALLOW 15 MINUTES FLASH-OFF BEFORE SPRAYING CLEARCOAT. TOPCOATING Apply clearcoat per manufacturer's label instructions: CLEARCOAT REDUCTIONS ^ DC-88 Diamont Clear 4 Vol. Parts ^ DH-44 Diamont Hardener 1 Vol. Part ^ MC-1000 Clear 4 Vol. Parts ^ 894 Hardener 1 Vol. Part ^ LC-1300 Supreme Gold Clear 4 Vol. Parts ^ LH-1301 Hardener 1 Vol. Part Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8229 ^ 92354 Glasurit Clear 100 Parts ^ 521-111 Elastifier 20 Parts ^ 929-29 Hardener 60 Parts Apply 2 wet coats with 5 to 10 minutes flash time between coats. Overnight dry or force dry at 140~F for 30 minutes. CAUTION: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS. (E) Lower Body-Side Stone Chip Protection Program Ford Motor Company has recently initiated a program to provide improved stone-chip protection on some vehicles and to increase the corrosion protection on cars and trucks. Some customers are unaware of body side anti-stone chip protection which appears as wavy orange peel texture on the lower body areas. Ford is increasing the use of PVC (poly vinyl chloride) material which is applied in a thicker coating on the lower body-side. This material has been in use on vehicles destined for the Canadian market for many years. This PVC material is now applied at the following plants on ALL vehicles. ^ Edison - Ranger ^ Hermosillo - Escort/Tracer ^ Louisville - Ranger and Explorer ^ Ohio Truck - Econoline ^ Wayne - Escort/Tracer This process is also planned for Kansas City, Oakville, Twin Cities and Wixom. This material can be identified by the "orange peel" appearance and a visible "break-line" between protected and unprotected areas in the lower body areas. CAUTION: THIS PROTECTION MUST NOT BE REMOVED IF VEHICLE IS EXPECTED TO MAINTAIN THE CORROSION PROTECTION. Some customers have expressed concerns due to the appearance of the treated areas. These customers did not know about the extra protection this material provides their vehicle. Once explained, customers were pleased with the added protection and accepted the orange peel finish. NOTE: DEALERS SHOULD ADVISE THEIR SALES PEOPLE, SERVICE PEOPLE, AND CUSTOMERS, OF THE REASONS AND BENEFITS OF THIS PROTECTION. CANADIAN DEALERS STRESS THIS AS A SELLING POINT WITH THEIR SALES PEOPLE. IT IS CONSIDERED A COMPETITIVE ADVANTAGE. (F) Surface Defect Removal Without Repainting Exterior paint surface damage or imperfections, where the primer coat does not show through, should be restored without repainting. The restoration of gloss and luster, after the condition has been repaired, is possible with new techniques and improved materials. The following procedure is applicable to surface conditions such as dirt particles, orange peel, runs, sags, industrial fallout stains, swirl marks, light scratches and other minor surface imperfections. For dirt particles or scratches in several localized areas, the entire panel should be refinished to maintain a uniform appearance. PREPARATION To repair the affected surface it must be clean and dry. Mask off adjacent panels, mouldings, stripe and character lines as required. CAUTION: EYE PROTECTION, AND FACE MASK SHOULD BE WORN. RINGS, BRACELETS, WATCHES AND BELT BUCKLES MUST BE REMOVED TO PREVENT ACCIDENTAL DAMAGE TO PAINT FINISH. SERVICE PROCEDURE 1. Remove sanding marks with rubbing compound. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8230 2. Swirl marks, evident after buffing, are removed by polishing. 3. Remove light scratches and small dirt particles with a power buffer and medium buffing compound followed with polishing. 4. Remove deeper scratches and heavy dirt particles or orange peel, by wet sanding. 5. Buff with compound to remove the sanding marks and then polish to remove the swirl marks from the buffing operation. NOTE: PERFORM A TRIAL REPAIR WITH A SMALL AREA. FIRST, TRY POLISHING; IF THIS IS NOT SUCCESSFUL, TRY BUFFING AND, FINALLY, USE WET SANDING TO REMOVE THE CONDITION. USE MOST EFFECTIVE TECHNIQUE ON REMAINDER OF AREAS. AN OUTLINE OF THE COMPLETE PROCEDURE AND REQUIRED MATERIALS FOLLOWS. POLISHING - VERY MINOR SCRATCHES OR SWIRL MARKS AND/OR RESTORING A DULL FINISH 1. Apply a small amount of Meguiar's Mirror Glaze, or equivalent, to the affected panel (or pad). 2. Use a suitable electric or air powered polish/buffing wheel (1750 max. RPM) and a Meguiar's Finesse Polishing Pad, or equivalent, to polish the affected area until all swirl marks are gone and desired luster is obtained. 3. When polishing, keep the pad flat against the surface. Do not bear down. The weight of the buffer is sufficient. CAUTION: DO NOT MIX PRODUCTS! USE A SEPARATE, DEDICATED BUFFING PAD FOR EACH PRODUCT TO ACHIEVE DESIRED RESULTS. Variable speed buffers are available in a variety of buffing speeds. The recommended speed range is 1200-1750 RPM. COMPOUNDING - LIGHT SCRATCHES, SMALL DIRT PARTICLES, MINOR GRIND MARKS, AND SANDING MARKS 1. Apply Meguiar's Rubbing Compound (medium) or equivalent to the panel with a clean compound pad on the wheel. 2. Spread the compound evenly and continue buffing until the condition is removed. 3. Keep the wheel flat to the surface and use light to moderate pressure and long strokes. 4. Periodically check the finish and add compound as required. 5. When buffing is complete, polish the panel as described previously. Twisted wool cutting pads are the most effective compounding pads to use with Glaze Machine Cleaner for removing paint defects and heavy oxidation. Following the use of a wool compounding pad, it may be necessary to polish the finish with No. 2 Mirror Glaze Hi-Tech Cleaner using a Mirror Glaze Finesse Polishing Pad to remove the deep swirl marks. GENERAL TECHNIQUES AND HINTS ^ "Foam" buffing pads create added gloss and depth of color on all types of paint finishes without creating buffer swirl marks. ^ When "buffing out" oxidation or other paint defects with a cleaning material, use a liberal amount of material, slower buffing motion and added downward pressure to increase cutting action. ^ Always apply cleaner to buffing pad, not directly on the oxidized paint surface. Dry paint absorbs material into pores upon contact. ^ Always keep the face of the buffing pad completely flat to the surface, reducing the risk of buffer swirl marks. Watch your pad, especially on angled surfaces, to be certain that it stays flat. ^ Avoid short rapid strokes. Move the buffer slowly across the surface using long straight motions and overlap by 50% the buffing pattern left by the previous pass. This insures uniform coverage and allows both material and buffer to perform at maximum efficiency. ^ Avoid buffing directly on raised character lines. The reduced paint film on these surfaces increases the risk of paint burn through. It is best to buff up to them from each side. ^ Always use a "wet buff" technique on a basecoat/clearcoat finish. This is a precaution against buffer swirls. Stop buffing just after the product begins to break down and before an overall dry, glossy finish appears. After "wet buffing", use a towel to wipe off the excess material. ^ Always use a "dry buff" technique on light colored, conventional paint finishes. Continue buffing until the material breaks down and only a slight film remains for final wipe off. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8231 ^ If a paint blemish remains after buffing, reapply a small amount of material over the blemish. Confine your buffing strokes to the immediate area of the blemish while applying additional downward pressure and keeping the pad flat. NOTE: ALWAYS KEEP THE PAD MOVING AND LIMIT YOUR STROKES OVER THE BLEMISH TO PREVENT EXCESSIVE HEAT BUILD-UP AND POSSIBLE BURN THROUGH. STOP IMMEDIATELY IF THE SURFACE BECOMES TOO HOT TO LAY THE PALM OF YOUR HAND ON IT. NOTE: HEAT BUILD-UP: WHEN BUFFING CREATES EXCESSIVE HEAT, HAZING MAY APPEAR ACROSS THE SURFACE BEING BUFFED AND THE PRODUCT MAY DRY LIKE A FILM AND REFUSE TO BUFF OUT. TO REMEDY, WIPE THE AREA DOWN WITH COOL WATER, DRY THE SURFACE AND RESUME BUFFING ... AT A LOWER RPM IF POSSIBLE. NOTE: STATIC: STATIC ELECTRICITY MAY BE PRESENT ON PAINTED FIBERGLASS/PLASTIC SURFACE BEING BUFFED, THE MATERIAL MAY DRY LIKE A FILM OR TURN "GUMMY" AND BEGIN TO BALL UP. TO REMEDY, GROUND THE SURFACE BEING BUFFED TO METAL. WET SANDING Paint defects and sanding marks must be completely removed without using compounds and abrasive cleaners that scar the finish. Mirror Glaze Hi-Tech Finesse Sanding Papers provide uniformity in grit particle size and distribution. Using these precision made sanding papers, water sanding marks can be removed with Meguiar's cleaner and finesse polishing pads. ^ Typical paint defects that are repaired with this system include: dirt-in paint, solvent pop, cratering, orange peel, drips, scratches, water spots, and acid rain. ^ Always use the least abrasive (highest grit) sanding products possible to do this job. The following wet sanding procedure utilizes light grit sand paper or sanding blocks for removal of surface damage. These materials cut quickly leaving a uniform finish requiring a minimum of buffing to restore gloss. PROCEDURE 1. Squeeze water to flush the area to be sanded. Continue to flush water to the surface during sanding for maximum lubrication. 2. Use small circular motions to contain the abrasion to the immediate area of the defect. Keep the blocks in water when not in use. 3. If the sanding block is cutting too slow, switch to a lower grade block and resume sanding. When 90% of the defect is removed, switch to a 2000 grade Finesse Sanding Paper or Sanding Block to finish smoothing and prepare the surface for buffing. 4. Finesse Sanding Blocks can be shaped to work on any angle. When the block is wet, rub it against a dry sanding block for shaping. 5. When using Finesse Sanding Papers, wrap the paper tightly around a E-7200 Backing Pad. This pad evenly distributes pressure over the entire surface of the sanding paper. This creates a uniform sanding pattern. 6. Plan your strokes to limit the abrasion to the smallest area possible. NOTE: ALWAYS SAND IN ONE DIRECTION AND KEEP YOUR STROKES STRAIGHT. 7. Always finish sanding with 2000 Grit Finesse Sanding Paper. This eliminates the need for compounding. 8. Buff out sanding marks by applying Meguiar's Cleaner with a Finesse "Foam" Polishing Pad. Follow with a Mirror Glaze Polish for swirl-free gloss. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C.'s) OR EXCESS MATERIALS RUNS AND SAGS REMOVAL This procedure consists of shaving the run or sag flush with a commercial single edge razor blade, shaving file or sanding with a hard block and then compounding. NOTE: IF IT IS NECESSARY TO SHAVE RUNS AND SAGS WITH A RAZOR BLADE, FIRST DULL THE CORNERS WITH SANDPAPER TO AVOID SCRATCHING THE ADJACENT PANEL FINISH. MEGUIAR'S PRODUCTS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8232 PART NUMBER GRADE PART NAME S-1005 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Half Sheets S-1205 1200 S-1505 1600 S-2005 2000 S-1000 1000 Mirror Glaze Hi-Tech Finesse Sanding Papers - Full Sheets 8-1200 1200 8-1500 1500 S-2000 2000 E-7200 - Mirror Glaze Hi-Tech Finesse Backing Pad E-2000 - Mirror Glaze Hi-Tech Tach Sponge K-400 400 Mirror Glaze Hi-Tech Finesse Sanding Blocks K-1000 1000 K-1500 1500 K-2000 2000 K-3000 3000 Other Applicable Articles: 82-3-3 (G) Color Compatible Spray Primer Chart Ford has released color compatible spray primers for exterior and some interior surfaces. Colored sprayed primers are being used by our "Best-in-Class" competition and are now being implemented at Ford in order to improve process capability and to help in minimizing unsightly paint chipping from stone abrasion. Color keyed (matched) spray primer for exterior body colors is being used in an effort to help in the elimination of unsightly paint chipping from stone abrasion. As with "Best-In-Class" competition, the engine compartment will be left with color compatible primer only and not be topcoated as per past practice. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8233 Figure 5 When any paint repair is required, remember that the vehicle may have a colored primer. Refer to the Spray Primer Chart, Figure 5. This information may be of help in correction of exterior paint color match concerns. (H) Paint Repair For Tinted Clear Coat Ford introduced (Early Spring, 1991) a new paint color using a tinted clearcoat. The first color to use this new system is Rio Red. If a paint repair is necessary, refer to the following procedure for repair instructions. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8234 BACKGROUND The Probe production paint system for Rio Red includes a Medium Green E-Coat primer, a Light Gray spray primer, bright Rio Red (E4) basecoat and a slightly Red tinted clearcoat topcoat. NOTE: BEFORE ANY REPAIRS ARE BEGUN, IT IS CRITICAL THAT PRIMER, RED BASECOAT AND TINTED CLEARCOAT BE SPRAYED ON A TEST PANEL. THE COLOR MATCH IN EACH STEP IS VERY IMPORTANT FOR A SUCCESSFUL REPAIR. WARNING: ALWAYS WEAR A NOISHA/MSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE ALL OTHER RECOMMENDED SAFETY EQUIPMENT. SMALL SPOT REPAIR PROCEDURE 1 Wash the vehicle with detergent soap and water. 2 Wipe the vehicle down with wax and grease remover. 3. Sand the spot using 400 grit paper. Do not sand through the E-coat. 4. Wipe the sanded surface again with wax and grease remover/pre-cleaner. ^ BASF Product # 90 Pre-Kleano ^ PPG Product # DX 330 ^ S-W Product # R7-K156 ^ DuPont Product # 3919 S ^ Sikkens Product # M 600 5. Mix and apply tintable (Light Gray) self-etching or epoxy primer per manufacturer's label instructions. NOTE: COLOR MATCH OF PRIME COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. ^ BASF Product # DE 17 ^ PPG Product # DP 40 ^ S-W Product # E2-G973 ^ DuPont Product # 615S ^ Sikkens Product # 1016 6. Mix and apply bright Rio Red base coat material per manufacturer's label instructions. NOTE: COLOR MATCH OF BASE CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. 7. Mix and apply red tinted clearcoat material per manufacturer's label instructions. NOTE: COLOR MATCH OF TINTED CLEAR COAT IS KEY IN COLOR MATCH OF REPAIRED AREA. FULL PANEL REPAIR PROCEDURE 1. Wash the vehicle with detergent soap and water. 2. Wipe the vehicle down with wax and grease remover. 3. Sand the complete panel and feather edge into the next panel using 400 grit paper. Do not sand through the E-Coat primer. 4. Wipe the sanded surface with wax and grease remover. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8235 5. Mix and apply tintable (light gray) primer per manufacturer's label instructions. 6. Mix and apply Rio Red basecoat per manufacturer's label instructions. 7. Mix and apply Red tinted clearcoat per manufacturer's label instructions. 8. Mix and apply one coat of non-tinted clearcoat per manufacturer's label instructions. NOTE: COLOR MATCH OF EACH COAT ARE KEY TO COLOR MATCH OF FINISH REPAIR. WARNING: OUR ENVIRONMENT IS PRECIOUS - PLEASE USE PROPER DISPOSAL TECHNIQUES FOR ANY VOLATILE ORGANIC COMPOUNDS (V.O.C's) OR EXCESS MATERIALS. (I) Paintable Plastics Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8236 Figure 6 The Paintable Plastics Chart, Figure 6, is a summary of widely used plastics in our industry. The standard symbol should be located on the part for ease of material identification. If painting or repair of these plastics is necessary, the following chart identifies those materials which can be painted. Refer to paint manufacturer for specific paint material recommendations. NOTE: MATERIALS MAY REQUIRE PRIME COAT SEE "YES", UNDER "CAN BE PAINTED" COLUMN. (J) 1992 Paint Color Codes Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 91181 > Sep > 91 > Exterior Paint - Comprehensive Repair Procedures > Page 8237 Figure 7 The 1992 Paint Color Codes are listed in Figure 7. NOTE: REFER TO THE SERVICE LABOR TIME STANDARDS MANUAL AND THE SPECIFIC PROCEDURE WITHIN THIS BULLETIN FOR REIMBURSEMENT. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OASIS CODES: 106000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure Technical Service Bulletin # 90153 Date: 900719 Lower Body Stone Protection - Repair Procedure PAINT - LOWER BODY STONE PROTECTION REPAIR TIPS Article No. 90-15-3 FORD: 1985-90 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-90 TAURUS 1988-90 FESTIVA, PROBE LINCOLN-MERCURY: 1985-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, TOPAZ, TOWN CAR 1986-90 SABLE 1987-90 TRACER LIGHT TRUCK: 1985-90 BRONCO II, BRONCO, ECONOLINE, F-150, F-250, F-350, RANGER 1988-90 F SUPER DUTY ISSUE: A service repair procedure has been developed to restore damaged factory-applied lower body stone protection vinyl material. ACTION: If service is required, use the following procedure to restore damaged lower body stone protected areas. This abrasion resistant coating material (D9AZ-19515-A) is primarily for repair of factory-applied protective coatings. However, this material may also be installed on previously unprotected vehicles. If the vehicle has body damage in the area of the factory-applied coating, body damage must be repaired before repairing the protective coating. WARNING: WHENEVER USING PAINT, SOLVENT, REFINISHING OR RECONDITIONING MATERIALS, WEAR A NOSE OR FACE MASK, PLUS HAVE ADEQUATE VENTILATION IN THE WORK AREA. Large Repair Areas A large repair area, resulting from peeling or damage, will require removal of the factory-applied vinyl coating. NOTE: WHERE SHEET METAL IS DAMAGED TO THE EXTENT THAT A FENDER, DOOR OR QUARTER PANEL REPLACEMENT IS REQUIRED, (OR IN AN INITIAL INSTALLATION), SKIP STEPS # 1 - 3. 1. Use a heat gun or lamp to soften the vinyl coating until it is pliable. 2. Scrape off the softened vinyl with a putty knife or similar tool. If necessary, sand off any hard-to-remove vinyl coating using an orbital disc sander (# 80 Disc). NOTE: THE REPAIR MATERIAL, ABRASION RESISTANT COATING (D9AZ-19515-A), IS NOT SUITABLE FOR "SPOT" REPAIRS. THE OLD COATING MUST BE REMOVED COMPLETELY FROM EACH DAMAGED PANEL. 3. Make the necessary repairs to the sheet metal. Coating Preparation and Applications: The abrasion resistant coating is available in quart cans. About two quarts will be required for an initial installation on a passenger car similar to a factory-applied system. Slightly more will be required for a larger vehicle such as an Econoline. The specified dry film thickness of 15 to 20 mils (.015 to .020") will require at least three or possibly four applications of coating material, with flash off time allowed between coats. As with painting, spray coat the complete lower panel. The adherence of this coating to properly prepared sheet metal is excellent and it is not necessary to prime the repaired sheet metal. However, adhesion will be adversely affected unless the sheet metal (either repaired or new) is prepared in accordance with the following procedure. Coating Preparation - Masking Car 1. Install covers over the wheels. 2. Determine the area to be coated. ^ If the vehicle has lower body side mouldings (12-14" above the "turn under" of the rocker Panel), the moulding can serve as the upper margin of the area to be coated. ^ If the vehicle does not have suitable mouldings, a sculpture or break line in the sheet metal can be used. ^ The method used in masking off the upper coating margin line will depend on the presence or absence of mouldings in this area. VEHICLES WITH SIDE MOULDINGS 3. Position the masking tape so that the moulding lower side is covered down to, but not on the sheet metal. VEHICLES WITHOUT SIDE MOULDINGS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure > Page 8242 4. If the contour of the body side has a break line, or if an arbitrary line is chosen, mask off the upper coating margin using Scotch "Fine Line" tape. This is available nationally from 3M Company Distributors. a. Apply the normal masking tape and paper protection for the vehicle body side first. Position them about a 1/4" above the margin line. b. Apply the "Fine Line" tape over the regular masking tape with the lower edge at the upper coating margin line. c. Extend this "Fine Line" tape into the wheel opening, in absence of wheel opening mouldings, to allow the flange to be coated. d. Since the protective coating does not adhere well to flexible plastic stone shields, mask off the front of the plastic rear stone shield, if exposed. NOTE: IT IS NOT NECESSARY TO MASK OFF THE BODY DOOR OPENINGS IN THE COATING AREA BECAUSE THEY WILL BE UNIFORMLY COATED WHERE THE DOOR MARGINS ALLOW THE COATING TO ENTER. HOWEVER, THESE DOOR OPENING AREAS SHOULD BE CLEANED TO ASSURE COATING ADHERENCE. Coating Preparation - Sheet Metal REPAIRED SHEET METAL 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover and allow to flash off. 2. Scuff sand (# 180 Grit Paper) the glossy surface of the painted areas to be coated. 3. Remove sanding dust using a lint-free tack cloth and compressed air. NEW SHEET METAL 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover and allow to flash off. 2. Scuff sand (# 180 Grit Paper) the prime paint in the area to be coated. 3. Remove sanding dust using a lint-free tack cloth and compressed air. INITIAL INSTALLATION 1. Using a clean lint-free cloth, solvent wipe the area to be coated with a silicone and wax remover. 2. Sand the glossy surface of the paint in the coating area. (A D/A sander, 220/240 Grit Disc does a good fast job.) CAUTION: DO NOT SAND THROUGH THE COLOR COAT INTO THE PRIMER. 3. Remove sanding dust using a lint-free tack cloth and compressed air. Coating Application Coating applications must be applied with care. ^ The coating must be applied with commercial equipment by an experienced automotive painter. ^ The coating must be thoroughly agitated and used without thinning. ^ Since the material is reasonably heavy-bodied, a pressure cup equipped spray gun is recommended. ^ Satisfactory coating appearance (orange peel) will result with gun pressure of approximately 30 P.S.I. and cup pressures of approximately 15 P.S.I. Spray Procedure Since the lower exposed painted fender, rocker and quarter panel down flanges are to be coated, the vehicle should be elevated high enough so that the painter can spray this area effectively. When an initial installation is to be made, a remote, two-quart capacity pressure cup makes a much more efficient tool because the spray gun can be used closer to the floor. The spray gun, fluid hose and cup must be cleaned immediately after use. While lacquer thinner may be used when the suggested clean up material is unavailable, the Ford Vinyl Paint Precleaner (VC-542-A) is quicker and much more efficient. With the spray gun at 30 P.S.I. and pressure feed cup at 15 P.S.I. proceed as follows: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 90153 > Jul > 90 > Lower Body Stone Protection - Repair Procedure > Page 8243 1. Apply a wet, sag-free coat. Allow 3 to 5 minutes flash off. 2. Apply a second wet, sag-free coat. Allow 3 to 5 minutes flash off. 3. Apply a third wet, sag-free coat. Allow 3 to 5 minutes flash off. 4. Apply a final wet, sag-free coat. Allow 3 to 5 minutes flash off. Pull off the "Fine Line" tape, exposing the raw upper edge of the coating. 5. Immediately clean the spray equipment using Ford Vinyl Paint Precleaner (VC-542-A) or equivalent. 6. Air drying time depends on the refinishing materials that are used. ^ If you refinish with acrylic lacquer, allow one hour for drying (at 70~F). ^ If you refinish with acrylic enamel, allow two hours for drying (at 70~F). Color Coat In order to paint the entire coated area as well as the upper raw edge, mask off the upper margin line using the "Fine Line" tape. Position the tape 1/16" above the coating edge. The protective coating area can now be finish painted. NOTE: IF DAMAGED SHEET METAL EXTENDS ABOVE THE PROTECTIVE COATING AREA, NORMAL PRIME/COLOR PAINT PROCEDURES SHOULD BE FOLLOWED. Suggested Equipment ^ DeVilbiss - Spray Gun - Model JGA-502-704-FX or equivalent ^ DeVilbiss - Remote Pressure Cup - Model KB-520 (2 Quarts), Model KB-521 (1 Quart) or equivalent ^ Binks - Spray Gun - Model 62 (# 63 Air Cap, # SS Fluid Tip, # 363 AN Needle) ^ Binks - Attached Pressure Cup - Model 80 (1 Quart, with Air Adjusting Gage) or equivalent. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100, 1800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials Paint: All Technical Service Bulletins Paint - Cosmetic Damage From Airborn Materials PAINT COSMETIC DAMAGE FROM AIRBORN MATERIALS Article No. 89-13-3 FORD: 1989 and prior ALL FORD LINES LINCOLN-MERCURY: 1989 and prior ALL LINCOLN-MERCURY LINES LIGHT TRUCK: 1989 and prior ALL LIGHT TRUCK LINES ISSUE: Paint may be damaged from various sources of airborn materials. The two different types are: ^ Inorganic ^ Organic Sometimes it is hard to identify the type of paint damage and know how to remove it. This TSB article gives detailed information and descriptions of both types of airborn materials. It also outlines the service procedures for treating them. ACTION: If service is required, identify the source of damage involved by referring to the following information. Use the following recommended service procedure to correct concerns. INORGANIC AIRBORN MATERIAL The effects of inorganic airborn materials can be seen as: ^ Dark blotches in the paint where the pigment in the paint surface has been attacked ^ Irregular spots that are cracked or etched around the edges and dull in the centers. ^ Small orange colored spots caused by iron particles may appear on the paint surface. Generally, materials that attack a paint film are either acidic or alkaline in nature. Sulfuric and nitric acids, in general, cause extreme damage to automative paint finishes. Even very small concentrations of the same materials can cause chemical spotting damage. Due to evaporation and condensation, these acids can create severe etching "spots" that may eventually crack or lift the paint film after some time in service. Although some automotive finishes are more resistant than others, none are completely immune to these chemicals. The most resistant paints used today are the urethanes because their resin system is least likely to react with chemicals. Air dry coatings are more susceptible to attack only when they are fresh. The longer the paint dries the more resistant it becomes. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 8248 Metallic colors are more intolerant to chemicals because aluminum flake is fairly reactive with either an acid or alkali. The following chart contains the most common acid materials found on automotive finishes. The chart shows a color, the corresponding damage appearance and also the chemical causal agent. It is not applicable for Basecoat/Clearcoat finishes. * "Caustic" refers to any alkaline substance that may be "harsh" or "corrosive" depending on strength or concentration. The following "pH" chart show the relationship between acidic and alkaline chemicals and their corresponding pH values. This chart is provided for informational reference only. ORGANIC AIRBORN MATERIALS Organic damage is generally easier to identify. Organic damage is mostly due to tree sap, bird and insect droppings, dead insects (Figure 8) and pollen. Tree sap is easily identified by clear raised drops that may be hard or sticky. Bee or bug dropping spots may appear brownish or yellow in color, about an eighth to a quarter inch in diameter. Dead and decomposing insect bodies are readily visible to the eye. Pollen deposits are small yellow clusters. Each of these items is potentially damaging to any currently available paint system. Other noticeable traits of organic damage are spots that are raised (swelling) micro-crazing (cracked) and pitting, due to pollen eating into the paint film. The active ingredients in most organic contaminants are tannic and formic acids . These acids are found in berries and bodily fluids of insects and birds. Investigations completed at dealerships show that the bright lot lights tend to attract insects. The use of "soft lights" for display and storage lot illumination will help reduce damage resulting from decomposing bugs and droppings by decreasing the number of bugs attracted to these lights. Organic damage is accelerated by heat. During very hot weather conditions, it is important to wash vehicles more often. ORGANIC AND INORGANIC REPAIR PROCEDURES FOR MILD DAMAGE Iron dust particles may imbed themselves into the paint film. On some light colored vehicles after some weathering, tiny dots of rust start to appear. They Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 8249 feel rough to the touch and are difficult to remove. The best way to remove these particles is by treating the finish with an oxalic acid-detergent-water wash. Use the following procedure to perform this service repair. NOTE: OXALIC ACID WASH IS ALSO PRE-PACKAGED IN VARIOUS STRENGTHS UNDER VARIOUS BRAND NAMES, IF YOU CHOOSE NOT TO MIX YOUR OWN BATCHES. 1. Wash and degrease the vehicle first, using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent, and a suitable wax and grease remover. If this does not remove all of the iron particles, proceed with the oxalic acid wash. 2. Prepare a quantity of oxalic acid-detergent-water solution as follows: a. Dissolve 6-8 ounces of Oxalic Acid (powder) in one gallon of warm water. b. Add 1-2 tablespoons full of non-alkaline detergent such as Ford Multi Purpose Cleaner. 3. Apply this solution liberally to all affected surfaces of the vehicle with a large sponge. Keep the surface wet until the technician can no longer feel any surface roughness with bare or gloved fingertips. NOTE: IF THIS IS NOT DONE THOROUGHLY, STAINING MAY REDEVELOP IF IRON PARTICLES ARE LEFT BEHIND. 4. Rinse the area with clean water. CAUTION: FAILURE TO THOROUGHLY RINSE THIS SURFACE COULD RESULT IN CORROSION OF ANODIZED ALUMINUM OR STAINLESS STEEL PARTS WITH PROLONGED CONTACT. 5. If the iron particles are not totally removed after 2 washings, use one or both of the procedures listed for minor chemical contamination. NOTE: THE USE OF POLISHING (WITH WAX), SANDING WITH MICRO FINE SANDPAPER (1500 GRIT OR GREATER) OR BUFFING WITH VERY LIGHT COMPOUND SHOULD ONLY BE DONE AS A LAST RESORT. CHEMICAL CONTAMINATION Chemical contamination, either acid or alkali, can cause off-color spots and crack the paint film. In the presence of moisture (dew), sulfur contamination will change the color (light/dark) of the paint pigments. (This does not apply to Basecoat/Clearcoat) Since this contamination affects the pigments, lacquers and enamels show no difference in resistance. Production thermal drying and air drying finishes are likely to be spotted. Minor chemical contamination can be removed by using the following step by step procedure. 1. Wash the vehicle first by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent to remove the exterior foreign materials. 2. If the spotting is extensive and on the horizontal surfaces, then machine polish. 3. Apply a light grit polishing compound to the affected surface by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum cutting efficiency. 4. Polish off the spots using a buffer operating at 1700-1800 rpm. Confine polishing to the spotted areas. Repeat as necessary until all spots have been removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all contamination. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 8250 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OR SAND OUT, THEN REFINISHING IS REQUIRED. ORGANIC MATERIAL REPAIR PROCEDURE FOR MILD DAMAGE Minor organic damage can be removed by using the following step by step procedure. 1. Wash and degrease the vehicle thoroughly by using Ford Multi Purpose Cleaner (B8A-19523-B) or equivalent and a wax and grease remover to remove all organics. 2. Inspect the vehicle horizontal surfaces. If spotting or paint film swelling is extensive, use a buffer to repair. 3. Apply a light grit polishing compound to the affected areas by using a soft brush. The compound should be applied to a small area at a time so that it can be buffed out while still wet to get maximum efficiency. 4. Polish off the spots or swelling marks using a buffer that operates between 1700-1800 rpm. Polishing should be confined to the affected areas only. Repeat as necessary until all spots or marks are removed. 5. Remove spots on curved surfaces, near edges, and next to mouldings or ornaments by hand polishing as follows: a. Apply some polishing compound to a cotton cloth. (Do not use a synthetic cloth.) b. Rub vigorously until the spots are no longer visible. c. Clean off excess polishing compound by using a clean cloth and compressed air. 6. Buff out the polishing marks and bring up the gloss by using a buffer equipped with a clean, dry lambs wool pad. NOTE: IF POLISHING DOES NOT SUFFICIENTLY REMOVE DAMAGE, THE VEHICLE CAN BE WET SANDED USING 1500 GRIT SANDPAPER AND THE FOLLOWING PROCEDURE. Wet Sanding Procedure 1. Clean the exterior surface of the vehicle with Ford Multi Purpose cleaner or an equivalent to remove all organics. 2. Apply 1500 grit sandpaper to a rubber padded sanding block to sand the paint surface. 3. Use a squirt bottle filled with water to lubricate the 1500 grit sandpaper as you begin to sand only the damaged areas. Water is an abrasive as well as a lubricant in this step. NOTE: IF THE DAMAGE HAS GONE DEEPLY INTO THE PAINT FILM AND IT WILL NOT POLISH OUT, THEN REFINISHING IS REQUIRED. PAINT RECONDITIONING PROCEDURES FOR SEVERE DAMAGE Acrylic enamel single stage or base/clear paint systems should be painted by using the following procedure. 1. .Wash the vehicle with Ford Multi Purpose Cleaner or equivalent to remove all organic materials. 2. Wash the areas to be painted with wax and grease remover. 3. Prepare the area as follows: a. Neutralize the affected areas with baking soda (sodium bicarbonate) and water. b. Rinse the surface off with plain water. c. Wash the panel with a mild soapy detergent. d. Dry the panel completely. NOTE: IF THE DAMAGE IS THROUGH THE TOP COAT FINISH AND INTO THE PRIMERS, THE PANEL MUST BE SANDED DOWN TO BARE METAL OR PLASTIC AND THEN REFINISHED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 89133 > Jun > 89 > Paint - Cosmetic Damage From Airborn Materials > Page 8251 4. Apply a self-etching primer for metal surfaces only. NOTE: A FLEX ADDITIVE MAY BE NECESSARY WHEN WORKING WITH FLEXIBLE PLASTICS Then proceed as follows: a. Let dry per instructions. b. Apply a two component urethane primer surfacer. c. Sand the surface with 400 grit sandpaper to get to proper finish. d. Finish sanding with 600 grit sandpaper. 5. Solvent wash panel with wax and grease remover. Then, tack wipe it. 6. Apply base coat or top coat material per applicable paint system. NOTE: THE USE OF ACRYLIC URETHANE ENAMEL IS HIGHLY RECOMMENDED FOR THIS TYPE OF REPAIR. 7. Apply clear acrylic urethane if you are using a base/clear paint system. WAYS TO MINIMIZE EFFECTS OF AIRBORN MATERIAL DAMAGE During the past year, Ford Motor Company and major paint suppliers have participated in a survey to analyze the effects of airborn materials. This survey was conducted on foreign and domestic vehicles. It resulted in the following interesting conclusions. 1. Keeping the vehicles clean, washing frequently with de-ionized water and drying by hand or mechanical means will help minimize the effects of inorganic and organic materials. 2. Spray washing without rubbing will not totally remove all residue on the surface of the vehicle. Damage could possibly occur over a longer period of time. 3. Care should be taken to not allow any painted vehicle surface to become wet in direct sunlight. (A sprinkler system can cause damage if the vehicles are not dried.) Possible alkaline water or mineral deposit may be the cause. 4. The use of "Soft Lights" for lighting around storage lots and showing areas will minimize the attraction of insects and the possibility of organic damage. 5. Ford Motor Company is piloting a program for a transit/storage coating to be applied on the horizontal surfaces of all vehicles. These coatings have shown good protection to the paint surface. They are clear in color and should be left on the vehicles until they are sold. 6. We are testing many "permanent paint sealants" used by dealers. Until all testing is completed, we cannot give any recommendations for what products to use. Testing has shown that a sealant that allows water to bead up on the vehicle does not help to dissipate the materials on the paint surface. Sheeting of water on the vehicle is highly desirable. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 8912189614 > Jun > 89 > Paint - Codes/Cross References Paint: All Technical Service Bulletins Paint - Codes/Cross References PAINT - 1989 COLOR CHART - AFTERMARKET SUPPLIER CROSS - REFERENCE LIST Article No. 89-12-1 FORD: 1989 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1989 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOWN CAR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 8912189614 > Jun > 89 > Paint - Codes/Cross References > Page 8256 ISSUE: The following 1989 Ford and Lincoln-Mercury color chart provides all of the supplier paint code numbers for the Ford two-digit paint codes listed on the Vehicle Certification Label. ACTION: Paint should be available in either lacquer or enamel from the manufacturers; however, not all manufacturers provide both mixing types. To get the best color match, either the "Factory Pack" or "Intermix" is okay to use. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > 88225 > Oct > 88 > Wheel Cover - Paint Chiping Paint: All Technical Service Bulletins Wheel Cover - Paint Chiping WHEEL COVERS - TWO PIECE - PAINT CHIPS WHILE PRYING OFF CENTER ORNAMENT Article No. 88-22-5 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The paint on two-piece wheel covers may be chipped if the center ornament is removed with a screw driver or any other tool with sharp edges. The lug wrench supplied with the vehicle has a curved tip with rounded edges to prevent paint chip damage to the cover when prying off the center ornament. ACTION: Use the lug wrench supplied with the vehicle to remove the center ornament from a two-piece wheel cover. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 1100, 3300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8261 Paint: By Symptom Technical Service Bulletin # 9384 Date: 930414 Exterior Clearcoat - Cracking/Eroding/Peeling Off Article No. 93-8-4 April 14, 1993 PAINT - EXTERIOR CLEARCOAT "MICROCHECKING", HAZING OR PEELING FORD: 1983-93 THUNDERBIRD 1984-93 TEMPO 1985-93 ESCORT 1986 LTD 1986-93 TAURUS 1989-93 CROWN VICTORIA, MUSTANG, PROBE LINCOLN-MERCURY: 1983-93 COUGAR 1984-92 MARK VII 1984-93 TOPAZ 1985-89 TRACER 1986 MARQUIS 1986-93 SABLE 1988-93 CONTINENTAL, TOWN CAR 1989-93 GRAND MARQUIS 1991-93 TRACER 1993 MARK VIII LIGHT TRUCK: 1983-93 RANGER 1986-93 AEROSTAR 1987-90 BRONCO II 1988-93 F SUPER DUTY, F-47 1991-93 ECONOLINE, EXPLORER 1992-93 F-150-350 SERIES 1993 VILLAGER ISSUE: The clearcoat layer of the basecoat/clearcoat paint system may "microcheck" (crack and erode), turn white, flake or peel off the vehicle. This condition is noticeable on the horizontal surfaces only. ACTION: Inspect the vehicle and if repair is necessary, refer to the following procedure for service details. This is a wet on wet procedure. Sanding is not required after the seal coat is applied. NOTE: READ THE ENTIRE SERVICE REPAIR PROCEDURE BEFORE STARTING REPAIRS. REPAIR PROCEDURE WARNING: ALWAYS WEAR A NIOSH/OSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT. 1. Wash the vehicle with soap and water. 2. Verify clearcoat to basecoat or primer adhesion by applying a 2" wide masking tape strip on all horizontal body panels. a. Pull the tape up quickly b. Inspect the adhesive side for paint removal. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8262 NOTE: IF PAINT WAS REMOVED DURING TAPE TEST, THE ENTIRE CLEARCOAT AND BASECOAT SHOULD BE REMOVED FROM THE PANEL. 3. Wipe down the areas to be repainted with wax and grease remover. ^ BASF product # 900 PreKleano or equivalent 4. Sand the affected surface with 150/240 grit sand paper. Remove only clearcoat and colorcoat, featheredge areas with 320 grit paper. NOTE: DO NOT REMOVE SPRAY PRIMER OR E-COAT. 5. Blow off the area to remove loose dust or debris. 6. Wipe the sanded surface with wax or grease remover. ^ BASF product # 901 Prekleano or equivalent 7. Tack off area. 8. Mix and apply one coat of epoxy primer for adhesion and let dry per manufacturer's label instruction (20 - 30 minutes). ^ BASF product # DE 15, PA16, PR80 or equivalent NOTE: DO NOT SAND THE NEWLY PRIMED AREAS. 9. Mix and apply two coats of the appropriate colored primer surface sealer. ^ BASF product # DP 21, Solo Color 1:1, then 2 parts of mixture 1 part DH 60, 30% PR80 or equivalent. 10. Mix and apply 2 coats or until hiding of basecoat per manufacturer's label instructions. Apply first coat to repair area only. Apply second coat over entire area. Allow a minimum of 15 minutes flash time before applying the clearcoat. ^ BASF # Diamont Basecoat Color and Diamont Reducer 1:1 or equivalent. 11. Mix and apply 2 coats of urethane clearcoat per manufacturer's label instructions. ^ BASF product # DC90 Diamond Clear, LH50 Diamond Hardener 2:1 or equivalent. 12. Polish if necessary. 13. Clean and detail the vehicle and return it to the customer. WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Technical Service Bulletin # 9192 Date: 910501 Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8263 This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. 6. Blow off the area with compressed air to remove any dirt and sanding residue. 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. 13. Apply top coat (body color) where necessary. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8264 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Technical Service Bulletin # 9384 Date: 930414 Exterior Clearcoat - Cracking/Eroding/Peeling Off Article No. 93-8-4 April 14, 1993 PAINT - EXTERIOR CLEARCOAT "MICROCHECKING", HAZING OR PEELING FORD: 1983-93 THUNDERBIRD 1984-93 TEMPO 1985-93 ESCORT 1986 LTD 1986-93 TAURUS 1989-93 CROWN VICTORIA, MUSTANG, PROBE LINCOLN-MERCURY: 1983-93 COUGAR 1984-92 MARK VII 1984-93 TOPAZ 1985-89 TRACER 1986 MARQUIS 1986-93 SABLE 1988-93 CONTINENTAL, TOWN CAR 1989-93 GRAND MARQUIS 1991-93 TRACER Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8265 1993 MARK VIII LIGHT TRUCK: 1983-93 RANGER 1986-93 AEROSTAR 1987-90 BRONCO II 1988-93 F SUPER DUTY, F-47 1991-93 ECONOLINE, EXPLORER 1992-93 F-150-350 SERIES 1993 VILLAGER ISSUE: The clearcoat layer of the basecoat/clearcoat paint system may "microcheck" (crack and erode), turn white, flake or peel off the vehicle. This condition is noticeable on the horizontal surfaces only. ACTION: Inspect the vehicle and if repair is necessary, refer to the following procedure for service details. This is a wet on wet procedure. Sanding is not required after the seal coat is applied. NOTE: READ THE ENTIRE SERVICE REPAIR PROCEDURE BEFORE STARTING REPAIRS. REPAIR PROCEDURE WARNING: ALWAYS WEAR A NIOSH/OSHA RECOMMENDED VAPOR/PARTICULATE RESPIRATOR AND USE OTHER RECOMMENDED SAFETY EQUIPMENT. 1. Wash the vehicle with soap and water. 2. Verify clearcoat to basecoat or primer adhesion by applying a 2" wide masking tape strip on all horizontal body panels. a. Pull the tape up quickly b. Inspect the adhesive side for paint removal. NOTE: IF PAINT WAS REMOVED DURING TAPE TEST, THE ENTIRE CLEARCOAT AND BASECOAT SHOULD BE REMOVED FROM THE PANEL. 3. Wipe down the areas to be repainted with wax and grease remover. ^ BASF product # 900 PreKleano or equivalent 4. Sand the affected surface with 150/240 grit sand paper. Remove only clearcoat and colorcoat, featheredge areas with 320 grit paper. NOTE: DO NOT REMOVE SPRAY PRIMER OR E-COAT. 5. Blow off the area to remove loose dust or debris. 6. Wipe the sanded surface with wax or grease remover. ^ BASF product # 901 Prekleano or equivalent 7. Tack off area. 8. Mix and apply one coat of epoxy primer for adhesion and let dry per manufacturer's label instruction (20 - 30 minutes). ^ BASF product # DE 15, PA16, PR80 or equivalent NOTE: DO NOT SAND THE NEWLY PRIMED AREAS. 9. Mix and apply two coats of the appropriate colored primer surface sealer. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8266 ^ BASF product # DP 21, Solo Color 1:1, then 2 parts of mixture 1 part DH 60, 30% PR80 or equivalent. 10. Mix and apply 2 coats or until hiding of basecoat per manufacturer's label instructions. Apply first coat to repair area only. Apply second coat over entire area. Allow a minimum of 15 minutes flash time before applying the clearcoat. ^ BASF # Diamont Basecoat Color and Diamont Reducer 1:1 or equivalent. 11. Mix and apply 2 coats of urethane clearcoat per manufacturer's label instructions. ^ BASF product # DC90 Diamond Clear, LH50 Diamond Hardener 2:1 or equivalent. 12. Polish if necessary. 13. Clean and detail the vehicle and return it to the customer. WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000 Technical Service Bulletin # 9192 Date: 910501 Paint - Paint Blistering or Peeling Off Bumper Covers Article No. 91-9-2 05/01/91 PAINT - BLISTERING OR PEELING OFF BUMPER COVERS - REPAIR TIPS FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR This TSB article is being republished in its entirety to provide a list of alternate suppliers and required materials. ISSUE: A service repair procedure has been developed to ensure good paint adhesion to the bumper covers. ACTION: If service is required, use the following procedure to ensure good paint adhesion to the bumper covers. NOTE: IF COMPLETE REPAINT OF THE COVER IS REQUIRED BECAUSE OF MULTIPLE BLISTERS OR PEELED AREAS, STRIP THE COVER BY SANDING. 1. Wash the bumper cover with water and a mild detergent. Rinse and let it dry. 2. Wipe the area to be repaired with a wax/grease remover. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8267 Figure 1 3. Sand the unpainted area with 400 grit paper and feather about one inch into the painted area, Figure 1. Sand the entire fascia, not just the peeled area. NOTE: DO NOT USE EXCESSIVE FORCE, JUST ENOUGH TO ROUGHEN THE SURFACE. 4. Finish sanding the area with 600 grit paper. 5. Check the feathered edge of paint for good adhesion. a. Carefully slide the edge of your fingernail from the unpainted area to the painted area. b. If the paint lifts, go back and start again with Step # 3. 6. Blow off the area with compressed air to remove any dirt and sanding residue. 7. Tack wipe to remove any contamination. 8. Wipe the area with a suitable anti-static wash solution. 9. Wipe the area with a wax and grease remover using a lint-free cloth. 10. Tack wipe to remove any remaining contamination. 11. Apply a clear sealer to the unpainted area. 12. Apply primer/filler to the unpainted area and feather into the existing paint. 13. Apply top coat (body color) where necessary. 14. Paint the black rubstrip strip with black primer only. The various paint materials, cleaner, sealers and primer-fillers listed above may be purchased locally from suppliers such as AKZO-Sikkens, BASF Corporation, PPG, Dupont and Sherwin Williams. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Paint, Striping and Decals > Paint > System Information > Technical Service Bulletins > All Other Service Bulletins for Paint: > Page 8268 Figure 2 A list of suppliers and materials required (alternates) is shown in Figure 2. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-3, 04/17/91 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 106000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module > Component Information > Locations Keyless Entry Module: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8277 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8278 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8279 Power Door Lock Relay: Electrical Diagrams Power Door Locks (Except Keyless Entry) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8280 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8281 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8282 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8283 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions Trunk / Liftgate Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8288 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8289 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Trunk / Liftgate Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 8290 Luggage Compartment Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Customer Interest for Sunroof / Moonroof Motor: > 93231 > Nov > 93 > Moon Roof - Wind Noise When Fully Open Sunroof / Moonroof Motor: Customer Interest Moon Roof - Wind Noise When Fully Open Article No. 93-23-1 11/10/93 ^ MOON ROOF - POWER - WINDNOISE/BUFFETING WHEN FULLY OPEN THUNDERBIRD/COUGAR BUILT FROM JOB 1 THROUGH 12/31/93 AND 1993 MARK VIII ^ WINDNOISE/BUFFETING FROM POWER MOON ROOF WHEN FULLY OPEN THUNDERBIRD/COUGAR BUILT FROM JOB-1 THROUGH 12/31/93 AND 1993 MARK VIII ^ POWER MOON ROOF - WINDNOISE/BUFFETING WHEN FULLY OPEN THUNDERBIRD/COUGAR BUILT FROM JOB-1 THROUGH 12/31/93 AND 1993 MARK VIII FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR 1993 MARK VIII This TSB article is being republished in its entirety to update the model year application and to revise the part number specified. ISSUE: The factory-installed power moon roof may exhibit "windnoise/buffeting" at speeds between 35 and 45 MPH (56 and 72 KM/H) when fully open. This occurs because the wind is unable to clear the opening without coming into the passenger compartment. ACTION: Take one of the following actions to resolve the concern. 1. Advise the customer to close the panel from the full open to about 2/3 open when traveling at speeds between 35 and 45 MPH (56 and 72 KM/H). This causes the wind to clear the smaller opening without coming into the passenger compartment. 2. If Step 1 is not acceptable, change the power moon roof motor to the 1994 design level (F4LY-15790-A). This part has an automatic stop at the desired low speed position as well as the full open position. Refer to the 1993 Thunderbird/Cougar or Mark VIII Service Manual, Section 01-17, for service details. PART NUMBER PART NAME CLASS F4LY-15790-A Power Moon Roof Motor A OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-20-1 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 932301A Remove and Replace Moon 0.7 Hr. Roof Motor - T'Bird/Cougar 932301B Remove and Replace Moon 0.6 Hr. Roof Motor - Mark VIII DEALER CODING BASIC PART NO. CONDITION CODE 15790 08 OASIS CODES: 105000, 205000, 701000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Sunroof / Moonroof Motor: > 93231 > Nov > 93 > Moon Roof - Wind Noise When Fully Open Sunroof / Moonroof Motor: All Technical Service Bulletins Moon Roof - Wind Noise When Fully Open Article No. 93-23-1 11/10/93 ^ MOON ROOF - POWER - WINDNOISE/BUFFETING WHEN FULLY OPEN THUNDERBIRD/COUGAR BUILT FROM JOB 1 THROUGH 12/31/93 AND 1993 MARK VIII ^ WINDNOISE/BUFFETING FROM POWER MOON ROOF WHEN FULLY OPEN THUNDERBIRD/COUGAR BUILT FROM JOB-1 THROUGH 12/31/93 AND 1993 MARK VIII ^ POWER MOON ROOF - WINDNOISE/BUFFETING WHEN FULLY OPEN THUNDERBIRD/COUGAR BUILT FROM JOB-1 THROUGH 12/31/93 AND 1993 MARK VIII FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR 1993 MARK VIII This TSB article is being republished in its entirety to update the model year application and to revise the part number specified. ISSUE: The factory-installed power moon roof may exhibit "windnoise/buffeting" at speeds between 35 and 45 MPH (56 and 72 KM/H) when fully open. This occurs because the wind is unable to clear the opening without coming into the passenger compartment. ACTION: Take one of the following actions to resolve the concern. 1. Advise the customer to close the panel from the full open to about 2/3 open when traveling at speeds between 35 and 45 MPH (56 and 72 KM/H). This causes the wind to clear the smaller opening without coming into the passenger compartment. 2. If Step 1 is not acceptable, change the power moon roof motor to the 1994 design level (F4LY-15790-A). This part has an automatic stop at the desired low speed position as well as the full open position. Refer to the 1993 Thunderbird/Cougar or Mark VIII Service Manual, Section 01-17, for service details. PART NUMBER PART NAME CLASS F4LY-15790-A Power Moon Roof Motor A OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 93-20-1 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 932301A Remove and Replace Moon 0.7 Hr. Roof Motor - T'Bird/Cougar 932301B Remove and Replace Moon 0.6 Hr. Roof Motor - Mark VIII DEALER CODING BASIC PART NO. CONDITION CODE 15790 08 OASIS CODES: 105000, 205000, 701000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Roof and Associated Components > Sunroof / Moonroof > Sunroof / Moonroof Motor > Component Information > Technical Service Bulletins > Page 8306 Sunroof / Moonroof Motor: Locations Center Of Roof, Behind Moonroof Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Locations Power Seat Motor: Locations Under Respective Seat Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips Seat Cover: Technical Service Bulletins Seat Leather - Cleaning Procedure Tips Article No. 98-17-1 09/01/98 SEAT - LEATHER CLEANING PROCEDURE - SERVICE TIP FORD: 1984-94 TEMPO 1984-97 THUNDERBIRD 1984-98 CROWN VICTORIA, ESCORT, MUSTANG 1986-98 TAURUS 1989-97 PROBE 1994-97 ASPIRE 1995-98 CONTOUR LINCOLN-MERCURY: 1984-94 TOPAZ 1984-97 COUGAR 1984-98 GRAND MARQUIS, TRACER 1984-99 TOWN CAR 1986-98 SABLE 1993-98 MARK VIII 1995-98 MYSTIQUE 1995-99 CONTINENTAL 1999 COUGAR LIGHT TRUCK: 1983-98 RANGER 1984-96 BRONCO 1984-97 F-250 HD 1984-98 ECONOLINE, F-150, F-250 LD 1986-97 AEROSTAR 1991-98 EXPLORER 1993-98 VILLAGER 1996-98 WINDSTAR 1997-98 EXPEDITION, MOUNTAINEER 1998 NAVIGATOR 1999 SUPER DUTY F SERIES This TSB article is being republished in its entirety to include the latest level parts and to include a revised Service Procedure. ISSUE The following TSB contains information regarding the cleaning of interior leather seats and trim. Improper cleaning procedures may damage the leather. If seats are not cleaned on a regular basis (every 4-6 weeks), normal wear and tear can cause excessive soiling. ACTION Ford Motor Company has developed a new kit (Deluxe Leather Care Kit - F8AZ-19G253-AA) to clean soiled seats without damaging the top coat of the leather. The kit contains a leather and vinyl cleaner along with a specially formulated sponge. Refer to the text for cleaning leather seats and trim. The Deluxe Leather Care Kit has been tested and approved for use on all Ford and Lincoln/Mercury leather and vinyl seating surfaces, and if used as directed, should be used for service repairs. Many household cleaners and sponges are too harsh to be used on leather and may actually cause permanent damage to the surface. Use this material on leather and vinyl seats that: ^ show excessive soiling ^ have been stained with coffee, lipstick, etc. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Cover > Component Information > Technical Service Bulletins > Seat Leather - Cleaning Procedure Tips > Page 8315 Refer to the instructions included in the kit for specific application procedures. After cleaning surface with cleaner and sponge, wipe area with water and a cotton cloth. NOTE AVOID EXCESSIVE APPLICATION OF CLEANER ALONG STITCHING. PART NUMBER PART NAME F8AZ-19G253-AA Deluxe Leather Care Kit OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-14-2 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 101000, 107000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 94201 > Oct > 94 > Front Seat Track Covers - Come Off When Moved Rearward Seat Track: Customer Interest Front Seat Track Covers - Come Off When Moved Rearward Article No. 94-20-1 10/05/94 ^ SEAT - FRONT - TRACK COVERS COME OFF WHEN SEAT IS ADJUSTED REARWARD ^ TRACKS - FRONT SEAT TRACK COVERS COME OFF WHEN SEAT IS MOVED REARWARD FORD: 1989-94 THUNDERBIRD 1992-94 CROWN VICTORIA LINCOLN-MERCURY: 1989-94 COUGAR 1992-94 GRAND MARQUIS 1993-94 MARK VIII ISSUE: The front seat track insulators or covers may come off when the seat is moved into the rearward position. This may be caused by contact between the seat track and the seat track insulator or between the seat track cover and the carpeting. ACTION: On Grand Marquis and Crown Victoria, replace the seat track insulator with a revised insulator which has an improved design to avoid contact with the seat track. On Thunderbird, Cougar and Mark VIII, reinstall the seat track cover and provide an improved attachment for the cover. Refer to the following appropriate Service Procedures for specific details. SERVICE PROCEDURES GRAND MARQUIS AND CROWN VICTORIA 1. Verify the concern. 2. Remove and discard the old inboard rear track insulators. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 94201 > Oct > 94 > Front Seat Track Covers - Come Off When Moved Rearward > Page 8324 3. Install the new design inboard rear track insulators. Refer to the Application Chart for the correct part numbers. THUNDERBIRD, COUGAR, MARK VIII 1. Verify the concern and inspect the seat track covers for damage. a. If cover requires replacement, install a new seat track cover. Refer to the Application Chart for the appropriate service part. b. If the seat track covers are not damaged, proceed to Step 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 94201 > Oct > 94 > Front Seat Track Covers - Come Off When Moved Rearward > Page 8325 2. Drill two (2) 1 mm (0.40") holes in the rear portion of the outer seat track covers as shown in Figure 1. 3. Position the seat track covers on the track assembly. Refer to Figure 2. 4. Cut a 6" (152 mm) length of fine steel wire. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 94201 > Oct > 94 > Front Seat Track Covers - Come Off When Moved Rearward > Page 8326 5. Feed the wire through the new holes in the seat track cover as shown in Figure 3 and twist the wire ends until the cover is fully secured to the seat track assembly. 6. Trim the excess wire leaving 1/2" (12.7 mm) of twisted wire. Refer to Figure 4. 7. Bend the remaining 1/2" (12.7 mm) of twisted wire upward, positioning it behind the shield and flush to the rivet as shown in Figure 4. This keeps the wire from interfering with the operation of the seat track assembly and avoids possible customer contact. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 94201 > Oct > 94 > Front Seat Track Covers - Come Off When Moved Rearward > Page 8327 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991 Lincolns And All 1992-94 Models, Basic Warranty Coverage For 1989-91 Except 1991 Lincolns OPERATION DESCRIPTION TIME 942001AT Modify Both Seat Track 0.5 Hr. Covers - Thunderbird/Cougar/Mark VIII 942001A Modify One Seat Track 0.3 Hr. Cover - Thunderbird/Cougar/Mark VIII 942001BT Modify Both Seat Track 0.4 Hr. Covers - Crown Victoria/Grand Marquis 942001B Modify One Seat Track 0.3 Hr. Cover - Crown Victoria/Grand Marquis DEALER CODING BASIC PART NO. CONDITION CODE 7061748, 7061749 58 OASIS CODES: 101000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 9223 > Jan > 92 > Power Seat - Operation Slow/Stalled/Inoperative Seat Track: Customer Interest Power Seat - Operation Slow/Stalled/Inoperative Article No. 92-2-3 01/16/92 POWER SEAT - TRACK - SLOW, STALLED AND/OR INOPERATIVE SEAT OPERATION FORD: 1989-90 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR ISSUE: The power seat operation may be slow, stalled and/or inoperative. This occurs because the power seat tracks need to be cleaned and lubed. ACTION: Clean and lube the power seat tracks by using the following service procedure. 1. Wipe the track slides with solvent (naphtha or kerosene) and dry with a clean rag. 2. Move the seat to a full forward position. a. Wipe with solvent. b. Apply multi-purpose grease to the exposed rear area of the track slides. 3. Move the seat to a full rearward position. a. Wipe with solvent. b. Apply multi-purpose grease (aerosol or tube type) to the exposed front area of the track slides. PART NUMBER PART NAME CLASS D7AZ-19584-AA Multi-Purpose Grease (Aerosol B Spray) D0AZ-19584-AA Multi-Purpose Grease (Tube) B OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 920203A Clean And Lube Power 0.3 Hr. Seat Tracks DEALER CODING BASIC PART NO. CONDITION CODE 7061710 41 OASIS CODES: 101000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > Customer Interest for Seat Track: > 90195 > Sep > 90 > Seat Track - Sticking/Slow/Inoperative Seat Track: Customer Interest Seat Track - Sticking/Slow/Inoperative SEAT TRACK - POWER - SLOW OR NO MOVEMENT - LACK OF LUBRICATION Article No. 90-19-5 FORD: 1986-90 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1986-90 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR ISSUE: Inoperative, sticking or slow seat track movement may be caused by lack of lubrication of the tracks. ACTION: Apply Mini-Vent Lubricant on the stationary portion of the seat track slides. Refer to the following procedure for service details. 1. Move the seat to the full forward position. Figure 1 2. Apply lubricant on the exposed rear area of the seat track slides, Figure 1. 3. Move the seat to the full rearward position. 4. Apply lubricant on the exposed front area of the seat track slides. NOTE: REFER TO THE APPROPRIATE SHOP MANUAL, SECTION 41-08 IF THE CONCERN HAS NOT BEEN CORRECTED. PART NUMBER PART NAME CLASS D3AZ-19553-A Ford Mini-Vent Lubricant AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901905A Lube Seat Tracks 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7061704 41 OASIS CODES: 101000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 94201 > Oct > 94 > Front Seat Track Covers - Come Off When Moved Rearward Seat Track: All Technical Service Bulletins Front Seat Track Covers - Come Off When Moved Rearward Article No. 94-20-1 10/05/94 ^ SEAT - FRONT - TRACK COVERS COME OFF WHEN SEAT IS ADJUSTED REARWARD ^ TRACKS - FRONT SEAT TRACK COVERS COME OFF WHEN SEAT IS MOVED REARWARD FORD: 1989-94 THUNDERBIRD 1992-94 CROWN VICTORIA LINCOLN-MERCURY: 1989-94 COUGAR 1992-94 GRAND MARQUIS 1993-94 MARK VIII ISSUE: The front seat track insulators or covers may come off when the seat is moved into the rearward position. This may be caused by contact between the seat track and the seat track insulator or between the seat track cover and the carpeting. ACTION: On Grand Marquis and Crown Victoria, replace the seat track insulator with a revised insulator which has an improved design to avoid contact with the seat track. On Thunderbird, Cougar and Mark VIII, reinstall the seat track cover and provide an improved attachment for the cover. Refer to the following appropriate Service Procedures for specific details. SERVICE PROCEDURES GRAND MARQUIS AND CROWN VICTORIA 1. Verify the concern. 2. Remove and discard the old inboard rear track insulators. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 94201 > Oct > 94 > Front Seat Track Covers - Come Off When Moved Rearward > Page 8341 3. Install the new design inboard rear track insulators. Refer to the Application Chart for the correct part numbers. THUNDERBIRD, COUGAR, MARK VIII 1. Verify the concern and inspect the seat track covers for damage. a. If cover requires replacement, install a new seat track cover. Refer to the Application Chart for the appropriate service part. b. If the seat track covers are not damaged, proceed to Step 3. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 94201 > Oct > 94 > Front Seat Track Covers - Come Off When Moved Rearward > Page 8342 2. Drill two (2) 1 mm (0.40") holes in the rear portion of the outer seat track covers as shown in Figure 1. 3. Position the seat track covers on the track assembly. Refer to Figure 2. 4. Cut a 6" (152 mm) length of fine steel wire. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 94201 > Oct > 94 > Front Seat Track Covers - Come Off When Moved Rearward > Page 8343 5. Feed the wire through the new holes in the seat track cover as shown in Figure 3 and twist the wire ends until the cover is fully secured to the seat track assembly. 6. Trim the excess wire leaving 1/2" (12.7 mm) of twisted wire. Refer to Figure 4. 7. Bend the remaining 1/2" (12.7 mm) of twisted wire upward, positioning it behind the shield and flush to the rivet as shown in Figure 4. This keeps the wire from interfering with the operation of the seat track assembly and avoids possible customer contact. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 94201 > Oct > 94 > Front Seat Track Covers - Come Off When Moved Rearward > Page 8344 Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1991 Lincolns And All 1992-94 Models, Basic Warranty Coverage For 1989-91 Except 1991 Lincolns OPERATION DESCRIPTION TIME 942001AT Modify Both Seat Track 0.5 Hr. Covers - Thunderbird/Cougar/Mark VIII 942001A Modify One Seat Track 0.3 Hr. Cover - Thunderbird/Cougar/Mark VIII 942001BT Modify Both Seat Track 0.4 Hr. Covers - Crown Victoria/Grand Marquis 942001B Modify One Seat Track 0.3 Hr. Cover - Crown Victoria/Grand Marquis DEALER CODING BASIC PART NO. CONDITION CODE 7061748, 7061749 58 OASIS CODES: 101000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 9223 > Jan > 92 > Power Seat - Operation Slow/Stalled/Inoperative Seat Track: All Technical Service Bulletins Power Seat - Operation Slow/Stalled/Inoperative Article No. 92-2-3 01/16/92 POWER SEAT - TRACK - SLOW, STALLED AND/OR INOPERATIVE SEAT OPERATION FORD: 1989-90 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR ISSUE: The power seat operation may be slow, stalled and/or inoperative. This occurs because the power seat tracks need to be cleaned and lubed. ACTION: Clean and lube the power seat tracks by using the following service procedure. 1. Wipe the track slides with solvent (naphtha or kerosene) and dry with a clean rag. 2. Move the seat to a full forward position. a. Wipe with solvent. b. Apply multi-purpose grease to the exposed rear area of the track slides. 3. Move the seat to a full rearward position. a. Wipe with solvent. b. Apply multi-purpose grease (aerosol or tube type) to the exposed front area of the track slides. PART NUMBER PART NAME CLASS D7AZ-19584-AA Multi-Purpose Grease (Aerosol B Spray) D0AZ-19584-AA Multi-Purpose Grease (Tube) B OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 920203A Clean And Lube Power 0.3 Hr. Seat Tracks DEALER CODING BASIC PART NO. CONDITION CODE 7061710 41 OASIS CODES: 101000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Seat Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Seat Track: > 90195 > Sep > 90 > Seat Track - Sticking/Slow/Inoperative Seat Track: All Technical Service Bulletins Seat Track - Sticking/Slow/Inoperative SEAT TRACK - POWER - SLOW OR NO MOVEMENT - LACK OF LUBRICATION Article No. 90-19-5 FORD: 1986-90 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1986-90 CONTINENTAL, COUGAR, GRAND MARQUIS, SABLE, TOWN CAR ISSUE: Inoperative, sticking or slow seat track movement may be caused by lack of lubrication of the tracks. ACTION: Apply Mini-Vent Lubricant on the stationary portion of the seat track slides. Refer to the following procedure for service details. 1. Move the seat to the full forward position. Figure 1 2. Apply lubricant on the exposed rear area of the seat track slides, Figure 1. 3. Move the seat to the full rearward position. 4. Apply lubricant on the exposed front area of the seat track slides. NOTE: REFER TO THE APPROPRIATE SHOP MANUAL, SECTION 41-08 IF THE CONCERN HAS NOT BEEN CORRECTED. PART NUMBER PART NAME CLASS D3AZ-19553-A Ford Mini-Vent Lubricant AM OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901905A Lube Seat Tracks 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7061704 41 OASIS CODES: 101000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Seats > Vacuum/Pressure Pump, Seats > Component Information > Locations Vacuum/Pressure Pump: Locations Under Respective Seat Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Fuel Door Switch > Component Information > Locations Fuel Door Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 8365 OASIS CODES: 201000, 201200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions Power Door Lock Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8370 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8371 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8372 Power Door Lock Switch: Electrical Diagrams Power Door Locks (Except Keyless Entry) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8373 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8374 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8375 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8376 Keyless Entry Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Locations Power Mirror Switch: Locations Body & Chassis Components Lower Rear Of LH Door Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions Power Mirror Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8382 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8383 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8384 Power Mirrors Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Locations Power Trunk / Liftgate Lock Switch: Locations In Center Rear Of Trunk Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions Power Trunk / Liftgate Lock Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8390 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8391 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Trunk / Liftgate Lock Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8392 Luggage Compartment Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Locations Trunk / Liftgate Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions Trunk / Liftgate Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8398 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8399 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Trunk / Liftgate Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 8400 Luggage Compartment Release Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor Cowl: Customer Interest Cowl - Water Leaks On Passenger Side Front Floor Article No. 91-15-1 07/24/91 LEAK - WATER - PASSENGER SIDE FRONT FLOOR FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: Water leaks may occur on the passenger side front floor area. This usually happens during heavy rain, with the car parked nose up or during high blower operation while driving. Water enters the right hand cowl top air vent because of inadequate sealing around the air intake collar. Figure 1 ACTION: Install an extension assembly - cowl vent deflector and a screen assembly - cowl vent right hand side. Refer to the following procedure for service details. 1. Open the hood and remove the right and left hand windshield wiper arms. 2. Remove the engine compartment seal from the front edge of the cowl top leaf screen, Figure 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor > Page 8410 Figure 2 3. Remove ten (10) screws holding the cowl top leaf screens, Figure 2. Carefully position the left hand screen on the windshield out of the way. NOTE: IT IS NOT NECESSARY TO DISCONNECT THE WASHER HOSES ON THE LEFT HAND SIDE. 4. Remove and throw away the right hand screen. 5. Apply black silicone rubber sealer (D6AZ-19562-BA) to the upper cowl body seam behind the A/C air inlet. a. A continuous bead of sealer must be applied to the rear cowl body seam around the right corner and up the right seam to the cowl drain, near the edge of the hood hinge. b. Inspect the seal between the air inlet and cowl surface. Apply sealer as required to assure a water tight seal. Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > Customer Interest for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor > Page 8411 Figure 4 6. Install the extension assembly - cowl vent deflector (F1SZ-63021B26-A) as shown in Figures 3 and 4. a. Snap the extension assembly on top of the existing collar. b. Be sure that the higher vertical wall is facing the front of the car. NOTE: PLACE BOTH HANDS OVER THE ENDS OF THE PART AND EXERT AN EQUAL AMOUNT OF FORCE TO FASTEN THE SNAPS. 7. Install the new screen assembly - cowl vent right hand (F1SZ-63018A16-A) onto the right hand side of the vehicle. 8. Reinstall all removed parts on the car. PART NUMBER PART NAME CLASS F1SZ-63021B26-A Extension Assembly - Cowl BG Vent Deflector F1SZ-83018A16-A Screen Assembly - Cowl Vent B (RH) D6AZ-19562-BA Silicone Rubber - Black B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-23-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911501A Install Deflector And Screen 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7001934 35 OASIS CODES: 110000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor Cowl: All Technical Service Bulletins Cowl - Water Leaks On Passenger Side Front Floor Article No. 91-15-1 07/24/91 LEAK - WATER - PASSENGER SIDE FRONT FLOOR FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: Water leaks may occur on the passenger side front floor area. This usually happens during heavy rain, with the car parked nose up or during high blower operation while driving. Water enters the right hand cowl top air vent because of inadequate sealing around the air intake collar. Figure 1 ACTION: Install an extension assembly - cowl vent deflector and a screen assembly - cowl vent right hand side. Refer to the following procedure for service details. 1. Open the hood and remove the right and left hand windshield wiper arms. 2. Remove the engine compartment seal from the front edge of the cowl top leaf screen, Figure 1. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor > Page 8417 Figure 2 3. Remove ten (10) screws holding the cowl top leaf screens, Figure 2. Carefully position the left hand screen on the windshield out of the way. NOTE: IT IS NOT NECESSARY TO DISCONNECT THE WASHER HOSES ON THE LEFT HAND SIDE. 4. Remove and throw away the right hand screen. 5. Apply black silicone rubber sealer (D6AZ-19562-BA) to the upper cowl body seam behind the A/C air inlet. a. A continuous bead of sealer must be applied to the rear cowl body seam around the right corner and up the right seam to the cowl drain, near the edge of the hood hinge. b. Inspect the seal between the air inlet and cowl surface. Apply sealer as required to assure a water tight seal. Figure 3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cowl: > 91151 > Jul > 91 > Cowl - Water Leaks On Passenger Side Front Floor > Page 8418 Figure 4 6. Install the extension assembly - cowl vent deflector (F1SZ-63021B26-A) as shown in Figures 3 and 4. a. Snap the extension assembly on top of the existing collar. b. Be sure that the higher vertical wall is facing the front of the car. NOTE: PLACE BOTH HANDS OVER THE ENDS OF THE PART AND EXERT AN EQUAL AMOUNT OF FORCE TO FASTEN THE SNAPS. 7. Install the new screen assembly - cowl vent right hand (F1SZ-63018A16-A) onto the right hand side of the vehicle. 8. Reinstall all removed parts on the car. PART NUMBER PART NAME CLASS F1SZ-63021B26-A Extension Assembly - Cowl BG Vent Deflector F1SZ-83018A16-A Screen Assembly - Cowl Vent B (RH) D6AZ-19562-BA Silicone Rubber - Black B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-23-2 WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911501A Install Deflector And Screen 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7001934 35 OASIS CODES: 110000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > Customer Interest for Weatherstrip: > 89114 > Jun > 89 > Door Weatherstrip - Comes Loose Weatherstrip: Customer Interest Door Weatherstrip - Comes Loose ^ TRIM-EXTERIOR-DOOR WEATHERSTRIP COMES LOOSE ^ WEATHERSTRIP-DOOR-POOR RETENTION Article No. 89-11-4 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Door weatherstrips may come loose from the body door opening flange during high ambient temperatures. This may be caused by poor retention of the weatherstrip carrier to the body door opening mounting flange. ACTION: Install new push-on retainer clips on the body opening flange. Refer to the following procedure for service details. 1. Remove the door weatherstrip from the "A" pillar, door header and "B" pillar body opening flange. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 44-06 for service details. 2. Insert eight (8) push-on retainer clips per side on the body opening flange about six inches apart along the "A" pillar door header and "B" pillar as shown in Figure 1. NOTE: THE CLIPS ARE PACKAGED IN QUANITIES OF EIGHT (8). TWO (2) PACKAGES ARE REQUIRED FOR EACH VEHICLE. 3. Re-install the door weatherstrip over the retaining clips. PART NUMBER PART NAME CLASS N806369-S Clip-Pkg. of 8 S OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891104A Install Weatherstrip 0.4 Hrs. Retaining Clips DEALER CODING BASIC PART NO. CONDITION CODE 7020708 33 OASIS CODES: 1052 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Weatherstrip: > 89114 > Jun > 89 > Door Weatherstrip - Comes Loose Weatherstrip: All Technical Service Bulletins Door Weatherstrip - Comes Loose ^ TRIM-EXTERIOR-DOOR WEATHERSTRIP COMES LOOSE ^ WEATHERSTRIP-DOOR-POOR RETENTION Article No. 89-11-4 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Door weatherstrips may come loose from the body door opening flange during high ambient temperatures. This may be caused by poor retention of the weatherstrip carrier to the body door opening mounting flange. ACTION: Install new push-on retainer clips on the body opening flange. Refer to the following procedure for service details. 1. Remove the door weatherstrip from the "A" pillar, door header and "B" pillar body opening flange. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 44-06 for service details. 2. Insert eight (8) push-on retainer clips per side on the body opening flange about six inches apart along the "A" pillar door header and "B" pillar as shown in Figure 1. NOTE: THE CLIPS ARE PACKAGED IN QUANITIES OF EIGHT (8). TWO (2) PACKAGES ARE REQUIRED FOR EACH VEHICLE. 3. Re-install the door weatherstrip over the retaining clips. PART NUMBER PART NAME CLASS N806369-S Clip-Pkg. of 8 S OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891104A Install Weatherstrip 0.4 Hrs. Retaining Clips DEALER CODING BASIC PART NO. CONDITION CODE 7020708 33 OASIS CODES: 1052 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Service and Repair Clutch Switch: Service and Repair Removal 1. Remove screw attaching switch to bracket. 2. Disconnect electrical connector. 3. Remove switch assembly. Installation 1. Install switch on bracket. 2. Connect electrical connector. 3. Install attaching switch to bracket. 4. Adjust clutch switch as described under ADJUSTMENT PROCEDURES. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Brush Assembly > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Brush Assembly: > 8934 > Feb > 89 > Speed Control - Abnormal Operation When Hot Cruise Control Brush Assembly: Customer Interest Speed Control - Abnormal Operation When Hot Article No. 89-3-4 SPEED CONTROL - COAST AND ACCELERATION MODES - ABNORMAL OPERATION IN HIGH AMBIENT TEMPERATURES FORD: 1986-89 ALL LINCOLN-MERCURY: 1986-89 ALL LIGHT TRUCK: 1986-89 ALL ISSUE: Abnormal speed control operation in the coast and acceleration modes may be caused by loss of electrical contact between the steering wheel slip rings and brush assembly. This condition usually occurs in high ambient temperatures when the steering wheel slip rings and brush assembly are warm. ACTION: Improve the electrical continuity of the steering wheel slip rings and brush assembly by applying a new service released grease on the contact area. Refer to the following procedure for service details. 1. Remove the steering wheel, Refer to the appropriate Car or Light Truck Shop Manual for service details. 2. Clean the old grease from the steering wheel slip rings and brush assembly contact areas. 3. Apply the new service released grease, (E8AZ-19590-A), on the steering wheel slip rings and brush assembly contact surfaces. This new grease can be identified by its bright orange/red color. 4. Reinstall steering wheel. PART NUMBER PART NAME CLASS E8AZ-19590-A Grease B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 890304A TIME: 0.4 Hr. DLR. CODING: Basic Part No. 9C899 Condition Code: 53 OASIS CODES: 2900 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Brush Assembly > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Brush Assembly: > 8934 > Feb > 89 > Speed Control Abnormal Operation When Hot Cruise Control Brush Assembly: All Technical Service Bulletins Speed Control - Abnormal Operation When Hot Article No. 89-3-4 SPEED CONTROL - COAST AND ACCELERATION MODES - ABNORMAL OPERATION IN HIGH AMBIENT TEMPERATURES FORD: 1986-89 ALL LINCOLN-MERCURY: 1986-89 ALL LIGHT TRUCK: 1986-89 ALL ISSUE: Abnormal speed control operation in the coast and acceleration modes may be caused by loss of electrical contact between the steering wheel slip rings and brush assembly. This condition usually occurs in high ambient temperatures when the steering wheel slip rings and brush assembly are warm. ACTION: Improve the electrical continuity of the steering wheel slip rings and brush assembly by applying a new service released grease on the contact area. Refer to the following procedure for service details. 1. Remove the steering wheel, Refer to the appropriate Car or Light Truck Shop Manual for service details. 2. Clean the old grease from the steering wheel slip rings and brush assembly contact areas. 3. Apply the new service released grease, (E8AZ-19590-A), on the steering wheel slip rings and brush assembly contact surfaces. This new grease can be identified by its bright orange/red color. 4. Reinstall steering wheel. PART NUMBER PART NAME CLASS E8AZ-19590-A Grease B OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION: 890304A TIME: 0.4 Hr. DLR. CODING: Basic Part No. 9C899 Condition Code: 53 OASIS CODES: 2900 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Brush Assembly > Component Information > Service and Repair > Ground Brush Cruise Control Brush Assembly: Service and Repair Ground Brush Fig. 31 Ground Brush Replacement. Continental, Sable & Taurus 1. Pull upward on upper middle edge of the horn cover/pad assembly and separate it from the steering wheel. 2. Disconnect horn switch electrical connectors from horn cover/pad assembly, then set the assembly aside. 3. Disconnect electrical connector from the speed control/horn brush contact plate terminal. 4. Remove and discard steering wheel attaching nut. 5. Using a puller, remove steering wheel from shaft. To prevent damage never hit steering wheel attaching bolt or use a knock-off type steering wheel puller. 6. Remove tilt lever, if equipped. 7. Remove steering column lower trim shroud. 8. Separate speed control brush wire harness at connector and remove wire retainers from steering column, Fig. 31. 9. Remove brush assembly retaining screw, then the brush assembly. 10. Reverse procedure to install noting the following: a. Torque new steering wheel attaching nut to 23-33 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Brush Assembly > Component Information > Service and Repair > Ground Brush > Page 8451 Cruise Control Brush Assembly: Service and Repair Speed Control/Horn Brush Contact Plate 1. Pull upward on upper middle edge of the horn cover/pad assembly and separate it from the steering wheel. 2. Disconnect horn switch electrical connectors from horn cover/pad assembly, then set the assembly aside. 3. Disconnect electrical connector from the speed control/horn brush contact plate terminal. 4. Remove and discard steering wheel attaching nut. 5. Using a puller, remove steering wheel from shaft. To prevent damage never hit steering wheel attaching bolt or use a knock-off type steering wheel puller. 6. Working from back side of steering wheel, remove three retaining screws, then the speed control/horn brush contact plate. 7. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Servo: > 901210 > Jun > 90 > Speed Control - Clicking/Buzzing Noise Cruise Control Servo: Customer Interest Speed Control - Clicking/Buzzing Noise ^ SPEED CONTROL - "CLICKING" OR "BUZZING" NOISE ^ NOISE - "CLICKING" OR "BUZZING" FROM SPEED CONTROL Article No. 90-12-10 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A "clicking" or "buzzing" noise may come from the speed control system. It starts from the servo solenoids when the SET/ACCEL button is first engaged. The noise may be transmitted from the servo bracket through the body sheet metal. ACTION: Install a rubber noise isolation pad between the servo and the servo bracket. Refer to the following service procedure. 1. Remove the servo and bracket assembly. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 37-05 for service details. 2. Remove the bracket from the servo. 3. Using a 5/8" (15.875 mm) drill, enlarge the two existing bracket holes which are used to attach the servo to the bracket, Figure 1. 4. Install a rubber isolation pad (E3ZZ-9F770-A) between the servo and bracket. Figure 1 5. Install two (2) eyelets (E3ZZ-9F769-A) on the isolation pad from the side opposite the servo, Figure 1. 6. Attach the bracket/isolator assembly to the servo. NOTE: IF THE VEHICLE WAS BUILT WITH SERVO (PART NO. STAMPED ON PART, E9SF-9C735-AA/AB/AC - BLACK COLORED BACKPLATE), REPLACE IT WITH SERVO (FOSZ-9C735-A) WHICH HAS A GOLD COLORED BACKPLATE. IF THE VEHICLE IS EQUIPPED WITH SERVO (FOSF-9C735-AA STAMPED ON PART), REUSE THE SERVO. 7. Reinstall servo. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 37-05 for service details. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Customer Interest for Cruise Control Servo: > 901210 > Jun > 90 > Speed Control - Clicking/Buzzing Noise > Page 8460 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901210A Install Isolation Pads 1.0 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 9C735 56 OASIS CODES: 2900, 7100, 7113 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo: > 901210 > Jun > 90 > Speed Control - Clicking/Buzzing Noise Cruise Control Servo: All Technical Service Bulletins Speed Control - Clicking/Buzzing Noise ^ SPEED CONTROL - "CLICKING" OR "BUZZING" NOISE ^ NOISE - "CLICKING" OR "BUZZING" FROM SPEED CONTROL Article No. 90-12-10 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A "clicking" or "buzzing" noise may come from the speed control system. It starts from the servo solenoids when the SET/ACCEL button is first engaged. The noise may be transmitted from the servo bracket through the body sheet metal. ACTION: Install a rubber noise isolation pad between the servo and the servo bracket. Refer to the following service procedure. 1. Remove the servo and bracket assembly. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 37-05 for service details. 2. Remove the bracket from the servo. 3. Using a 5/8" (15.875 mm) drill, enlarge the two existing bracket holes which are used to attach the servo to the bracket, Figure 1. 4. Install a rubber isolation pad (E3ZZ-9F770-A) between the servo and bracket. Figure 1 5. Install two (2) eyelets (E3ZZ-9F769-A) on the isolation pad from the side opposite the servo, Figure 1. 6. Attach the bracket/isolator assembly to the servo. NOTE: IF THE VEHICLE WAS BUILT WITH SERVO (PART NO. STAMPED ON PART, E9SF-9C735-AA/AB/AC - BLACK COLORED BACKPLATE), REPLACE IT WITH SERVO (FOSZ-9C735-A) WHICH HAS A GOLD COLORED BACKPLATE. IF THE VEHICLE IS EQUIPPED WITH SERVO (FOSF-9C735-AA STAMPED ON PART), REUSE THE SERVO. 7. Reinstall servo. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 37-05 for service details. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Cruise Control Servo: > 901210 > Jun > 90 > Speed Control - Clicking/Buzzing Noise > Page 8466 OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 901210A Install Isolation Pads 1.0 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 9C735 56 OASIS CODES: 2900, 7100, 7113 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 8467 Cruise Control Servo: Locations Engine Compartment Component Locations LH Front Of Engine Compartment, Behind Fender Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 8468 Cruise Control Servo: Service and Repair Fig. 22 Servo Assembly Replacement. Mark VII Fig. 23 Servo Assembly Replacement. Cougar & Thunderbird 1. Remove air cleaner assembly, and position to front of vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Technical Service Bulletins > Page 8469 2. Separate speed control actuator cable from the accelerator cable. 3. On Mark VII models, disconnect servo electrical connector, Fig. 22. 4. On Cougar and Thunderbird models, disconnect servo electrical connector located near radiator support, Fig. 23. 5. On all models, apply parking brake. 6. Raise and support lefthand front of vehicle. 7. Remove left front wheel assembly. 8. Remove inner fender splash shield. 9. Remove two servo assembly vacuum hoses from servo. 10. On Mark VII models, remove two servo mounting bracket to A-pillar attaching screws. 11. On Cougar and Thunderbird models, remove two servo mounting bracket-to-shotgun brace attaching screws. 12. On all models, remove two actuator cable cover-to-servo retaining nuts, then the cover, cable, and rubber boot. 13. Remove two servo-to-mounting bracket retaining nuts. 14. Remove two bolts from front of servo. 15. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments Cruise Control Servo Cable: Adjustments Fig. 14 Actuator Cable 1. Remove speed control actuator cable retaining clip, Fig. 14. 2. Push actuator cable through adjuster until slight tension is felt. 3. Insert cable retaining clip and snap into place. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Adjustments > Page 8473 Cruise Control Servo Cable: Service and Repair To replace actuator assembly, remove servo assembly, attach new actuator cable assembly to servo, and install complete assembly. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision Technical Service Bulletin # 9025B6 Date: 901221 Horn/Speed Control Switch Assembly - Revision ^ CAR WIRING DIAGRAMS - HORN/SPEED CONTROL SWITCH ASSEMBLY SCHEMATICS REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - HORN/SPEED CONTROL SWITCH ASSEMBLY SCHEMATICS REVISED ^ SHOP MANUAL - SECTION 37-05 - HORN/SPEED CONTROL SWITCH ASSEMBLY SCHEMATICS REVISED Article No. 90-25B-6 FORD: 1986-90 TAURUS 1988-90 CROWN VICTORIA 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1986-90 SABLE 1988-90 CONTINENTAL, GRAND MARQUIS, MARK VII, TOWN CAR 1989-90 COUGAR ISSUE: The Horn/Speed Control Switch Assembly schematics shown in the publications listed below are incorrect. Speed switch wiring and circuit numbers have also been updated. ^ 1986 - 1990 Taurus/Sable Shop Manuals ^ 1986 -1989 Taurus/Sable EVTMs ^ 1988 -1990 Mark VII Shop Manuals ^ 1988 - 1989 Mark VII EVTMs ^ 1988 -1990 Continental Shop Manuals ^ 1988 -1989 Continental EVTMs ^ 1988 -1990 Lincoln Town Car/Crown Victoria/Grand Marquis Shop Manuals ^ 1988 - 1990 Lincoln Town Car EVTMs ^ 1988 - 1989 Crown Victoria/Grand Marquis EVTMs ^ 1989 - 1990 Thunderbird/Cougar Shop Manuals ACTION: Refer to the pages following this TSB article for the revised schematics and correct circuit numbers/color codes. OTHER APPLICABLE ARTICLES: 90-18B-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8478 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8479 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8480 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8481 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8482 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8483 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8484 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8485 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8486 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8487 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8488 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8489 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8490 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8491 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8492 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8493 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8494 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8495 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8496 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8497 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8498 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8499 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8501 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8502 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8503 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8504 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8505 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8506 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8507 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8508 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8509 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8510 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 8511 Cruise Control Switch: Service and Repair 1. Pull upward on upper middle edge of the horn cover/pad assembly and separate it from the steering wheel. 2. Disconnect horn switch electrical connectors from horn cover/pad assembly, then set the assembly aside. 3. Disconnect electrical connector from the speed control/horn brush contact plate terminal. 4. On models with standard steering wheel, use your fingers to pry out the speed control switch. Remove switch and harness assembly from steering wheel. 5. On models with sport steering wheel, remove four speed control switch retaining screws. Remove switch and harness assembly from steering wheel. 6. On all models, reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Vacuum Vent Solenoid > Component Information > Locations Cruise Control Vacuum Vent Solenoid: Locations On Top Of Brake Pedal Support Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Vacuum Vent Solenoid > Component Information > Locations > Page 8515 Cruise Control Vacuum Vent Solenoid: Adjustments Fig. 16 Vacuum Dump Valve The vacuum dump valve, Fig. 16, is adjusted in its mounting bracket. It should be adjusted closed (no vacuum leak) when the brake pedal is released, and open when the pedal is depressed. Use a hand vacuum pump to make this adjustment. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Cruise Control Vacuum Vent Solenoid > Component Information > Locations > Page 8516 Cruise Control Vacuum Vent Solenoid: Service and Repair Removal 1. Remove vacuum hose from valve. 2. Remove valve from bracket. Installation 1. Install valve to bracket. 2. Connect vacuum hose. 3. Adjust valve as described under ADJUSTMENT PROCEDURES. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control > Component Information > Service and Repair Clutch Switch: Service and Repair Removal 1. Remove screw attaching switch to bracket. 2. Disconnect electrical connector. 3. Remove switch assembly. Installation 1. Install switch on bracket. 2. Connect electrical connector. 3. Install attaching switch to bracket. 4. Adjust clutch switch as described under ADJUSTMENT PROCEDURES. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision Technical Service Bulletin # 9025B6 Date: 901221 Horn/Speed Control Switch Assembly - Revision ^ CAR WIRING DIAGRAMS - HORN/SPEED CONTROL SWITCH ASSEMBLY SCHEMATICS REVISED ^ ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - HORN/SPEED CONTROL SWITCH ASSEMBLY SCHEMATICS REVISED ^ SHOP MANUAL - SECTION 37-05 - HORN/SPEED CONTROL SWITCH ASSEMBLY SCHEMATICS REVISED Article No. 90-25B-6 FORD: 1986-90 TAURUS 1988-90 CROWN VICTORIA 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1986-90 SABLE 1988-90 CONTINENTAL, GRAND MARQUIS, MARK VII, TOWN CAR 1989-90 COUGAR ISSUE: The Horn/Speed Control Switch Assembly schematics shown in the publications listed below are incorrect. Speed switch wiring and circuit numbers have also been updated. ^ 1986 - 1990 Taurus/Sable Shop Manuals ^ 1986 -1989 Taurus/Sable EVTMs ^ 1988 -1990 Mark VII Shop Manuals ^ 1988 - 1989 Mark VII EVTMs ^ 1988 -1990 Continental Shop Manuals ^ 1988 -1989 Continental EVTMs ^ 1988 -1990 Lincoln Town Car/Crown Victoria/Grand Marquis Shop Manuals ^ 1988 - 1990 Lincoln Town Car EVTMs ^ 1988 - 1989 Crown Victoria/Grand Marquis EVTMs ^ 1989 - 1990 Thunderbird/Cougar Shop Manuals ACTION: Refer to the pages following this TSB article for the revised schematics and correct circuit numbers/color codes. OTHER APPLICABLE ARTICLES: 90-18B-5 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8525 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8526 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8527 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8528 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8529 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8530 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8531 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8532 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8533 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8534 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8535 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8536 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8537 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8538 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8539 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8540 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8541 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8542 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8543 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8544 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8545 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8546 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8547 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8548 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8549 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8550 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8551 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8552 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8553 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8554 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8555 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8556 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Horn/Speed Control Switch Assembly - Revision > Page 8557 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component Information > Technical Service Bulletins > Page 8558 Cruise Control Switch: Service and Repair 1. Pull upward on upper middle edge of the horn cover/pad assembly and separate it from the steering wheel. 2. Disconnect horn switch electrical connectors from horn cover/pad assembly, then set the assembly aside. 3. Disconnect electrical connector from the speed control/horn brush contact plate terminal. 4. On models with standard steering wheel, use your fingers to pry out the speed control switch. Remove switch and harness assembly from steering wheel. 5. On models with sport steering wheel, remove four speed control switch retaining screws. Remove switch and harness assembly from steering wheel. 6. On all models, reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information > Description and Operation ABS Light: Description and Operation This lamp will be illuminated when the ignition switch is placed in the On position. The lamp maybe illuminated for as long as 30 seconds as a bulb and system check. For 89-90 Probe, the light will flash when self-test is activated. If lamp remains illuminated or comes on while operating the vehicle, a problem in the anti-lock brake system is indicated. When lamp is illuminated, place ignition switch in Off position, then restart engine. If lamp still remains illuminated, the anti-lock brake system should be serviced. The brake system will remain functional, but without the anti-lock function. After servicing the anti-lock brake system, the lamp will automatically be reset when vehicle is operated at a speed over 25 MPH. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Locations Audible Warning Device: Locations I/P Components RH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions Audible Warning Device: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8568 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8569 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8570 Audible Warning Device: Electrical Diagrams Warning Chime Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component Information > Diagrams > Diagram Information and Instructions > Page 8571 Warning Chime Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Brake Pad Wear Sensor > Component Information > Locations Brake Pad Wear Sensor: Locations At Respective Wheels, On Brake Housing Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation Charge Lamp/Indicator: Description and Operation A red alternator charge indicator is located in the instrument cluster. This indicator glows when there is no alternator output. If the system is working normally, the following conditions will be present. 1. With ignition switch Off, charge indicator is Off. 2. With ignition switch in Run (engine not running), charge indicator is On. 3. With ignition switch in Run (engine running), charge indicator is Off. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Charge Lamp/Indicator > Component Information > Description and Operation > Page 8579 Charge Lamp/Indicator: Testing and Inspection If charge indicator does not come on with the ignition switch in Run position and the engine not running, check the I circuit (ignition switch to regulator I terminal) for an open circuit or burned out charge indicator. Replace indicator, if necessary. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions Cigarette Lighter: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8584 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8585 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8586 Cigarette Lighter: Electrical Diagrams Cigar Lighter And Turn Signal Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Component Information > Diagrams > Diagram Information and Instructions > Page 8587 Cigar Lighter Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Component Information > Service and Repair Dashboard / Instrument Panel: Service and Repair Fig. 15 Steering Column Lower Trim Cover Removal, 1989 Cougar & Thunderbird. Fig. 16 Steering Column Opening Reinforcement Removal, 1989 Cougar & Thunderbird. Fig. 17 Steering Column Wiring Connectors, 1989 Cougar & Thunderbird. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Component Information > Service and Repair > Page 8591 Fig. 18 Removing Cowl Trim Panel, 1989 Cougar & Thunderbird. Fig. 19 Removing Floor Console, 1989 Cougar & Thunderbird. Fig. 12 Removing I/P Retaining Screws. Cougar & Thunderbird Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Component Information > Service and Repair > Page 8592 Fig. 21 Removing Upper Finish Panels, 1989 Cougar & Thunderbird. Fig. 22 Removing I/P From Cowl, 1989 Cougar & Thunderbird. 1. Disconnect battery ground cable. 2. Disconnect all underhood wiring connectors from main wiring harness. Remove rubber grommet seal from dash panel and push wiring hamess and connectors into passenger compartment. Fig. 15. 3. Remove steering column lower trim cover, Fig. 15. 4. Remove six steering column lower opening reinforcement retaining screws, Fig. 16. 5. Remove steering column upper and lower shrouds. 6. Disconnect steering column wiring connectors, Fig. 17. 7. Remove shift interlock switch. 8. Disconnect steering column lower universal joint. 9. Support steering column and remove four nuts retaining column to support. Remove column from vehicle. 10. Remove one screw retaining left side of instrument panel to parking brake bracket. 11. Install lower steering column lower opening reinforcement, Fig. 16. Reinforcement prevents instrument panel from twisting when being removed from vehicle. 12. Remove right and left side cowl trim panels, Fig. 18. 13. Open floor console door and remove container and mat to gain access to two console to floorpan retaining screws. Remove screws, Fig. 19. 14. On models with 5 speed manual transmission, remove gear shift knob. 15. On all models, remove two rear finish panel retaining screws. 16. Tilt finish panel forward and disconnect electrical connectors, then remove finish panel. 17. Remove two front console to instrument panel retaining screws and remove console. 18. Remove two nuts retaining center of instrument panel to floor. 19. Open glove compartment, squeeze sides of bin and lower to full open position. 20. From underneath instrument panel and through glove compartment opening, disconnect wiring and heater-A/C vacuum lines and control cables. 21. Remove two retaining screws from both the left and right sides of the instrument panel, Fig. 20. 22. Remove right and left side upper finish panels by pulling up to disengage snap-in retainers, Fig. 21. 23. Remove four screws retaining instrument panel to cowl top, Fig. 22. 24. Remove right and left roof rail trim panel panel, then remove door frame weather strip. 25. Carefully pull instrument panel away from cowl and disconnect any remaining wiring or controls. 26. Remove instrument panel from the vehicle. 27. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations I/P Components LH Side Of Dash, Near Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door/Trunk Ajar Indicator/Lamp > Component Information > Description and Operation Door/Trunk Ajar Indicator/Lamp: Description and Operation If the door is ajar, the shoulder belt will remain in the forward position at the A-pillar. The door ajar indicator located in the instrument panel will illuminate until the door is fully closed and the shoulder belt is in the locked position at the B-pillar. WARNING: THE VEHICLE SHOULD NOT BE DRIVEN UNLESS THE DOORS ARE FULLY CLOSED AND THE SHOULDER BELTS ARE IN THE LOCKED POSITION AT THE B-PILLAR. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations Door Switch: Locations Body & Chassis Components In Respective Door Latch Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Door Switch > Component Information > Locations > Page 8602 Door Switch: Service and Repair REMOVAL and INSTALLATION 1. Remove connector at switch. 2. Using an ohmmeter such as Rotunda Digital Volt Ohm Meter 007-00001, or an equivalent probe between switch terminal and ground (latch). 3. With door in latched (fully closed) position, switch should be open. 4. With door open, switch must be closed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions Vehicle Maintenance Monitor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 8607 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 8608 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 8609 Vehicle Maintenance Monitor: Electrical Diagrams Vehicle Maintenance Monitor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Vehicle Maintenance Monitor <--> [Emissions Maintenance Light] > Component Information > Diagrams > Diagram Information and Instructions > Page 8610 Vehicle Maintenance Monitor Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level Fuel Gauge: Customer Interest Fuel Gauge - Intermittently Shows Increase In Fuel Level Article No. 91-13-4 06/26/91 GAUGE - FUEL - ELECTRONIC - SHOWS FUEL INCREASES OR DISPLAYS "CO" INTERMITTENTLY - VEHICLES BUILT FROM 6/1/89 TO 1/15/90 FORD: 1989-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989-90 AEROSTAR This TSB article is being republished in its entirety to correct the fuel pump/sender part number listed for the 1989 Taurus/Sable. ISSUE: The electronic instrument cluster (EIC) fuel gauge may intermittently show an increase in the fuel level or display circuit open "CO". This happens when the fuel tank level is above 1/2 full. The condition is caused by either an intermittent high resistance contact or an open circuit internal to the fuel sender unit. ACTION: Perform the diagnostic procedures outlined in the appropriate Shop Manual, Sections 33-05 for Cars and 13-01A for the Aerostar to determine if a new fuel pump/sender is required. 1. Replace the fuel sender assembly. Refer to the appropriate Shop Manual, Sections 24-35 for cars and 13-03 for the Aerostar for service details. FUEL PUMP/SENDER APPLICATION CHART MODEL YEAR APPLICATION DESCRIPTION PART NUMBER 1989 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-C 1990 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-A 1989-90 Continental Fuel Pump/Sender E90Z-9H307-A 1989-90 Mark VII Fuel Pump/Sender E5LY-9275-A 1989 Town Car Fuel Pump/Sender E5VY-9275-A 1990 Town Car Fuel Pump/Sender F0VY-9H307-C 1989-90 Thunderbird/Cougar Fuel Pump/Sender F1SZ-9H307-B 1989-90 Aerostar Fuel Pump/Sender E99Z-9H307-A PART NUMBER PART NAME CLASS F0DZ-9H307-C Fuel Pump/Sender C E90Z-9H307-A Fuel Pump/Sender B F0DZ-9H307-A Fuel Pump/Sender B E5LY-9275-A Fuel Pump/Sender R E5VY-9275-A Fuel Pump/Sender BM F0VY-9H307-C Fuel Pump/Sender B F1SZ-9H307-B Fuel Pump/Sender B E99Z-9H307-A Fuel Pump/Sender B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-7-11 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Customer Interest: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level > Page 8619 OPERATION DESCRIPTION TIME 911304A Replace Fuel Pump/Sender 1.5 Hrs. - 1990 Town Car, Thunderbird, Cougar 911304A Replace Fuel Pump/Sender 1.2 Hrs. - Aerostar 911304A Replace Fuel Pump/Sender 1.0 Hr. - Continental, 1989 Town Car 911304A Replace Fuel Pump/Sender 0.9 Hr. - Taurus, Sable, Mark VII DEALER CODING BASIC PART NO. CONDITION CODE 9H307 28 OASIS CODES: 204000, 204100, 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 91134 > Jun > 91 > Fuel Gauge Intermittently Shows Increase In Fuel Level Fuel Gauge: All Technical Service Bulletins Fuel Gauge - Intermittently Shows Increase In Fuel Level Article No. 91-13-4 06/26/91 GAUGE - FUEL - ELECTRONIC - SHOWS FUEL INCREASES OR DISPLAYS "CO" INTERMITTENTLY - VEHICLES BUILT FROM 6/1/89 TO 1/15/90 FORD: 1989-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989-90 AEROSTAR This TSB article is being republished in its entirety to correct the fuel pump/sender part number listed for the 1989 Taurus/Sable. ISSUE: The electronic instrument cluster (EIC) fuel gauge may intermittently show an increase in the fuel level or display circuit open "CO". This happens when the fuel tank level is above 1/2 full. The condition is caused by either an intermittent high resistance contact or an open circuit internal to the fuel sender unit. ACTION: Perform the diagnostic procedures outlined in the appropriate Shop Manual, Sections 33-05 for Cars and 13-01A for the Aerostar to determine if a new fuel pump/sender is required. 1. Replace the fuel sender assembly. Refer to the appropriate Shop Manual, Sections 24-35 for cars and 13-03 for the Aerostar for service details. FUEL PUMP/SENDER APPLICATION CHART MODEL YEAR APPLICATION DESCRIPTION PART NUMBER 1989 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-C 1990 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-A 1989-90 Continental Fuel Pump/Sender E90Z-9H307-A 1989-90 Mark VII Fuel Pump/Sender E5LY-9275-A 1989 Town Car Fuel Pump/Sender E5VY-9275-A 1990 Town Car Fuel Pump/Sender F0VY-9H307-C 1989-90 Thunderbird/Cougar Fuel Pump/Sender F1SZ-9H307-B 1989-90 Aerostar Fuel Pump/Sender E99Z-9H307-A PART NUMBER PART NAME CLASS F0DZ-9H307-C Fuel Pump/Sender C E90Z-9H307-A Fuel Pump/Sender B F0DZ-9H307-A Fuel Pump/Sender B E5LY-9275-A Fuel Pump/Sender R E5VY-9275-A Fuel Pump/Sender BM F0VY-9H307-C Fuel Pump/Sender B F1SZ-9H307-B Fuel Pump/Sender B E99Z-9H307-A Fuel Pump/Sender B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-7-11 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 91134 > Jun > 91 > Fuel Gauge Intermittently Shows Increase In Fuel Level > Page 8625 OPERATION DESCRIPTION TIME 911304A Replace Fuel Pump/Sender 1.5 Hrs. - 1990 Town Car, Thunderbird, Cougar 911304A Replace Fuel Pump/Sender 1.2 Hrs. - Aerostar 911304A Replace Fuel Pump/Sender 1.0 Hr. - Continental, 1989 Town Car 911304A Replace Fuel Pump/Sender 0.9 Hr. - Taurus, Sable, Mark VII DEALER CODING BASIC PART NO. CONDITION CODE 9H307 28 OASIS CODES: 204000, 204100, 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 9025B10 > Dec > 90 > Instrument Cluster Schematic - Revision Fuel Gauge: All Technical Service Bulletins Instrument Cluster Schematic - Revision ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1989 - PAGE 111 - INSTRUMENT CLUSTER SCHEMATIC REVISED Article No. 90-25B-10 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The schematic for the Gauges Cluster on Page 111 of the 1989 Thunderbird /Cougar EVTM has some incorrect circuit information. The base cluster has a single function Fuel Anti-Slosh Module and the performance cluster has a combination Check Gauge/Fuel Anti-Slosh Module. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge: > 9025B10 > Dec > 90 > Instrument Cluster Schematic - Revision > Page 8630 The Check Gauge light and its circuit are not illustrated. Some of the Flex circuit connections are incorrect. ACTION: Refer to the pages following this TSB article for the updated schematics. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 9025B10 > Dec > 90 > Instrument Cluster Schematic - Revision Fuel Gauge: All Technical Service Bulletins Instrument Cluster Schematic - Revision ELECTRICAL/VACUUM TROUBLESHOOTING MANUAL - 1989 - PAGE 111 - INSTRUMENT CLUSTER SCHEMATIC REVISED Article No. 90-25B-10 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The schematic for the Gauges Cluster on Page 111 of the 1989 Thunderbird /Cougar EVTM has some incorrect circuit information. The base cluster has a single function Fuel Anti-Slosh Module and the performance cluster has a combination Check Gauge/Fuel Anti-Slosh Module. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge: > 9025B10 > Dec > 90 > Instrument Cluster Schematic - Revision > Page 8636 The Check Gauge light and its circuit are not illustrated. Some of the Flex circuit connections are incorrect. ACTION: Refer to the pages following this TSB article for the updated schematics. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Technical Service Bulletins > Page 8637 Fuel Gauge: Description and Operation Bimetal Type The fuel level indicator gauge pointer is attached to a wire wound bimetal strip, which, when heated by a signal from the fuel sender unit, produces the appropriate level indication When the curent is low there is little heating effect and the point moves a short distance As the current increases, it produces a greater heating effect, causing the pointer to move a greater distance. Magnetic Type The fuel level indicating system is a magnetic type system, which consists of the sending unit located in the fuel tank, an anti-slosh module located on the back of the instrument cluster, and a fuel gauge located in the instrument cluster. The sending unit changes resistance according to the level of fuel in the fuel tank, which varies the current flow through the gauge. The pointer position varies proportionately to the current flow. In this system, the sending unit resistance is low when the fuel level is low and high when the fuel level is high. The pointer of the magnetic gauge remains in position when the ignition is turned to the Off position. O some models, an anti-slosh module is used to dampen out fluctuating fuel signals from the sender. Some vehicles are equipped with a low fuel warning indicator. The anti-slosh module will also actuate the low fuel indicator when the fuel level in the tank reaches 1/16 to 1/8 full. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Pinpoint Tests Fuel Gauge: Pinpoint Tests Fig. 1 Fuel Indicating System Diagnosis (Part 1 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 8640 Fig. 1 Fuel Indicating System Diagnosis (Part 2 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 8641 Fig. 1 Fuel Indicating System Diagnosis (Part 3 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 8642 Fig. 1 Fuel Indicating System Diagnosis (Part 4 Of 5). Models w/Magnetic Gauge Fig. 1 Fuel Indicating System Diagnosis (Part 5 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 8643 Fig. 2 Fuel Indicating System Diagnosis (Part 1 Of 2) Fig. 2 Fuel Indicating System Diagnosis (Part 2 Of 2) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information > Testing and Inspection > Pinpoint Tests > Page 8644 Fuel Gauge: Component Tests and General Diagnostics Magnetic Type The required test equipment consists of a Rotunda Gauge Tester part No. 021-00055 or equivalent, a pair of 10 ohm and 75 ohm resistor or another fuel sender of known quality. 1. Perform test with resistors as follows: a. Disconnect wiring connector at sender unit, then connect resistor between gauge lead and a suitable ground. b. Turn ignition switch to On position. c. With 10 ohm resitor, the gauge pointer should contact the Full mark. d. With 75 ohm resistor, the gauge pointer should contact the Empty mark. 2. Perform test with fuel sender of known quality as follows: a. Turn ignition switch to Off position. b. Disconnect wiring connector from sender and connect it to test sender. c. Move float rod away from fuel filter against Full stop position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or above the Full mark. d. Move float rod toward fuel filter against Empty stop position. Turn ignition switch to Off position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or below the Empty mark. e. If gauge performs as indicated, perform fuel sender unit tests. Refer to DIAGNOSTIC CHARTS for fuel sender unit tests. f. If gauge is out of calibration at the Empty mark, or both the Empty and Full mark, replace gauge. Bimetal Type The required test equipment consists of a Rotunda Gauge Tester part No. 021-00055 or equivalent, a pair of 22 ohm and 145 ohm resistor or another fuel sender of known quality. 1. Perform test with resistors as follows: a. Disconnect wiring connector at sender unit, then connect resistor between gauge lead and a suitable ground. b. Turn ignition switch to On position. c. With 145 ohm resitor, the gauge pointer should contact the Full mark. d. With 22 ohm resistor, the gauge pointer should contact the Empty mark. 2. Perform test with fuel sender of known quality as follows: a. Turn ignition switch to Off position. b. Disconnect wiring connector from sender and connect it to test sender. c. Move float rod away from fuel filter against Full stop position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or above the Full mark. d. Move float rod toward fuel filter against Empty stop position. Turn ignition switch to Off position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or below the Empty mark. e. If gauge performs as indicated, perform fuel sender unit tests. Refer to DIAGNOSTIC CHARTS for fuel sender unit tests. f. If gauge is out of calibration at the Empty mark, or both the Empty and Full mark, replace gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level Fuel Gauge Sender: Customer Interest Fuel Gauge - Intermittently Shows Increase In Fuel Level Article No. 91-13-4 06/26/91 GAUGE - FUEL - ELECTRONIC - SHOWS FUEL INCREASES OR DISPLAYS "CO" INTERMITTENTLY - VEHICLES BUILT FROM 6/1/89 TO 1/15/90 FORD: 1989-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989-90 AEROSTAR This TSB article is being republished in its entirety to correct the fuel pump/sender part number listed for the 1989 Taurus/Sable. ISSUE: The electronic instrument cluster (EIC) fuel gauge may intermittently show an increase in the fuel level or display circuit open "CO". This happens when the fuel tank level is above 1/2 full. The condition is caused by either an intermittent high resistance contact or an open circuit internal to the fuel sender unit. ACTION: Perform the diagnostic procedures outlined in the appropriate Shop Manual, Sections 33-05 for Cars and 13-01A for the Aerostar to determine if a new fuel pump/sender is required. 1. Replace the fuel sender assembly. Refer to the appropriate Shop Manual, Sections 24-35 for cars and 13-03 for the Aerostar for service details. FUEL PUMP/SENDER APPLICATION CHART MODEL YEAR APPLICATION DESCRIPTION PART NUMBER 1989 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-C 1990 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-A 1989-90 Continental Fuel Pump/Sender E90Z-9H307-A 1989-90 Mark VII Fuel Pump/Sender E5LY-9275-A 1989 Town Car Fuel Pump/Sender E5VY-9275-A 1990 Town Car Fuel Pump/Sender F0VY-9H307-C 1989-90 Thunderbird/Cougar Fuel Pump/Sender F1SZ-9H307-B 1989-90 Aerostar Fuel Pump/Sender E99Z-9H307-A PART NUMBER PART NAME CLASS F0DZ-9H307-C Fuel Pump/Sender C E90Z-9H307-A Fuel Pump/Sender B F0DZ-9H307-A Fuel Pump/Sender B E5LY-9275-A Fuel Pump/Sender R E5VY-9275-A Fuel Pump/Sender BM F0VY-9H307-C Fuel Pump/Sender B F1SZ-9H307-B Fuel Pump/Sender B E99Z-9H307-A Fuel Pump/Sender B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-7-11 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level > Page 8653 OPERATION DESCRIPTION TIME 911304A Replace Fuel Pump/Sender 1.5 Hrs. - 1990 Town Car, Thunderbird, Cougar 911304A Replace Fuel Pump/Sender 1.2 Hrs. - Aerostar 911304A Replace Fuel Pump/Sender 1.0 Hr. - Continental, 1989 Town Car 911304A Replace Fuel Pump/Sender 0.9 Hr. - Taurus, Sable, Mark VII DEALER CODING BASIC PART NO. CONDITION CODE 9H307 28 OASIS CODES: 204000, 204100, 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 891411 > Jul > 89 > Fuel Gauge - Occasionally Sticks In FULL Position Fuel Gauge Sender: Customer Interest Fuel Gauge - Occasionally Sticks In FULL Position GAUGE-FUEL-OCCASIONALLY STICKS IN "FULL" POSITION Article No. 89-14-11 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A fuel gauge that ocassionally sticks in the "FULL" position may be caused by a binding fuel pump float assembly. The fuel pump float binds on the inner surface of the fuel tank and holds the float in the "FULL" position. This is most likely to occur when driving on unpaved or rough roads. ACTION: Modify the fuel pump float to prevent the binding condition. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 24-12 for removal and installation instructions. 1. Remove the fuel pump assembly. 2. Unscrew the nut from the end of the float rod assembly. 3. Remove the float from the rod. 4. Using a sharp knife, cut 3/8" to 1/2" (9.525 mm to 12.7 mm) off the end of the float. 5. Reinstall the shortened float on the float rod. 6. Install float retaining nut. NOTE: ALLOW CLEARANCE BETWEEN THE RETAINING NUT AND FLOAT SO THAT THE FLOAT SPINS FREELY. 7. Using diagonal cutters, trim the float rod so that it is flush with the retaining nut. 8. Reinstall the fuel sender. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891411A Modify Float 1.3 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 41 OASIS CODES: 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Intermittently Shows Increase In Fuel Level Article No. 91-13-4 06/26/91 GAUGE - FUEL - ELECTRONIC - SHOWS FUEL INCREASES OR DISPLAYS "CO" INTERMITTENTLY - VEHICLES BUILT FROM 6/1/89 TO 1/15/90 FORD: 1989-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989-90 AEROSTAR This TSB article is being republished in its entirety to correct the fuel pump/sender part number listed for the 1989 Taurus/Sable. ISSUE: The electronic instrument cluster (EIC) fuel gauge may intermittently show an increase in the fuel level or display circuit open "CO". This happens when the fuel tank level is above 1/2 full. The condition is caused by either an intermittent high resistance contact or an open circuit internal to the fuel sender unit. ACTION: Perform the diagnostic procedures outlined in the appropriate Shop Manual, Sections 33-05 for Cars and 13-01A for the Aerostar to determine if a new fuel pump/sender is required. 1. Replace the fuel sender assembly. Refer to the appropriate Shop Manual, Sections 24-35 for cars and 13-03 for the Aerostar for service details. FUEL PUMP/SENDER APPLICATION CHART MODEL YEAR APPLICATION DESCRIPTION PART NUMBER 1989 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-C 1990 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-A 1989-90 Continental Fuel Pump/Sender E90Z-9H307-A 1989-90 Mark VII Fuel Pump/Sender E5LY-9275-A 1989 Town Car Fuel Pump/Sender E5VY-9275-A 1990 Town Car Fuel Pump/Sender F0VY-9H307-C 1989-90 Thunderbird/Cougar Fuel Pump/Sender F1SZ-9H307-B 1989-90 Aerostar Fuel Pump/Sender E99Z-9H307-A PART NUMBER PART NAME CLASS F0DZ-9H307-C Fuel Pump/Sender C E90Z-9H307-A Fuel Pump/Sender B F0DZ-9H307-A Fuel Pump/Sender B E5LY-9275-A Fuel Pump/Sender R E5VY-9275-A Fuel Pump/Sender BM F0VY-9H307-C Fuel Pump/Sender B F1SZ-9H307-B Fuel Pump/Sender B E99Z-9H307-A Fuel Pump/Sender B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-7-11 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level > Page 8663 OPERATION DESCRIPTION TIME 911304A Replace Fuel Pump/Sender 1.5 Hrs. - 1990 Town Car, Thunderbird, Cougar 911304A Replace Fuel Pump/Sender 1.2 Hrs. - Aerostar 911304A Replace Fuel Pump/Sender 1.0 Hr. - Continental, 1989 Town Car 911304A Replace Fuel Pump/Sender 0.9 Hr. - Taurus, Sable, Mark VII DEALER CODING BASIC PART NO. CONDITION CODE 9H307 28 OASIS CODES: 204000, 204100, 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > RSB89170 > Nov > 89 > Fuel Pump/Sender Defective Parts Return Technical Service Bulletin # RSB89170 Date: 891122 Remanufacturer Letter # 1 November 22, 1989 RSB # 89-170 To: All Ford Authorized Remanufacturers Subject: Sort and Return of Fuel & Send Assy. - E9DZ-9H307-C E5ZZ-9A407-A Gentlemen: Because certain fuel pump and sender assemblies may not meet Ford's high quality requirements, you are authorized to return unused parts for credit. Part Number Explanation E9DZ-9H307-C Action Required E5ZZ-9A407-A ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 - 1989; 0901 September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section, write "Returned per FPSD Purge 1079". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Returns restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Remanufacturer Letter # 2 November 22, 1989 RSB # 89-171 To: Ford Authorized Remanufacturers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1080". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > RSB89170 > Nov > 89 > Fuel Pump/Sender Defective Parts Return > Page 8668 ^ Return parts to your Facing PDC using least expensive trarisportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 1 December 7, 1989 To: Ford and Lincoln Mercury, Dealers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date ccde of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section Write "Returned per FPSD Purge # 1080". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 3 December 7, 1989 To: Ford and Lincoln Mercury Dealers Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > RSB89170 > Nov > 89 > Fuel Pump/Sender Defective Parts Return > Page 8669 Subject: Return of Fuel Pump & Sender Assy. - E9DZ-9H307-C and Fuel Pump & Bracket Assy. E5ZZ-9A407-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1079". ^ Return parts to your Facing PDC using-least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject part. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacemeut stock of the same part numbers is available for ordering immediately. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89146 > Jul > 89 > Fuel Tank Sending Unit Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89146 > Jul > 89 > Fuel Tank Sending Unit Connector Replacement > Page 8674 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 891411 > Jul > 89 > Fuel Gauge Occasionally Sticks In FULL Position Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Occasionally Sticks In FULL Position GAUGE-FUEL-OCCASIONALLY STICKS IN "FULL" POSITION Article No. 89-14-11 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A fuel gauge that ocassionally sticks in the "FULL" position may be caused by a binding fuel pump float assembly. The fuel pump float binds on the inner surface of the fuel tank and holds the float in the "FULL" position. This is most likely to occur when driving on unpaved or rough roads. ACTION: Modify the fuel pump float to prevent the binding condition. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 24-12 for removal and installation instructions. 1. Remove the fuel pump assembly. 2. Unscrew the nut from the end of the float rod assembly. 3. Remove the float from the rod. 4. Using a sharp knife, cut 3/8" to 1/2" (9.525 mm to 12.7 mm) off the end of the float. 5. Reinstall the shortened float on the float rod. 6. Install float retaining nut. NOTE: ALLOW CLEARANCE BETWEEN THE RETAINING NUT AND FLOAT SO THAT THE FLOAT SPINS FREELY. 7. Using diagonal cutters, trim the float rod so that it is flush with the retaining nut. 8. Reinstall the fuel sender. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891411A Modify Float 1.3 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 41 OASIS CODES: 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89251 > Dec > 89 > All Technical Service Bulletins for Fuel Gauge Sender: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Intermittently Shows Increase In Fuel Level Article No. 91-13-4 06/26/91 GAUGE - FUEL - ELECTRONIC - SHOWS FUEL INCREASES OR DISPLAYS "CO" INTERMITTENTLY - VEHICLES BUILT FROM 6/1/89 TO 1/15/90 FORD: 1989-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989-90 AEROSTAR This TSB article is being republished in its entirety to correct the fuel pump/sender part number listed for the 1989 Taurus/Sable. ISSUE: The electronic instrument cluster (EIC) fuel gauge may intermittently show an increase in the fuel level or display circuit open "CO". This happens when the fuel tank level is above 1/2 full. The condition is caused by either an intermittent high resistance contact or an open circuit internal to the fuel sender unit. ACTION: Perform the diagnostic procedures outlined in the appropriate Shop Manual, Sections 33-05 for Cars and 13-01A for the Aerostar to determine if a new fuel pump/sender is required. 1. Replace the fuel sender assembly. Refer to the appropriate Shop Manual, Sections 24-35 for cars and 13-03 for the Aerostar for service details. FUEL PUMP/SENDER APPLICATION CHART MODEL YEAR APPLICATION DESCRIPTION PART NUMBER 1989 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-C 1990 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-A 1989-90 Continental Fuel Pump/Sender E90Z-9H307-A 1989-90 Mark VII Fuel Pump/Sender E5LY-9275-A 1989 Town Car Fuel Pump/Sender E5VY-9275-A 1990 Town Car Fuel Pump/Sender F0VY-9H307-C 1989-90 Thunderbird/Cougar Fuel Pump/Sender F1SZ-9H307-B 1989-90 Aerostar Fuel Pump/Sender E99Z-9H307-A PART NUMBER PART NAME CLASS F0DZ-9H307-C Fuel Pump/Sender C E90Z-9H307-A Fuel Pump/Sender B F0DZ-9H307-A Fuel Pump/Sender B E5LY-9275-A Fuel Pump/Sender R E5VY-9275-A Fuel Pump/Sender BM F0VY-9H307-C Fuel Pump/Sender B F1SZ-9H307-B Fuel Pump/Sender B E99Z-9H307-A Fuel Pump/Sender B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-7-11 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89251 > Dec > 89 > All Technical Service Bulletins for Fuel Gauge Sender: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level > Page 8693 OPERATION DESCRIPTION TIME 911304A Replace Fuel Pump/Sender 1.5 Hrs. - 1990 Town Car, Thunderbird, Cougar 911304A Replace Fuel Pump/Sender 1.2 Hrs. - Aerostar 911304A Replace Fuel Pump/Sender 1.0 Hr. - Continental, 1989 Town Car 911304A Replace Fuel Pump/Sender 0.9 Hr. - Taurus, Sable, Mark VII DEALER CODING BASIC PART NO. CONDITION CODE 9H307 28 OASIS CODES: 204000, 204100, 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89251 > Dec > 89 > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return Technical Service Bulletin # RSB89170 Date: 891122 Remanufacturer Letter # 1 November 22, 1989 RSB # 89-170 To: All Ford Authorized Remanufacturers Subject: Sort and Return of Fuel & Send Assy. - E9DZ-9H307-C E5ZZ-9A407-A Gentlemen: Because certain fuel pump and sender assemblies may not meet Ford's high quality requirements, you are authorized to return unused parts for credit. Part Number Explanation E9DZ-9H307-C Action Required E5ZZ-9A407-A ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 - 1989; 0901 September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section, write "Returned per FPSD Purge 1079". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Returns restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Remanufacturer Letter # 2 November 22, 1989 RSB # 89-171 To: Ford Authorized Remanufacturers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1080". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89251 > Dec > 89 > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 8698 ^ Return parts to your Facing PDC using least expensive trarisportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 1 December 7, 1989 To: Ford and Lincoln Mercury, Dealers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date ccde of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section Write "Returned per FPSD Purge # 1080". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 3 December 7, 1989 To: Ford and Lincoln Mercury Dealers Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89251 > Dec > 89 > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 8699 Subject: Return of Fuel Pump & Sender Assy. - E9DZ-9H307-C and Fuel Pump & Bracket Assy. E5ZZ-9A407-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1079". ^ Return parts to your Facing PDC using-least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject part. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacemeut stock of the same part numbers is available for ordering immediately. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89251 > Dec > 89 > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89251 > Dec > 89 > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 8704 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89251 > Dec > 89 > All Technical Service Bulletins for Fuel Gauge Sender: > 891411 > Jul > 89 > Fuel Gauge - Occasionally Sticks In FULL Position Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Occasionally Sticks In FULL Position GAUGE-FUEL-OCCASIONALLY STICKS IN "FULL" POSITION Article No. 89-14-11 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A fuel gauge that ocassionally sticks in the "FULL" position may be caused by a binding fuel pump float assembly. The fuel pump float binds on the inner surface of the fuel tank and holds the float in the "FULL" position. This is most likely to occur when driving on unpaved or rough roads. ACTION: Modify the fuel pump float to prevent the binding condition. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 24-12 for removal and installation instructions. 1. Remove the fuel pump assembly. 2. Unscrew the nut from the end of the float rod assembly. 3. Remove the float from the rod. 4. Using a sharp knife, cut 3/8" to 1/2" (9.525 mm to 12.7 mm) off the end of the float. 5. Reinstall the shortened float on the float rod. 6. Install float retaining nut. NOTE: ALLOW CLEARANCE BETWEEN THE RETAINING NUT AND FLOAT SO THAT THE FLOAT SPINS FREELY. 7. Using diagonal cutters, trim the float rod so that it is flush with the retaining nut. 8. Reinstall the fuel sender. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891411A Modify Float 1.3 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 41 OASIS CODES: 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Component Information > Technical Service Bulletins > Customer Interest for Axle Beam Bushing: > 93312 > Feb > 93 > Rear Axle - Moan or Slow Beating Noise At 55 MPH Axle Beam Bushing: Customer Interest Rear Axle - Moan or Slow Beating Noise At 55 MPH Article No. 93-3-12 February 3, 1993 ^ NOISE - "MOAN" OR "SLOW BEATING" NOISE FROM AXLE ^ AXLE - "MOAN" OR "SLOW BEATING" NOISE WHILE DRIVING 55 M.P.H. (88 KM/H) OR OVER FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: A "moan" or "slow beating" noise may be heard near the axle, while driving 55 m.p.h. (88 KM/H) or over, due to the axle ring and pinion gears. This condition can occur with the transmission in either Drive (D) or Overdrive (OD). ACTION: Use the following service procedure to check and, if necessary, replace the axle isolator bushings. SERVICE PROCEDURE 1. Test drive the vehicle. At a speed of 55 m.p.h. (88 KM/H) or over, shift the transmission from Overdrive (OD) to Drive (D). 2. If the "moan" or "slow beating" noise is still heard, replace the axle isolator bushings (F3SZ-4B424-A or F3SZ-4B431-B). Refer to the 1992 Thunderbird/Cougar Service Manual, Section 02-01, for removal and installation procedures. NOTE: THE DESIGN OF THE NEW AXLE ISOLATOR BUSHINGS MOAN ELIMINATE OR REDUCE THE "MOAN" NOISE, BUT IT WILL NOT CHANGE OR REDUCE VIBRATIONS CAUSED BY THE DRIVESHAFT OR TIRES. PART NUMBER PART NAME CLASS F3SZ-4B424-A Upper Axle Isolator Bushing (2 C Required) F3SZ-4B431-B Lower Axle Isolator Bushing (2 C Required) WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models. Eligible Under Bumper To Bumper Coverage For 1992 Models. OPERATION DESCRIPTION TIME 930312A Replace Rear Axle Insulator 1.5 Hrs. Bushings DEALER CODING BASIC PART NO. CONDITION CODE 4209 56 OASIS CODES: 509000, 597997, 702000, 702300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Axle Beam Bushing: > 93312 > Feb > 93 > Rear Axle - Moan or Slow Beating Noise At 55 MPH Axle Beam Bushing: All Technical Service Bulletins Rear Axle - Moan or Slow Beating Noise At 55 MPH Article No. 93-3-12 February 3, 1993 ^ NOISE - "MOAN" OR "SLOW BEATING" NOISE FROM AXLE ^ AXLE - "MOAN" OR "SLOW BEATING" NOISE WHILE DRIVING 55 M.P.H. (88 KM/H) OR OVER FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: A "moan" or "slow beating" noise may be heard near the axle, while driving 55 m.p.h. (88 KM/H) or over, due to the axle ring and pinion gears. This condition can occur with the transmission in either Drive (D) or Overdrive (OD). ACTION: Use the following service procedure to check and, if necessary, replace the axle isolator bushings. SERVICE PROCEDURE 1. Test drive the vehicle. At a speed of 55 m.p.h. (88 KM/H) or over, shift the transmission from Overdrive (OD) to Drive (D). 2. If the "moan" or "slow beating" noise is still heard, replace the axle isolator bushings (F3SZ-4B424-A or F3SZ-4B431-B). Refer to the 1992 Thunderbird/Cougar Service Manual, Section 02-01, for removal and installation procedures. NOTE: THE DESIGN OF THE NEW AXLE ISOLATOR BUSHINGS MOAN ELIMINATE OR REDUCE THE "MOAN" NOISE, BUT IT WILL NOT CHANGE OR REDUCE VIBRATIONS CAUSED BY THE DRIVESHAFT OR TIRES. PART NUMBER PART NAME CLASS F3SZ-4B424-A Upper Axle Isolator Bushing (2 C Required) F3SZ-4B431-B Lower Axle Isolator Bushing (2 C Required) WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models. Eligible Under Bumper To Bumper Coverage For 1992 Models. OPERATION DESCRIPTION TIME 930312A Replace Rear Axle Insulator 1.5 Hrs. Bushings DEALER CODING BASIC PART NO. CONDITION CODE 4209 56 OASIS CODES: 509000, 597997, 702000, 702300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Component Information > Technical Service Bulletins > Customer Interest: > 89251 > Dec > 89 > Ignition Lock - Ignition Key Hard to Remove Ignition Switch Lock Cylinder: Customer Interest Ignition Lock - Ignition Key Hard to Remove ^ LOCK - IGNITION - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS ^ IGNITION SWITCH - KEY HARD TO REMOVE - VEHICLES WITH AUTOMATIC TRANSMISSIONS Article No. 89-25-1 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hard to remove ignition key may be caused by a misadjusted transmission control shift cable for the floor mounted automatic shifter. A shift cable that is out of adjustment can result in: ^ The customer not fully engaging the console shift lever in Park which is the key removal position (PARK) ^ The customer not being able to rotate the key to the "LOCK" position ACTION: Adjust the transmission control shifter cable. Refer to the following procedure for service details. 1. Place the console shift lever in "Overdrive". Make sure the shifter is latched in the detent. 2. Set the parking brake. 3. Raise the vehicle. 4. Loosen the shift cable adjusting nut. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 17-02 for service details. 5. Make sure the shift cable is loose and free to self-locate to the transmission mounted bracket. 6. Tighten the shift cable adjusting nut to a torque of 10-18 lb.ft. (13-25 N-m). OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 892501A Adjust Shift Cable 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7E395 07 OASIS CODES: 2700, 2760, 5104 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Component Information > Technical Service Bulletins > All Other Service Bulletins for Ignition Switch Lock Cylinder: > 93312 > Feb > 93 > Rear Axle - Moan or Slow Beating Noise At 55 MPH Axle Beam Bushing: All Technical Service Bulletins Rear Axle - Moan or Slow Beating Noise At 55 MPH Article No. 93-3-12 February 3, 1993 ^ NOISE - "MOAN" OR "SLOW BEATING" NOISE FROM AXLE ^ AXLE - "MOAN" OR "SLOW BEATING" NOISE WHILE DRIVING 55 M.P.H. (88 KM/H) OR OVER FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: A "moan" or "slow beating" noise may be heard near the axle, while driving 55 m.p.h. (88 KM/H) or over, due to the axle ring and pinion gears. This condition can occur with the transmission in either Drive (D) or Overdrive (OD). ACTION: Use the following service procedure to check and, if necessary, replace the axle isolator bushings. SERVICE PROCEDURE 1. Test drive the vehicle. At a speed of 55 m.p.h. (88 KM/H) or over, shift the transmission from Overdrive (OD) to Drive (D). 2. If the "moan" or "slow beating" noise is still heard, replace the axle isolator bushings (F3SZ-4B424-A or F3SZ-4B431-B). Refer to the 1992 Thunderbird/Cougar Service Manual, Section 02-01, for removal and installation procedures. NOTE: THE DESIGN OF THE NEW AXLE ISOLATOR BUSHINGS MOAN ELIMINATE OR REDUCE THE "MOAN" NOISE, BUT IT WILL NOT CHANGE OR REDUCE VIBRATIONS CAUSED BY THE DRIVESHAFT OR TIRES. PART NUMBER PART NAME CLASS F3SZ-4B424-A Upper Axle Isolator Bushing (2 C Required) F3SZ-4B431-B Lower Axle Isolator Bushing (2 C Required) WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1991 And Prior Models. Eligible Under Bumper To Bumper Coverage For 1992 Models. OPERATION DESCRIPTION TIME 930312A Replace Rear Axle Insulator 1.5 Hrs. Bushings DEALER CODING BASIC PART NO. CONDITION CODE 4209 56 OASIS CODES: 509000, 597997, 702000, 702300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Component Information > Description and Operation > Auxiliary Fuel Bowl Vent Tube Bowl Vent Valve: Description and Operation Auxiliary Fuel Bowl Vent Tube Fig. 44 Auxiliary fuel bowl vent tube Used on some vehicles, this auxiliary vent tube, Fig. 44, is teed into the primary fuel bowl vent tube to vent the fuel bowl when the internal vent is closed (external vent is closed) and the solenoid or thermal vent valves are closed. This tube is vented to the air cleaner. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Component Information > Description and Operation > Auxiliary Fuel Bowl Vent Tube > Page 8747 Bowl Vent Valve: Description and Operation Carburetor Fuel Bowl Thermal Vent Valve Fig. 10 Carburetor fuel bowl thermal vent valve The thermal vent valve, Fig. 10, used on some vehicles, is a temperature actuated on/off valve, that is inserted in the carburetor to carbon canister vent line. This valve is closed when the engine compartment is cold, preventing fuel tank vapors, generated when the fuel tank heats up before the engine compartment, from being vented through the carburetor bowl. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Component Information > Description and Operation > Auxiliary Fuel Bowl Vent Tube > Page 8748 Bowl Vent Valve: Description and Operation Vacuum Bowl Vent Valve Fig. 51 Vacuum bowl vent valve This valve, Fig. 51, used on some vehicles, is a vacuum operated on/off valve. This valve controls vapor flow from the carburetor bowl to the carbon canister. When the engine is running, manifold vacuum closes the flow path from the carburetor bowl to the carbon canister. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component Information > Testing and Inspection > Component Information > Description and Operation > Auxiliary Fuel Bowl Vent Tube > Page 8749 Bowl Vent Valve: Description and Operation Vacuum/Thermostatic Bowl Vent Valve Fig. 52 Vacuum/thermoststic bowl vent valve This valve, Fig. 52, used on some vehicles, is a vacuum/temperature operated on/off valve. This valve controls vapor flow from the carburetor bowl to the carbon canister. When the engine is running, manifold vacuum closes the flow path from the carburetor bowl to the carbon canister. This valve also closes the bowl to canister flow path when the temperature of the valve is less than 90° F even if there is no manifold vacuum. When the temperature of the valve exceeds 120° F, the valve is open except when closed by manifold vacuum. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Technical Service Bulletins > Customer Interest: > 90239 > Nov > 90 > Instrument Cluster - Dim or Blank Display Instrument Panel Bulb: Customer Interest Instrument Cluster - Dim or Blank Display ^ LAMP - ELECTRONIC AIR TEMPERATURE CONTROL - DISPLAY DIM OR BLANK CORRECT SERVICE BULB USAGE ^ LAMP - ELECTRONIC INSTRUMENT CLUSTER - DISPLAY DIM OR BLANK - CORRECT SERVICE BULB USAGE Article No. 90-23-9 FORD: 1985-91 THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-91 COUGAR 1986-89 SABLE 1988-91 CONTINENTAL LIGHT TRUCK: 1986-91 AEROSTAR ISSUE: A dim or blank display from the electronic instrument cluster (EIC) or the electronic air temperature control (EATC) may be caused by burned-out illumination bulbs. ACTION: Install a new bulb and socket assembly. Refer to the appropriate Shop Manual for service details. The correct service replacement bulb and socket assembly must be used to prevent component damage. NOTE: THE ORANGE BASE HALOGEN BULB AND SOCKET ASSEMBLY (E5SZ-13B765-C) IS THE ONLY BULB THAT IS SPECIFIED FOR USE IN THE 1988 CONTINENTAL. ALL OTHER VEHICLE APPLICATIONS SHOULD USE THE BLUE BASE XENON BULB (E89Z-13B765-A). DO NOT REPLACE STANDARD BULBS WITH HALOGEN OR XENON BULBS. OTHER APPLICABLE ARTICLES: None SUPERSEDES: 88-5-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 201100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 90239 > Nov > 90 > Instrument Cluster - Dim or Blank Display Instrument Panel Bulb: All Technical Service Bulletins Instrument Cluster - Dim or Blank Display ^ LAMP - ELECTRONIC AIR TEMPERATURE CONTROL - DISPLAY DIM OR BLANK CORRECT SERVICE BULB USAGE ^ LAMP - ELECTRONIC INSTRUMENT CLUSTER - DISPLAY DIM OR BLANK - CORRECT SERVICE BULB USAGE Article No. 90-23-9 FORD: 1985-91 THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-91 COUGAR 1986-89 SABLE 1988-91 CONTINENTAL LIGHT TRUCK: 1986-91 AEROSTAR ISSUE: A dim or blank display from the electronic instrument cluster (EIC) or the electronic air temperature control (EATC) may be caused by burned-out illumination bulbs. ACTION: Install a new bulb and socket assembly. Refer to the appropriate Shop Manual for service details. The correct service replacement bulb and socket assembly must be used to prevent component damage. NOTE: THE ORANGE BASE HALOGEN BULB AND SOCKET ASSEMBLY (E5SZ-13B765-C) IS THE ONLY BULB THAT IS SPECIFIED FOR USE IN THE 1988 CONTINENTAL. ALL OTHER VEHICLE APPLICATIONS SHOULD USE THE BLUE BASE XENON BULB (E89Z-13B765-A). DO NOT REPLACE STANDARD BULBS WITH HALOGEN OR XENON BULBS. OTHER APPLICABLE ARTICLES: None SUPERSEDES: 88-5-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 201100 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Bulb: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Wheel Hub: All Technical Service Bulletins Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Bulb: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 8769 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Bulb: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 8770 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Bulb: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Bulb: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 8780 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Bulb > Component Information > Technical Service Bulletins > All Other Service Bulletins for Instrument Panel Bulb: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 8781 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions Instrument Panel Circuit Board: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8790 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8791 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument Panel Circuit Board > Component Information > Diagrams > Diagram Information and Instructions > Page 8792 Instrument Panel Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Technical Service Bulletins > Ignition Key Warning Switch - Replacement Procedure Key Reminder Switch: Technical Service Bulletins Ignition Key Warning Switch - Replacement Procedure IGNITION SYSTEM-IGNITION KEY WARNING SWITCH-REPLACEMENT PROCEDURE SWITCH-IGNITION KEY WARNING-REPLACEMENT PROCEDURE Article No. 89-19-2 FORD: 1986-90 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1986-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR ISSUE: A new procedure for servicing the ignition key warning switch has been developed. The new procedure is not published in the shop manual. ACTION: Use the following service procedure to remove and install the ignition key warning switch. Figure 1 REMOVAL 1. Remove the ignition lock assembly from the steering column lock housing. Refer to the appropriate Car Shop Manual, Section 13-04 for service details. NOTE: LEAVE THE LOCK IN THE RUN POSITION. DO NOT TURN THE IGNITION KEY. 2. Remove the switch from the lock assembly using a screwdriver as shown in Figure 1. 3. Throw away the switch. Figure 2 INSTALLATION 1. Obtain a new key warning switch (11A127). 2. Place the switch halfway on the lock cylinder case. Note proper alignment as shown in Figure 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Technical Service Bulletins > Ignition Key Warning Switch - Replacement Procedure > Page 8797 Figure 3 3. While pressing down on the switch with the thumb, slide the switch into place making sure all tabs are in place, Figure 3. 4. Install the lock cylinder assembly. Refer to the procedure in Section 13-04 of the appropriate Car Shop Manual. PART NUMBER PART NAME CLASS E7DZ-11A127-A Key Warning Switch C (Continental, Taurus, Sable) E6SZ-11A127-A Key Warning Switch (All Other C Car Lines) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2500, 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Key Reminder Switch > Component Information > Technical Service Bulletins > Page 8798 Key Reminder Switch: Locations I/P Components Part Of Ignition Switch Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 91177 > Aug > 91 > Tape Player - Hissing Noise Maintenance Reminder Control Module: Customer Interest Tape Player - Hissing Noise Article No. 91-17-7 08/21/91 ^ RADIO - TAPE PLAYER - MAKES HISSING NOISE - CARS WITH VEHICLE MAINTENANCE MONITOR (VMM) ^ NOISE - "HISS" FROM TAPE PLAYER DURING QUIET PASSAGES - VEHICLES WITH VMM FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hissing noise may be heard from the tape player during quiet passages. This occurs because of electromagnetic interference from the transformer being picked up by the head of the tape player. ACTION: Install a new vehicle maintenance monitor. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-38, for service details. NOTE: SUSPECT VEHICLE MAINTENANCE MONITORS MUST BE REPLACED ONLY BY A VMM WITH A DATE CODE OF MAY 1990 OR LATER. THE DATE CODE IS ON A LABEL LOCATED ON THE TOP OF THE MODULE IN MONTH/DAY/YEAR FORMAT. FOR EXAMPLE, 10/09/90 MEANS OCTOBER 9, 1990. THIS ISSUE DOES NOT AFFECT 1991 MODELS. PART NUMBER PART NAME CLASS F1SZ-10E850-A Vehicle Maintenance Monitor B WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911707A Install Vehicle Maintenance 0.3 Hr. Monitor DEALER CODING BASIC PART NO. CONDITION CODE 10E850 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Maintenance Reminder Control Module: > 91177 > Aug > 91 > Tape Player - Hissing Noise Maintenance Reminder Control Module: All Technical Service Bulletins Tape Player - Hissing Noise Article No. 91-17-7 08/21/91 ^ RADIO - TAPE PLAYER - MAKES HISSING NOISE - CARS WITH VEHICLE MAINTENANCE MONITOR (VMM) ^ NOISE - "HISS" FROM TAPE PLAYER DURING QUIET PASSAGES - VEHICLES WITH VMM FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hissing noise may be heard from the tape player during quiet passages. This occurs because of electromagnetic interference from the transformer being picked up by the head of the tape player. ACTION: Install a new vehicle maintenance monitor. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-38, for service details. NOTE: SUSPECT VEHICLE MAINTENANCE MONITORS MUST BE REPLACED ONLY BY A VMM WITH A DATE CODE OF MAY 1990 OR LATER. THE DATE CODE IS ON A LABEL LOCATED ON THE TOP OF THE MODULE IN MONTH/DAY/YEAR FORMAT. FOR EXAMPLE, 10/09/90 MEANS OCTOBER 9, 1990. THIS ISSUE DOES NOT AFFECT 1991 MODELS. PART NUMBER PART NAME CLASS F1SZ-10E850-A Vehicle Maintenance Monitor B WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911707A Install Vehicle Maintenance 0.3 Hr. Monitor DEALER CODING BASIC PART NO. CONDITION CODE 10E850 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Maintenance Reminder Control Module: > 9038 > Jan > 90 > VMM Oil Change Indicator - Reset Procedure Maintenance Reminder Control Module: All Technical Service Bulletins VMM Oil Change Indicator Reset Procedure VEHICLE MAINTENANCE MONITOR (VMM) - OIL CHANGE INDICATOR - RESET PROCEDURE Article No. 90-3-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The VMM oil change indicator must be reset every time that the vehicle's oil is changed. This means... ^ The oil change indicator must be reset even if the vehicle's oil is changed before the VMM has indicated an oil change is needed. ^ The reset procedure is necessary to keep the information in the oil change indicator updated whenever the oil is changed. ^ If the reset procedure is not done, the VMM will indicate an oil change prematurely. ACTION: After the oil is changed, manually reset the VMM oil change indicator by using the following procedure. 1. With the ignition key in the OFF position, turn the ignition key to the RUN position, but do not start the engine. Figure 1 2. Within 15 seconds of turning the ignition to RUN, reset the VMM by inserting a straightened paper clip or similar tool through the reset hole and press firmly. The module is located in the top center of the instrument panel directly above the radio, Figure 1. ^ You will not be able to feel the reset switch operating because it has no perceptible movement when it is pushed. ^ The oil change message window will begin to flash when the switch has been activated. NOTE: IF THE RESET PROCEDURE IS NOT DONE WITHIN 15 SECONDS, THE PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. IF "NOW" IS FLASHING, DO NOT WAIT FOR IT TO STOP BEFORE PUSHING THE RESET SWITCH TO INITIATE THE OIL CHANGE RESET. 3. Continue to depress the reset switch until the oil change display stops flashing, which will take about 4 seconds. NOTE: IF THE RESET SWITCH IS RELEASED BEFORE THE OIL CHANGE DISPLAY STOPS FLASHING, THE RESET PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Maintenance Reminder Control Module: > 9038 > Jan > 90 > VMM Oil Change Indicator - Reset Procedure Maintenance Reminder Control Module: All Technical Service Bulletins VMM Oil Change Indicator Reset Procedure VEHICLE MAINTENANCE MONITOR (VMM) - OIL CHANGE INDICATOR - RESET PROCEDURE Article No. 90-3-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The VMM oil change indicator must be reset every time that the vehicle's oil is changed. This means... ^ The oil change indicator must be reset even if the vehicle's oil is changed before the VMM has indicated an oil change is needed. ^ The reset procedure is necessary to keep the information in the oil change indicator updated whenever the oil is changed. ^ If the reset procedure is not done, the VMM will indicate an oil change prematurely. ACTION: After the oil is changed, manually reset the VMM oil change indicator by using the following procedure. 1. With the ignition key in the OFF position, turn the ignition key to the RUN position, but do not start the engine. Figure 1 2. Within 15 seconds of turning the ignition to RUN, reset the VMM by inserting a straightened paper clip or similar tool through the reset hole and press firmly. The module is located in the top center of the instrument panel directly above the radio, Figure 1. ^ You will not be able to feel the reset switch operating because it has no perceptible movement when it is pushed. ^ The oil change message window will begin to flash when the switch has been activated. NOTE: IF THE RESET PROCEDURE IS NOT DONE WITHIN 15 SECONDS, THE PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. IF "NOW" IS FLASHING, DO NOT WAIT FOR IT TO STOP BEFORE PUSHING THE RESET SWITCH TO INITIATE THE OIL CHANGE RESET. 3. Continue to depress the reset switch until the oil change display stops flashing, which will take about 4 seconds. NOTE: IF THE RESET SWITCH IS RELEASED BEFORE THE OIL CHANGE DISPLAY STOPS FLASHING, THE RESET PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > Page 8822 Maintenance Reminder Control Module: Locations I/P Components Center Of Dash Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions Malfunction Indicator Lamp: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8827 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8828 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8829 Malfunction Indicator Lamp: Electrical Diagrams Warning Indicators Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8830 Warning Indicators Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 8831 Warning Indicators Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Malfunction Indicator Lamp > Component Information > Diagrams > Page 8832 Malfunction Indicator Lamp: Description and Operation The MIL light is intended to alert the driver of certain malfunctions in the engine control system. If such a fault occurs, the EEC-IV processor will substitute a value or values and continue operating. In some cases this action may result in a slight change in vehicle driveability. On 1988 models, the check engine light can be used to read codes. The check engine light on the front dash panel will remain on when a hard fault is present. During the Self-test sequence, a service code is reported by the check engine light. It will represent itself as a flash on the check engine light display on the dash panel. A single digit number of three will be reported by three flashes. However, as previously stated, a service code is represented by a two digit number, such as 2-3. As a result, the Self-test service code of 2-3 will appear on the check engine light display as two flashes, then after a two second pause, the light will flash three times. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings Odometer: Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND ODOMETER READINGS Article No. 89-2-7 FORD: 1989 AND PRIOR ALL CAR LINES LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle components or systems. The information in this TSB article is intended to assist technicians in speedometer/odometer concern diagnosis. ACTION: Use the following supplemental information below to assist in speedometer/odometer diagnostics. OPERATION A mechanical analog speedometer displays vehicle speed and the odometer displays total distance traveled. The speedometer/odometer assembly is cable driven by either a transmission or a transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed so that all are identical and have no error in the speedometer head. Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the speedometer/odometer. An electronic signal is sent from a speed sensor to the digital speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle, similar to a cable. Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio and speedometer/odometer drive and driven gears. TIRES Improper tire rolling radius and inflation pressure, temperature and size may contribute to inaccurate system readings. System accuracy testing should be performed after the tires are set at the correct pressure as shown on the safety compliance certification label. The tires should be warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a constant speed within the posted speed limit. AXLE/TRANSAXLE RATIO The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios are available, but usually are not a concern when dealing with speedometer/odometer concerns unless the gear ratio has been changed. WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel drive vehicles have several driven gears with various numbers of teeth available to correct input to the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears for correction. GENERAL DESCRIPTION The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance traveled. Ford Motor vehicles are well within those limits. The speed indication is biased high, except on police vehicles with certified calibration speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the actual speed. This is intended to protect the consumer against violating speed laws. Most customer concerns are related to speedometers reading too high at true speeds between 50 MPH and 65 MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10% greater than true speed. The speedometer head is an instrument which processes information sent to it by the rotating speedometer cable. If the system components send the Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information > Technical Service Bulletins > Speedometer/Odometer - Inaccurate Readings > Page 8837 wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the speedometer head odometer, start by checking the accuracy of the odometer even if the customer concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads established at mile increments or a known local course. If roads with mile markers are used, a five mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The odometer should be checked again to verify any corrective action. If the indicated speed error exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of drive gears, parts not splined or loose yoke nuts. If the vehicle has speed control, the speed accuracy can be checked using the verified odometer vs. time. The formula is as follows: 3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES: 60 MPH (96 Km/h) requires 60 seconds to cover one mile 55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile 50 MPH (80 Km/h) requires 72 seconds to cover one mile ARTICLE SUPERSEDED: 84-14-6, date 7/3/84 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2300, 2310, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Change Reminder Lamp > Component Information > Technical Service Bulletins > VMM Oil Change Indicator - Reset Procedure Oil Change Reminder Lamp: Technical Service Bulletins VMM Oil Change Indicator - Reset Procedure VEHICLE MAINTENANCE MONITOR (VMM) - OIL CHANGE INDICATOR - RESET PROCEDURE Article No. 90-3-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The VMM oil change indicator must be reset every time that the vehicle's oil is changed. This means... ^ The oil change indicator must be reset even if the vehicle's oil is changed before the VMM has indicated an oil change is needed. ^ The reset procedure is necessary to keep the information in the oil change indicator updated whenever the oil is changed. ^ If the reset procedure is not done, the VMM will indicate an oil change prematurely. ACTION: After the oil is changed, manually reset the VMM oil change indicator by using the following procedure. 1. With the ignition key in the OFF position, turn the ignition key to the RUN position, but do not start the engine. Figure 1 2. Within 15 seconds of turning the ignition to RUN, reset the VMM by inserting a straightened paper clip or similar tool through the reset hole and press firmly. The module is located in the top center of the instrument panel directly above the radio, Figure 1. ^ You will not be able to feel the reset switch operating because it has no perceptible movement when it is pushed. ^ The oil change message window will begin to flash when the switch has been activated. NOTE: IF THE RESET PROCEDURE IS NOT DONE WITHIN 15 SECONDS, THE PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. IF "NOW" IS FLASHING, DO NOT WAIT FOR IT TO STOP BEFORE PUSHING THE RESET SWITCH TO INITIATE THE OIL CHANGE RESET. 3. Continue to depress the reset switch until the oil change display stops flashing, which will take about 4 seconds. NOTE: IF THE RESET SWITCH IS RELEASED BEFORE THE OIL CHANGE DISPLAY STOPS FLASHING, THE RESET PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: Customer Interest Instrument Cluster Warning Lights - Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 8850 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Customer Interest for Oil Level Warning Indicator: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Oil Level Warning Indicator: Customer Interest Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster Warning Lights Dimly Lit Article No. 93-24-10 11/24/93 ^ LAMP - MALFUNCTION OF FOUR PIN LOW OIL LEVEL RELAY - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 ^ LAMPS - INSTRUMENT CLUSTER WARNING LIGHTS DIMLY LIT - VEHICLES BUILT AFTER 8/1/92 OR 1983-1993 VEHICLES THAT HAVE HAD SERVICE REPLACEMENT IGNITION SWITCHES AFTER 8/1/92 FORD: 1983 FAIRMONT 1983-89 CROWN VICTORIA, ESCORT 1983-93 MUSTANG, THUNDERBIRD 1983-94 PROBE 1984-86 LTD 1984-94 TEMPO LINCOLN-MERCURY: 1983 LN7, ZEPHYR 1983-87 CONTINENTAL, LYNX 1983-89 GRAND MARQUIS, TOWN CAR 1983-93 COUGAR 1984-86 CAPRI, MARQUIS 1984-94 TOPAZ LIGHT TRUCK: 1983-91 BRONCO 1983-93 ECONOLINE, F-150-350 SERIES, RANGER 1986-91 AEROSTAR 1991-93 EXPLORER ISSUE: The instrument cluster warning light(s) may be dimly lit or there may be a malfunction of the four pin low oil relay on vehicles so equipped. This could be due to the ignition switch. ACTION: If the vehicle displays the subject symptoms and meets the following conditions, replace the ignition switch. Refer to the appropriate Car or Light Truck Service Manual (Section 13-04 for 1983-1990 Cars, Section 11-04 for 1991-1993 Cars and Section 13-05 for 1983-1990 Light Trucks, Section 11-05 for 1991-1993 Light Trucks) for removal and installation procedures. Refer to the Parts Block in this article for correct parts usage. CONDITIONS ^ The vehicle has 14401 wiring attached to the P2 terminal of the ignition switch. Refer to the wiring schematic and/or Electrical And Vacuum Troubleshooting Manual (EVTM) for the concern vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 932410 > Nov > 93 > Instrument Cluster Warning Lights - Dimly Lit > Page 8860 ^ The vehicle is equipped with one of the ignition switches identified in the Ignition Switch Part Number Chart. NOTE: THE SERVICE PART NUMBERS FOR THE REPLACEMENT IGNITION SWITCHES WILL HAVE THE SAME PART NUMBERS AS THOSE REPLACED. THE NEW SWITCH HAS BEEN IMPROVED TO CORRECT THE SUBJECT ISSUE. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of The Bumper To Bumper For 1992/93 Models, Basic Warranty Coverage For All Other Models Except Lincolns. Major Component Warranty Coverage For Lincolns OPERATION DESCRIPTION TIME 932410A Replace Ignition Switch - 0.5 Hr. All Light and Compact Trucks DEALER CODING BASIC PART NO. CONDITION CODE 11572 X1 OASIS CODES: 201000, 201100, 206000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Oil Level Warning Indicator: > 89206 > Oct > 89 > Instrument Cluster/Radio - Memory Failures Oil Level Warning Indicator: All Technical Service Bulletins Instrument Cluster/Radio - Memory Failures ^ FUSE - MEMORY - CIRCUITS PROTECTED - SERVICE TIPS ^ INSTRUMENT CLUSTER - MEMORY FAILURES - SERVICE TIPS ^ RADIO - MEMORY FAILURES - SERVICE TIPS Article No. 89-20-6 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Instrument cluster or radio failures may be caused by a bad "Memory" fuse. This fuse controls the memory of the following items: ^ Vehicle Maintenance Monitor (oil level) ^ Radio Station Memory (and radio operation) ^ Electronic Instrument Cluster Memory (trip/fuel functions) ACTION: Check the 5 amp "Memory" fuse in the high current fuse cavity position "M". NOTE: THE EVTM USES THE TERM "HIGH CURRENT FUSE PANEL", WHILE THE SHOP MANUAL USES THE TERM "HIGH POWER DISTRIBUTION BOX". THESE TERMS REFER TO THE SAME COMPONENT. The high current fuse panel/high power distribution box is located in the engine compartment on the left-hand fender apron. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2200, 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 8865 Oil Level Warning Indicator: Description and Operation This system is used to indicate when engine oil level is 1-1/2 quarts or more below the specified level. The system consist an instrument panel warning lamp, electronic relay and a float type sensor which is located in the oil pan. The warning lamp will be illuminated during engine starting. If oil level is sufficient, the lamp will go out when engine is operating. If oil level is low, the lamp will remain on until engine oil is added or until ignition switch is placed in the off position. The module will take approximately 5 minutes to reset. If engine is started during this reset period, the last reading obtained will be displayed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Level Warning Indicator > Component Information > Technical Service Bulletins > Page 8866 Oil Level Warning Indicator: Testing and Inspection Fig. 12 Low Oil Level Indicator Diagnosis SYSTEM CHECK With oil at Full mark on dipstick and engine warm, start engine. Warning indicator should come on briefly in Start for bulb test, then go out. Turn engine Off. Drain 2 quarts of oil from engine. Wait for 5 minutes, then restart engine. Warning indicator should come On and stay On. If indicator does not come On, check the following; indicator, fuse, oil level relay and/or oil level sensor. SENSOR TEST If is best to conduct test with sensor in oil pan with hot oil to ensure oil properly drains from sensor. If removed from pan, sensor must first be submerged in warm oil to ensure proper positioning of float before testing. The sensor must be held horizontally during bench testing to ensure float remains correctly positioned. Connect positive lead of digital volt/ohmmeter to sensor terminal and negative lead to sensor housing. With sensor submerged in oil (engine full), meter should read Open. Resistance should be greater than 100,000 ohms. With sensor out of oil (oil drained), resistance should be less than 1000 ohms. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation Oil Pressure Gauge: Description and Operation The oil pressure indicating system is a magnetic type system, which consists of three primary coils, one of which is wound at a 90° angle to the other two. The coils form a magnetic field which varies in direction according to the variable resistance of the sender unit which is connected between two of them. A primary magnet, to which a shaft and pointer are attached, rotates to align to this primary field, resulting in pointer position. The bobbin/coil assembly is pressed into a metal housing which as two holes for dial mounting. The is no adjustment, calibration or maintenance required for these gauges. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Gauge > Component Information > Description and Operation > Page 8870 Fig. 8 Gauge Type Oil Pressure Indicator Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Switch <--> [Oil Pressure Sender] > Component Information > Locations Oil Pressure Switch: Locations Lower Right Hand Side, Front Of Engine, Below the Power Steering Bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation Oil Pressure Warning Lamp/Indicator: Description and Operation A red warning indicator glow when the oil pressure is below a prescribed valve. The indicator should come on when the ignition switch is first turned to the Run position. The indicator should go out within a few seconds after the engines starts, indicating that oil pressure is satisfactory. The oil switch is calibrated to close between 4.5-7.5 psi. The indicator is connect between the oil pressure switch unit (mounted on the engine) and the coil terminal of the ignition switch. On some vehicles only one warning indicator serving both the oil pressure switch and the temperature switch. These combined systems are identified by the word ENGINE on the warning indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Warning Lamp/Indicator > Component Information > Description and Operation > Page 8877 Oil Pressure Warning Lamp/Indicator: Testing and Inspection Disconnect temperature switch wire before testing oil pressure indicating system on vehicles that have an engine warning indicator. To test the oil pressure switch and warning indicator, turn ignition switch to Run, but do not start the engine. The warning indicator should come on. If the indicator does not come on, remove the wire from the switch terminal and connect wire to ground. If the indicator now comes on, the oil pressure switch is inoperative. Replace switch. If indicator does not come on with the switch wire connected to ground, the warning indicator is burned out or the system wiring is open. Replace indicator or service wiring. If indicator stays on with engine running and engine has adequate oil pressure, disconnect wire from oil pressure switch. The indicator should go out. If indicator goes out, replace oil pressure switch. If indicator does not go out, service shorted wiring between switch and indicator. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Body & Chassis Components Top Of Parking Brake Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > Customer Interest: > 91177 > Aug > 91 > Tape Player - Hissing Noise Maintenance Reminder Control Module: Customer Interest Tape Player - Hissing Noise Article No. 91-17-7 08/21/91 ^ RADIO - TAPE PLAYER - MAKES HISSING NOISE - CARS WITH VEHICLE MAINTENANCE MONITOR (VMM) ^ NOISE - "HISS" FROM TAPE PLAYER DURING QUIET PASSAGES - VEHICLES WITH VMM FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hissing noise may be heard from the tape player during quiet passages. This occurs because of electromagnetic interference from the transformer being picked up by the head of the tape player. ACTION: Install a new vehicle maintenance monitor. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-38, for service details. NOTE: SUSPECT VEHICLE MAINTENANCE MONITORS MUST BE REPLACED ONLY BY A VMM WITH A DATE CODE OF MAY 1990 OR LATER. THE DATE CODE IS ON A LABEL LOCATED ON THE TOP OF THE MODULE IN MONTH/DAY/YEAR FORMAT. FOR EXAMPLE, 10/09/90 MEANS OCTOBER 9, 1990. THIS ISSUE DOES NOT AFFECT 1991 MODELS. PART NUMBER PART NAME CLASS F1SZ-10E850-A Vehicle Maintenance Monitor B WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911707A Install Vehicle Maintenance 0.3 Hr. Monitor DEALER CODING BASIC PART NO. CONDITION CODE 10E850 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Maintenance Reminder Control Module: > 91177 > Aug > 91 > Tape Player - Hissing Noise Maintenance Reminder Control Module: All Technical Service Bulletins Tape Player - Hissing Noise Article No. 91-17-7 08/21/91 ^ RADIO - TAPE PLAYER - MAKES HISSING NOISE - CARS WITH VEHICLE MAINTENANCE MONITOR (VMM) ^ NOISE - "HISS" FROM TAPE PLAYER DURING QUIET PASSAGES - VEHICLES WITH VMM FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: A hissing noise may be heard from the tape player during quiet passages. This occurs because of electromagnetic interference from the transformer being picked up by the head of the tape player. ACTION: Install a new vehicle maintenance monitor. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-38, for service details. NOTE: SUSPECT VEHICLE MAINTENANCE MONITORS MUST BE REPLACED ONLY BY A VMM WITH A DATE CODE OF MAY 1990 OR LATER. THE DATE CODE IS ON A LABEL LOCATED ON THE TOP OF THE MODULE IN MONTH/DAY/YEAR FORMAT. FOR EXAMPLE, 10/09/90 MEANS OCTOBER 9, 1990. THIS ISSUE DOES NOT AFFECT 1991 MODELS. PART NUMBER PART NAME CLASS F1SZ-10E850-A Vehicle Maintenance Monitor B WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 911707A Install Vehicle Maintenance 0.3 Hr. Monitor DEALER CODING BASIC PART NO. CONDITION CODE 10E850 56 OASIS CODES: 207000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Maintenance Reminder Control Module: > 9038 > Jan > 90 > VMM Oil Change Indicator - Reset Procedure Maintenance Reminder Control Module: All Technical Service Bulletins VMM Oil Change Indicator Reset Procedure VEHICLE MAINTENANCE MONITOR (VMM) - OIL CHANGE INDICATOR - RESET PROCEDURE Article No. 90-3-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The VMM oil change indicator must be reset every time that the vehicle's oil is changed. This means... ^ The oil change indicator must be reset even if the vehicle's oil is changed before the VMM has indicated an oil change is needed. ^ The reset procedure is necessary to keep the information in the oil change indicator updated whenever the oil is changed. ^ If the reset procedure is not done, the VMM will indicate an oil change prematurely. ACTION: After the oil is changed, manually reset the VMM oil change indicator by using the following procedure. 1. With the ignition key in the OFF position, turn the ignition key to the RUN position, but do not start the engine. Figure 1 2. Within 15 seconds of turning the ignition to RUN, reset the VMM by inserting a straightened paper clip or similar tool through the reset hole and press firmly. The module is located in the top center of the instrument panel directly above the radio, Figure 1. ^ You will not be able to feel the reset switch operating because it has no perceptible movement when it is pushed. ^ The oil change message window will begin to flash when the switch has been activated. NOTE: IF THE RESET PROCEDURE IS NOT DONE WITHIN 15 SECONDS, THE PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. IF "NOW" IS FLASHING, DO NOT WAIT FOR IT TO STOP BEFORE PUSHING THE RESET SWITCH TO INITIATE THE OIL CHANGE RESET. 3. Continue to depress the reset switch until the oil change display stops flashing, which will take about 4 seconds. NOTE: IF THE RESET SWITCH IS RELEASED BEFORE THE OIL CHANGE DISPLAY STOPS FLASHING, THE RESET PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > All Other Service Bulletins for Maintenance Reminder Control Module: > 9038 > Jan > 90 > VMM Oil Change Indicator - Reset Procedure Maintenance Reminder Control Module: All Technical Service Bulletins VMM Oil Change Indicator Reset Procedure VEHICLE MAINTENANCE MONITOR (VMM) - OIL CHANGE INDICATOR - RESET PROCEDURE Article No. 90-3-8 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The VMM oil change indicator must be reset every time that the vehicle's oil is changed. This means... ^ The oil change indicator must be reset even if the vehicle's oil is changed before the VMM has indicated an oil change is needed. ^ The reset procedure is necessary to keep the information in the oil change indicator updated whenever the oil is changed. ^ If the reset procedure is not done, the VMM will indicate an oil change prematurely. ACTION: After the oil is changed, manually reset the VMM oil change indicator by using the following procedure. 1. With the ignition key in the OFF position, turn the ignition key to the RUN position, but do not start the engine. Figure 1 2. Within 15 seconds of turning the ignition to RUN, reset the VMM by inserting a straightened paper clip or similar tool through the reset hole and press firmly. The module is located in the top center of the instrument panel directly above the radio, Figure 1. ^ You will not be able to feel the reset switch operating because it has no perceptible movement when it is pushed. ^ The oil change message window will begin to flash when the switch has been activated. NOTE: IF THE RESET PROCEDURE IS NOT DONE WITHIN 15 SECONDS, THE PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. IF "NOW" IS FLASHING, DO NOT WAIT FOR IT TO STOP BEFORE PUSHING THE RESET SWITCH TO INITIATE THE OIL CHANGE RESET. 3. Continue to depress the reset switch until the oil change display stops flashing, which will take about 4 seconds. NOTE: IF THE RESET SWITCH IS RELEASED BEFORE THE OIL CHANGE DISPLAY STOPS FLASHING, THE RESET PROCEDURE MUST BE REDONE, STARTING FROM STEP 1 ABOVE. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Maintenance Reminder Control Module > Component Information > Technical Service Bulletins > Page 8904 Maintenance Reminder Control Module: Locations I/P Components Center Of Dash Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage Speedometer Module: Technical Service Bulletins Speedometer - Service Replacements With Pre-Set Mileage Article No. 93-12-9 06/09/93 SPEEDOMETER - ELECTRONIC INSTRUMENT CLUSTERS, PROGRAMMABLE SPEEDOMETER/ODOMETER MODULES - DIGITAL ELECTRONIC ODOMETERS - SERVICE REPLACEMENTS WITH PRE-SET VEHICLE MILEAGE FORD: 1985-92 THUNDERBIRD 1986-93 TAURUS 1989-92 PROBE 1992-93 CROWN VICTORIA LINCOLN-MERCURY: 1984-91 MARK VII 1984-93 CONTINENTAL 1985-92 COUGAR 1986-93 SABLE 1990-93 TOWN CAR 1992-93 GRAND MARQUIS LIGHT TRUCK: 1986-93 AEROSTAR 1992-93 ECONOLINE, F-150-350 SERIES 1993 VILLAGER ISSUE: Service replacement speedometer odometers, speedometer modules, electronic instrument clusters and PSOM (programmable speedometer/odometer module) clusters, with mileage preset to the mileage displayed on the removed cluster odometer, are now available. These components must be ordered through one of three Electronic Service Centers (Two (2) U.S.; One (1) Canadian). They will be provided on an exchange basis and will not be available through the parts depots. ACTION: If service is required, refer to the following ordering and shipping procedure. ORDERING PROCEDURE U.S. DEALERS The repair Form FPS 1878 must be filled out in sections 1A and 1B indicating the required vehicle information. A toll free phone call must be placed to the respective Electronic Service Center to relay the vehicle information: ^ Dealers who are normally serviced by the Detroit, New York and Atlanta Parts Distribution Centers should place their orders through the Eastern Electronic Service Center Call Line, 1-800-262-9606. ^ All other U.S. dealers should place their orders through the Western Electronic Service Center Call Line, 1-800-321-6969. CANADIAN DEALERS The repair Form 6125-2 must be filled out indicating the required vehicle information. To place an order through the Canadian Electronic Service Center, either fax the repair Form 6125-2 to FAX # 416-946-8975 or place a toll free phone call to 1-800-663-9974. ^ If the phone call or fax is placed to the Center before 4:00 p.m. on Monday through Thursday, the goal will be to provide the replacement cluster before close of business the following day. ^ If orders are placed on Friday or the day before a holiday, the cluster should be received on Monday or the day after the holiday. The clusters are shipped pre-paid freight. Assemblies shipped to Hawaii or Alaska should be received within forty-eight hours except on Fridays or the day before holidays. Saturday delivery is now available to dealers with Saturday operation hours. This service must be requested from the Service Center when placing the order. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 8909 SHIPPING PROCEDURES FOR REMOVED CLUSTER Service replacement assemblies will be shipped pre-paid freight. The return freight charge will be collect. Follow the Return Shipping Instructions enclosed in the container in which the assembly was received. The removed assembly must be returned to the Electronic Service Center in the same container. ^ Ensure that the original shipping label is completely removed from the outside of the shipping container. ^ Simply affix the collect return shipping label that is supplied. ^ Place the removed assembly in the container with a copy of the memo billing from the Electronic Service Center, and the completed manufacturer's copy of Form FPS 1878 (U.S.) or FPS 6125-2 (Canada). This will ensure proper procedure so that the core charge of $300.00 will not be billed. ^ The removed assembly must be returned to the Electronic Service Center within thirty calendar days or the core charge will be billed against the dealer parts account. HANDLING PROCEDURES FOR DIGITAL SPEEDOMETERS WITH UNKNOWN MILEAGE ACCUMULATION To comply with regulations pertaining to the accuracy of odometers, cores will be read to determine accuracy of the reported mileage. In nearly all instances, the mileage continues to accumulate in the odometer memory chip even though the odometer is non-functional. This mileage can be verified even though it is not visible on the removed odometer. The dealer must verify the mileage accumulated on the odometer. ^ If the mileage cannot be determined accurately, the dealer must indicate to the Electronic Service Center that the mileage is unknown. ^ In cases where the mileage is unknown, the law requires that we supply a replacement part with the mileage pre-set to "O" miles and the service odometer (circle "S") segment illuminated. ^ A sticker must be attached to the door indicating the mileage at the time of the service repair. COST AND WARRANTY INFORMATION The service assemblies will be billed on the monthly Dealer Parts Statement. Application is provided by part number, dealer cost and core charge. Refer to Dealer Service Manuals and the FPSD Parts and Accessories Price Listing. Repair Form FPS 1878 can be ordered from the Parts Distribution Center. Follow the normal parts allowance plus labor charge as shown in the Service Labor Time Standards Manual when requesting warranty reimbursement. The core charge should not be entered on the warranty claim form as there will not be a charge for the core if the removed assembly is returned to the Electronic Service Center within the specified 30-day period following receipt of the replacement assembly. DIGITAL ELECTRONIC ODOMETER REPLACEMENTS FOR UNSOLD NEW VEHICLES IN DEALER STOCK You must use a new digital odometer for unsold new vehicles in dealer stock. Simply enter the word "Stock" for the owner name on Form FPS 1878 and identify the order as a new unsold vehicle when placing the order. Dealer handling procedures will be the same as previously outlined. DEALER PARTS COUNTER RETAIL SALE There will be an occasion when it will be necessary to sell digital assemblies over the parts counter. Dealers must complete Form FPS 1878 (U.S.) or 6125-2 (Canada) and provide the same information as required for a service department repair. As with warranty repairs, the dealer must verify the mileage on the removed assembly. If the core is not received from the customer, you should charge the customer the core charge. You will be charged for the core if it is not returned. Orders will be processed the same day as received. SPECIFIC PART NUMBER ORDERING INFORMATION For 1984 thru 1987 Continental and all Mark VIII vehicles with an odometer concern, you can order just the NVM Module from the Service Centers (E4LY-17C269-A). If the concern is with the display, you can remove the NVM module from the cluster and order just the display (-10D922-), then install the NVM module into the replacement cluster. NOTE: ODOMETER MEMORY CONTROL ASSEMBLIES (-17C269-) HAVE TO BE RETURNED TO THE SERVICE CENTERS USING THE PROCEDURES AS PREVIOUSLY OUTLINED. THERE WILL BE A $300.00 CORE CHARGE IF YOU DO NOT RETURN THIS MODULE WITHIN 30 CALENDAR DAYS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 8910 If a cluster is needed for a vehicle prior to the 1984 model year, order it from your FPSD Parts Distribution Center. Analog PSOM components (tachometers and gauges) may now be ordered from your FPSD Distribution Center. You no longer have to order the entire cluster for those type of concerns. For any cluster with a speedometer/odometer concern, the entire cluster must be ordered from the Electronic Service Center. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 8911 When ordering an Analog PSOM cluster or 1992-93 Aerostar EIC, refer to Figures 1 and 2. The Service Center will need additional information concerning the PSOM Conversion Constant. This constant is important for correct vehicle performance. Please refer to the following procedures in your 1993 Body/Chassis Service Manuals for determining or changing the PSOM conversion constant. These procedures apply to both 1992 and 1993 vehicles equipped with PSOM clusters. ^ 1993 Aerostar, Ranger, Explorer Body/Chassis Service Manual, Page 13-02B-7, Test Step C4 through Page 13-02B-9, Test Step C7. ^ 1993 Econoline, F-150,F-250, F350, Bronco, F-super Duty Body/Chassis Service Manual, Page 13-02A-7, Test Step C4 through Page 13-02A-8, Test Step C7. NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 8912 IF A VEHICLE HAS EITHER HAD THE TIRE SIZE/TYPE CHANGED, OR HAS HAD MODIFICATIONS TO THE REAR AXLE, IT IS NECESSARY TO CHANGE THE PSOM CONVERSION CONSTANT. THIS CONVERSION CONSTANT CAN BE CHANGED AT THE DEALERSHIP SO IT IS NOT NECESSARY TO ORDER AN ENTIRE CLUSTER IN THESE CASES. TECHNICAL ASSISTANCE An Electronic Instrument Cluster Help Line is available at 1-800-461-6945 to assist with any technical concerns involving the digital electronic odometer or related wiring or hardware. A PSOM (Programmable Speedometer/Odometer Module) Cluster Help Line is available at 1-800-523-7763 to assist with any technical concerns involving the PSOM clusters or related wiring or hardware. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-14 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Buzzer > Component Information > Description and Operation Seat Belt Reminder Buzzer: Description and Operation SAFETY BELT WARNING CHIME CIRCUITRY When the ignition switch is turned to the RUN or START position, power is supplied to the tone generator chime assembly. The thermal timer supplies power to one side of the warning lamp (from 4 to 8 seconds) through the passive restraint module. Power is also supplied to one side of the warning lamp when either of the passive belt reel switches is open (shoulder belt disconnected), or whenever either shoulder belt transport is not properly located at the "B" pillar after the lap belt warning indication period is over. The opposite side of the lamp goes directly to ground. The chime goes to ground through the LH seat lap belt buckle switch, or through the passive restraint module, whenever either of the passive belt reel switches is open. All modes of operation use a constant (non-flashing) signal for the lamp. SAFETY BELT WARNING INDICATOR The safety belt warning indicator lamp in the instrument cluster will illuminate four to eight seconds. In the unlikely event the shoulder belt should stall before it reaches the B-pillar, the indicator lamp will remain illuminated after nine seconds and the chime will sound after 16 seconds until the shoulder belt is in its locked position at the B-pillar. If only the indicator lamp remains illuminated, check to ensure both shoulder belts are latched to the emergency release buckle. If they are latched, and the indicator lamp and chime remain on, perform Manual Override System procedures before driving the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled Seat Belt Reminder Lamp: Customer Interest Seat Belt Warning Lamp - Stays ON With Belt Buckled LAMP-WARNING STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES SAFETY BELT-WARNING LAMP STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES Article No. 89-14-1 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A safety belt warning lamp that stays "on" even though the safety belt is buckled may be caused by the passive restraint control assembly connectors. The two connectors may have been installed into the control assembly and not taped back to the wire harness on Canadian units without the motorized passive restraint system. Also, the jumper wire assembly to make sure of proper warning lamp/chime operation was not Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > Customer Interest: > 89141 > Jul > 89 > Seat Belt Warning Lamp - Stays ON With Belt Buckled > Page 8924 installed. ACTION: Disconnect passive restraint control assembly connectors and install a jumper wire assembly. Refer to the following procedure for service details. 1. Remove the left hand interior trim panel in the luggage compartment. Refer to the 1989 Thunderbird/Cougar Shop Manual, Page 45-03-05. 2. Disconnect both passive restraint control assembly connectors and tape them back to the wire harness, Figure 1. 3. Install a jumper wire assembly (E9SZ-14K691-A), Figure 1. 4. Reinstall the luggage compartment trim panel. PART NUMBER PART NAME CLASS E9SZ-14K691-A Jumper Wire Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Safety Restraint Warranty Coverage OPERATION DESCRIPTION TIME 891401A Install Jumper Wire 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 14A504 79 OASIS CODES: 1051, 2300, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89141 > Jul > 89 > Seat Belt Warning Lamp Stays ON With Belt Buckled Seat Belt Reminder Lamp: All Technical Service Bulletins Seat Belt Warning Lamp - Stays ON With Belt Buckled LAMP-WARNING STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES SAFETY BELT-WARNING LAMP STAYS "ON" WHEN SAFETY BELT IS BUCKLED-CANADIAN VEHICLES Article No. 89-14-1 Figure 1 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A safety belt warning lamp that stays "on" even though the safety belt is buckled may be caused by the passive restraint control assembly connectors. The two connectors may have been installed into the control assembly and not taped back to the wire harness on Canadian units without the motorized passive restraint system. Also, the jumper wire assembly to make sure of proper warning lamp/chime operation was not Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 89141 > Jul > 89 > Seat Belt Warning Lamp Stays ON With Belt Buckled > Page 8930 installed. ACTION: Disconnect passive restraint control assembly connectors and install a jumper wire assembly. Refer to the following procedure for service details. 1. Remove the left hand interior trim panel in the luggage compartment. Refer to the 1989 Thunderbird/Cougar Shop Manual, Page 45-03-05. 2. Disconnect both passive restraint control assembly connectors and tape them back to the wire harness, Figure 1. 3. Install a jumper wire assembly (E9SZ-14K691-A), Figure 1. 4. Reinstall the luggage compartment trim panel. PART NUMBER PART NAME CLASS E9SZ-14K691-A Jumper Wire Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Safety Restraint Warranty Coverage OPERATION DESCRIPTION TIME 891401A Install Jumper Wire 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 14A504 79 OASIS CODES: 1051, 2300, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear Tie Rod End: All Technical Service Bulletins Steering - Clunk/Rattle/Premature Tire Wear Article No. 93-13-2 06/23/93 ^ STEERING - POWER - INNER TIE ROD IN-VEHICLE REPLACEMENT PROCEDURE ^ STEERING - POWER - LACK OF CENTER FEEL AND VEHICLE WANDER ^ TIE ROD - INNER - IN-VEHICLE REPLACEMENT PROCEDURE ^ TIRES - FRONT - PREMATURE WEAR ^ NOISE - "CLUNK" OR "RATTLE" FROM FRONT END - INNER TIE ROD IN-VEHICLE REPLACEMENT PROCEDURE ^ SHUDDER DURING DECELERATION/BRAKING FORD: 1986-93 MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1991-93 ESCORT LINCOLN-MERCURY: 1986-92 MARK VII 1986-93 CONTINENTAL, COUGAR, SABLE, TOPAZ 1991-93 TRACER 1993 MARK VIII LIGHT TRUCK: 1986-93 AEROSTAR ISSUE: An inner tie rod in-vehicle replacement procedure has been developed for the subject vehicles. The inner tie rod is worn if it exhibits any lash or axial free-play. Worn inner tie rods may exhibit some of the following symptoms: ^ "Clunk" or "rattle" noise in the front end during vehicle deceleration or cruise operation modes when going over small bumps, etc. ^ Front tire wear ^ Inconsistent alignment toe setting by the service specialist ^ Lack of center feel ^ Vehicle wanders ^ Vehicle shudder during decel/braking ACTION: If service is required, use the following service procedure to install the inner tie rod assemblies. CAUTION: SERVICE AND REPAIR PROCEDURES DESCRIBED IN THE SERVICE MANUALS ARE TO BE MODIFIED PER THIS TSB ARTICLE. ALL SERVICE MANUAL NOTES, CAUTIONS AND WARNINGS SHOULD BE OBSERVED. THESE INNER TIE ROD PARTS MUST BE INSTALLED BY A QUALIFIED TECHNICIAN, OTHERWISE AN UNSAFE VEHICLE AND PERSONAL INJURY MAY RESULT. SAFE AND RELIABLE INSTALLATION OF STEERING/CHASSIS PARTS REQUIRE EXPERIENCE AND TOOLS SPECIALLY DESIGNED FOR THE JOB. DIAGNOSIS 1. Check for "clunk" noise, with the window down, engine OFF, steering column unlocked, by turning the steering wheel +/- 45~. ^ For the steel on steel type ball joints, a metal "clunk" noise may be heard. ^ For the steel on plastic type joints, refer to Step 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8936 2. Raise the front of the vehicle. a. With the tires unweighted, shake the tire from top/bottom (12/6 o'clock position) to determine wheel bearing play. b. Compare with left/right (9/3 o'clock position) tire shake which will also include the outer and inner tie rod lash. c. Holding the inner tie rod spindle during the latter tire shake may help verify the inner versus outer tie rod looseness. See Figure 1. NOTE: A MECHANICALLY LEVERAGED TOOL SUCH AS A CROWBAR MAY BE USEFUL FOR THIS DIAGNOSIS WHEN APPLIED TO THE TIRE. 3. Disregard the Service Manual pull test with two (2) to ten (10) pound pull requirement, since this may not be a reliable test. 4. The inner tie rod is worn and must be replaced if it exhibits any lash or axial free-play. INNER TIE ROD (GEAR IN-VEHICLE) REMOVAL 1. Prepare the vehicle for servicing. a. Unlock the steering column by turning the ignition key. b. Engage the parking brake. c. Raise and support the vehicle. d. Clean any loose dirt or oil from the power steering gear and boot bellows. 2. Disconnect the outer tie rod end from the steering knuckle. a. Loosen the jam nut and keep flush with outer tie rod. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8937 b. Disconnect the outer tie rod from the steering knuckle. Remove the cotter pin and castle nut by using Tie Rod End Remover TOOL-3290-D or equivalent, Figure 2. 3. Mark the threads at the jam nut location. a. Count and record the number of turns to remove the outer tie rod end from the inner tie rod. This information is useful in estimating the alignment setting. b. Remove the jam nut from the inner tie rod spindle. 4. Remove the left and right steering gear boot bellows along with the breather tube. NOTE MARK THE BREATHER TUBE AND BOOT BELLOWS LARGE ID CLAMP'S ORIENTATION ON THE HOUSING FOR LATER INSTALLATION REFERENCE. CAUTION: USE CARE NOT TO DAMAGE THE BELLOWS. 5. FOR STEEL ON STEEL BALL JOINTS, remove the rivet or rollpin securing the inner tie rod to the steering gear rack. a. Use a sharp chisel to gently pry up the rivet or rollpin. DO NOT CUT OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8938 b. Use side cutters or equivalent to remove the rivet, Figures 3 & 4. CAUTION: THE RIVET HAS A STEEL CORE WHICH WILL DEFORM THE STEERING GEAR RACK THREADS IF IT IS NOT COMPLETELY REMOVED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8939 c. Use Locknut Pin Remover D81P-3504-N or equivalent to remove the rollpin, Figure 5. If the rivet is not accessible, unscrew (see Step 6) the inner tie rod until it is accessible (less than 1 full turn). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8940 6. Remove the inner tie rod from the steering gear rack using a wrench on the rack teeth in combination with the following tools as shown in Figures 6 and 7. ^ Yoke Locknut Wrench T81P-3504-G or Inner Tie Rod Socket Tool D90P-3290-A - Tempo/Topaz ^ Nut Wrench T74P-3504-U - Aerostar, Thunderbird, Cougar, Continental, Mark VII & Mark VIII, Mustang, Taurus and Sable An adjustable wrench may be used on the rack teeth. CAUTION: HAVE STEERING GEAR AT OR NEAR THE FULL TURN (LOCK) POSITION. USE A WRENCH ON THE RACK TEETH (FLAT) TO RESIST RACK ROTATION AND PREVENT DAMAGE TO THE PINION DURING REMOVAL AND INSTALLATION. ALLOWING THE RACK AND PINION TO INTERNALLY RESIST TIGHTENING OR LOOSENING TORQUES MAY CAUSE DAMAGE TO THE STEERING GEAR. 7. Clean the following components. ^ The steering gear housing OD interface and boot bellows ID (each end). ^ The steering gear housing ID and rack as required. ^ All parts to be inspected and replaced if necessary. Make sure the rack threads are clean and dry. CAUTION: THOROUGHLY REMOVE ANY ABRASIVE MATERIAL. THESE CONTAMINANTS ARE EXTREMELY HARMFUL TO THE HIGH PRESSURE STEERING GEAR RACK SEAL INTERFACE. INSTALLATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8941 1. Refer to the Parts Block in this article for correct parts usage. 2. Replenish any grease (C3AZ-19578-A) which may have been removed from the rack teeth. 3. For replacement plastic on steel ball joints that do not have the rivet feature, proceed as follows: a. Clean any contamination, dirt or oil from the rack threads and wipe dry. CAUTION: THOROUGHLY REMOVE ANY ABRASIVE MATERIAL. THESE CONTAMINANTS ARE EXTREMELY HARMFUL TO THE HIGH PRESSURE STEERING GEAR RACK SEAL INTERFACE. b. Apply locking compound (E2FZ-19544-B) (Loctite 262 or equivalent) to the steering gear rack threads. The thread locking compound will set sufficiently so that the vehicle may be driven when the remove and replace procedure is complete, including the alignment toe. 4. Hold the rack securely as shown in Figure 7. If both inner tie rods are replaced, tighten each inner tie rod separately. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 55-60 lb.ft. (75-81 N-m). ^ For Tempo/Topaz, the torque specification is 40-50 lb.ft. (54-68 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8942 5. For ball joints that use the rivet (N804152-S), install rivet (which replaces the rollpin) using channel locks or equivalent, Figure 8. 6. Check the inner tie rod function by moving the tie rod spindle. Handshake in various directions. 7. Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the inner tie rod groove where the boot bellows attach with a clamp to the inner tie rod. This allows for toe-in adjustments without twisting the bellows. 8. Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the steering gear housing OD/boot bellows' large OD interface. This layer of grease will help keep water and contamination from entering the ball joint and rack sealing sur faces. 9. Install the boot bellows and breather tube. a. Check to see that the boot bellows are properly positioned over the steering gear housing bead at the large ID, and are in the tie rod groove at the small ID. b. Check to see that the boot bellows are not twisted and that the vent tube is securely inserted into the vent nipple AT BOTH BOOTS. c. At the boot bellows/housing large ID, install screw type (hose) clamps and position screw axis as shown in Figure 9. Tighten screw to 1.7-2.5 lb.ft. (2.3-3.4 N-m). CAUTION: DO NOT USE TIE STRAPS TO SECURE BOOT BELLOWS TO STEERING GEAR HOUSING. d. At the boot bellows/inner tie rod small ID, install clamp. 10. Install the jam nut and apply Disc Brake Caliper Slide Grease (D7AZ-19590-A) or equivalent, to the inner tie rod threads. 11. Install the outer tie rod to the inner tie rod. Count the number of turns recorded earlier. This approximates the previous alignment toe setting. 12. Tighten the jam nut against the outer tie rod end. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-50 lb.ft. (47-68 N-m). ^ For Tempo/Topaz, the torque specification is 42-50 lb.ft. (57-68 N-m). 13. Connect the outer tie rod to the steering knuckle. a. Tighten the castle nut at the steering knuckle to a minimum 27 lb.ft. (36 N-m). b. Continue tightening direction until the hole allows installation of a new cotter pin. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-47 lb.ft. (47-64 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8943 ^ For Tempo/Topaz, the torque specification is 27-32 lb.ft. (36-43 N-m). 14. Align the front end to specification. Refer to the appropriate Vehicle Service Manual for service details. OTHER APPLICABLE ARTICLES: 90-11-3 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1991 Lincolns And All 1992/93 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 931302A Install Both Tie Rod End 1.5 Hrs. Assemblies - Escort/Tracer 931302B Install Both Tie Rod End 1.9 Hrs. Assemblies - Tempo/Topaz 931302C Install Both Tie Rod End 1.6 Hrs. Assemblies - Taurus/Sable 931302D Install Both Tie Rod End 1.6 Hrs. Assemblies - Continental 931302E Install Both Tie Rod End 1.5 Hrs. Assemblies - Thunderbird/Cougar/ Mark/Mustang 931302F Install Both Tie Rod End 1.7 Hrs. Assemblies - Aerostar DEALER CODING BASIC PART NO. CONDITION CODE 3280 30 OASIS CODES: 303000, 390000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8949 2. Raise the front of the vehicle. a. With the tires unweighted, shake the tire from top/bottom (12/6 o'clock position) to determine wheel bearing play. b. Compare with left/right (9/3 o'clock position) tire shake which will also include the outer and inner tie rod lash. c. Holding the inner tie rod spindle during the latter tire shake may help verify the inner versus outer tie rod looseness. See Figure 1. NOTE: A MECHANICALLY LEVERAGED TOOL SUCH AS A CROWBAR MAY BE USEFUL FOR THIS DIAGNOSIS WHEN APPLIED TO THE TIRE. 3. Disregard the Service Manual pull test with two (2) to ten (10) pound pull requirement, since this may not be a reliable test. 4. The inner tie rod is worn and must be replaced if it exhibits any lash or axial free-play. INNER TIE ROD (GEAR IN-VEHICLE) REMOVAL 1. Prepare the vehicle for servicing. a. Unlock the steering column by turning the ignition key. b. Engage the parking brake. c. Raise and support the vehicle. d. Clean any loose dirt or oil from the power steering gear and boot bellows. 2. Disconnect the outer tie rod end from the steering knuckle. a. Loosen the jam nut and keep flush with outer tie rod. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8950 b. Disconnect the outer tie rod from the steering knuckle. Remove the cotter pin and castle nut by using Tie Rod End Remover TOOL-3290-D or equivalent, Figure 2. 3. Mark the threads at the jam nut location. a. Count and record the number of turns to remove the outer tie rod end from the inner tie rod. This information is useful in estimating the alignment setting. b. Remove the jam nut from the inner tie rod spindle. 4. Remove the left and right steering gear boot bellows along with the breather tube. NOTE MARK THE BREATHER TUBE AND BOOT BELLOWS LARGE ID CLAMP'S ORIENTATION ON THE HOUSING FOR LATER INSTALLATION REFERENCE. CAUTION: USE CARE NOT TO DAMAGE THE BELLOWS. 5. FOR STEEL ON STEEL BALL JOINTS, remove the rivet or rollpin securing the inner tie rod to the steering gear rack. a. Use a sharp chisel to gently pry up the rivet or rollpin. DO NOT CUT OFF. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8951 b. Use side cutters or equivalent to remove the rivet, Figures 3 & 4. CAUTION: THE RIVET HAS A STEEL CORE WHICH WILL DEFORM THE STEERING GEAR RACK THREADS IF IT IS NOT COMPLETELY REMOVED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8952 c. Use Locknut Pin Remover D81P-3504-N or equivalent to remove the rollpin, Figure 5. If the rivet is not accessible, unscrew (see Step 6) the inner tie rod until it is accessible (less than 1 full turn). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8953 6. Remove the inner tie rod from the steering gear rack using a wrench on the rack teeth in combination with the following tools as shown in Figures 6 and 7. ^ Yoke Locknut Wrench T81P-3504-G or Inner Tie Rod Socket Tool D90P-3290-A - Tempo/Topaz ^ Nut Wrench T74P-3504-U - Aerostar, Thunderbird, Cougar, Continental, Mark VII & Mark VIII, Mustang, Taurus and Sable An adjustable wrench may be used on the rack teeth. CAUTION: HAVE STEERING GEAR AT OR NEAR THE FULL TURN (LOCK) POSITION. USE A WRENCH ON THE RACK TEETH (FLAT) TO RESIST RACK ROTATION AND PREVENT DAMAGE TO THE PINION DURING REMOVAL AND INSTALLATION. ALLOWING THE RACK AND PINION TO INTERNALLY RESIST TIGHTENING OR LOOSENING TORQUES MAY CAUSE DAMAGE TO THE STEERING GEAR. 7. Clean the following components. ^ The steering gear housing OD interface and boot bellows ID (each end). ^ The steering gear housing ID and rack as required. ^ All parts to be inspected and replaced if necessary. Make sure the rack threads are clean and dry. CAUTION: THOROUGHLY REMOVE ANY ABRASIVE MATERIAL. THESE CONTAMINANTS ARE EXTREMELY HARMFUL TO THE HIGH PRESSURE STEERING GEAR RACK SEAL INTERFACE. INSTALLATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8954 1. Refer to the Parts Block in this article for correct parts usage. 2. Replenish any grease (C3AZ-19578-A) which may have been removed from the rack teeth. 3. For replacement plastic on steel ball joints that do not have the rivet feature, proceed as follows: a. Clean any contamination, dirt or oil from the rack threads and wipe dry. CAUTION: THOROUGHLY REMOVE ANY ABRASIVE MATERIAL. THESE CONTAMINANTS ARE EXTREMELY HARMFUL TO THE HIGH PRESSURE STEERING GEAR RACK SEAL INTERFACE. b. Apply locking compound (E2FZ-19544-B) (Loctite 262 or equivalent) to the steering gear rack threads. The thread locking compound will set sufficiently so that the vehicle may be driven when the remove and replace procedure is complete, including the alignment toe. 4. Hold the rack securely as shown in Figure 7. If both inner tie rods are replaced, tighten each inner tie rod separately. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 55-60 lb.ft. (75-81 N-m). ^ For Tempo/Topaz, the torque specification is 40-50 lb.ft. (54-68 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8955 5. For ball joints that use the rivet (N804152-S), install rivet (which replaces the rollpin) using channel locks or equivalent, Figure 8. 6. Check the inner tie rod function by moving the tie rod spindle. Handshake in various directions. 7. Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the inner tie rod groove where the boot bellows attach with a clamp to the inner tie rod. This allows for toe-in adjustments without twisting the bellows. 8. Apply steering gear grease (C3AZ-19578-A) (ESW-M1CC877-A) to the steering gear housing OD/boot bellows' large OD interface. This layer of grease will help keep water and contamination from entering the ball joint and rack sealing sur faces. 9. Install the boot bellows and breather tube. a. Check to see that the boot bellows are properly positioned over the steering gear housing bead at the large ID, and are in the tie rod groove at the small ID. b. Check to see that the boot bellows are not twisted and that the vent tube is securely inserted into the vent nipple AT BOTH BOOTS. c. At the boot bellows/housing large ID, install screw type (hose) clamps and position screw axis as shown in Figure 9. Tighten screw to 1.7-2.5 lb.ft. (2.3-3.4 N-m). CAUTION: DO NOT USE TIE STRAPS TO SECURE BOOT BELLOWS TO STEERING GEAR HOUSING. d. At the boot bellows/inner tie rod small ID, install clamp. 10. Install the jam nut and apply Disc Brake Caliper Slide Grease (D7AZ-19590-A) or equivalent, to the inner tie rod threads. 11. Install the outer tie rod to the inner tie rod. Count the number of turns recorded earlier. This approximates the previous alignment toe setting. 12. Tighten the jam nut against the outer tie rod end. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-50 lb.ft. (47-68 N-m). ^ For Tempo/Topaz, the torque specification is 42-50 lb.ft. (57-68 N-m). 13. Connect the outer tie rod to the steering knuckle. a. Tighten the castle nut at the steering knuckle to a minimum 27 lb.ft. (36 N-m). b. Continue tightening direction until the hole allows installation of a new cotter pin. ^ For Mustang, Mark, Thunderbird, Cougar, Taurus, Sable, Continental, Aerostar, the torque specification is 35-47 lb.ft. (47-64 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > All Other Service Bulletins for Seat Belt Reminder Lamp: > 93132 > Jun > 93 > Steering - Clunk/Rattle/Premature Tire Wear > Page 8956 ^ For Tempo/Topaz, the torque specification is 27-32 lb.ft. (36-43 N-m). 14. Align the front end to specification. Refer to the appropriate Vehicle Service Manual for service details. OTHER APPLICABLE ARTICLES: 90-11-3 WARRANTY STATUS: Eligible Under Bumper To Bumper For 1991 Lincolns And All 1992/93 Models, Basic Warranty Coverage For All Other Models OPERATION DESCRIPTION TIME 931302A Install Both Tie Rod End 1.5 Hrs. Assemblies - Escort/Tracer 931302B Install Both Tie Rod End 1.9 Hrs. Assemblies - Tempo/Topaz 931302C Install Both Tie Rod End 1.6 Hrs. Assemblies - Taurus/Sable 931302D Install Both Tie Rod End 1.6 Hrs. Assemblies - Continental 931302E Install Both Tie Rod End 1.5 Hrs. Assemblies - Thunderbird/Cougar/ Mark/Mustang 931302F Install Both Tie Rod End 1.7 Hrs. Assemblies - Aerostar DEALER CODING BASIC PART NO. CONDITION CODE 3280 30 OASIS CODES: 303000, 390000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Seat Belt Reminder Lamp > Component Information > Technical Service Bulletins > Page 8957 Seat Belt Reminder Lamp: Description and Operation SAFETY BELT WARNING CHIME CIRCUITRY When the ignition switch is turned to the RUN or START position, power is supplied to the tone generator chime assembly. The thermal timer supplies power to one side of the warning lamp (from 4 to 8 seconds) through the passive restraint module. Power is also supplied to one side of the warning lamp when either of the passive belt reel switches is open (shoulder belt disconnected), or whenever either shoulder belt transport is not properly located at the "B" pillar after the lap belt warning indication period is over. The opposite side of the lamp goes directly to ground. The chime goes to ground through the LH seat lap belt buckle switch, or through the passive restraint module, whenever either of the passive belt reel switches is open. All modes of operation use a constant (non-flashing) signal for the lamp. SAFETY BELT WARNING INDICATOR The safety belt warning indicator lamp in the instrument cluster will illuminate four to eight seconds. In the unlikely event the shoulder belt should stall before it reaches the B-pillar, the indicator lamp will remain illuminated after nine seconds and the chime will sound after 16 seconds until the shoulder belt is in its locked position at the B-pillar. If only the indicator lamp remains illuminated, check to ensure both shoulder belts are latched to the emergency release buckle. If they are latched, and the indicator lamp and chime remain on, perform Manual Override System procedures before driving the vehicle. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Brake Pad Wear Sensor > Component Information > Locations Brake Pad Wear Sensor: Locations At Respective Wheels, On Brake Housing Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations I/P Components LH Side Of Dash, Near Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations Door Switch: Locations Body & Chassis Components In Respective Door Latch Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Door Switch > Component Information > Locations > Page 8968 Door Switch: Service and Repair REMOVAL and INSTALLATION 1. Remove connector at switch. 2. Using an ohmmeter such as Rotunda Digital Volt Ohm Meter 007-00001, or an equivalent probe between switch terminal and ground (latch). 3. With door in latched (fully closed) position, switch should be open. 4. With door open, switch must be closed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level Fuel Gauge Sender: Customer Interest Fuel Gauge - Intermittently Shows Increase In Fuel Level Article No. 91-13-4 06/26/91 GAUGE - FUEL - ELECTRONIC - SHOWS FUEL INCREASES OR DISPLAYS "CO" INTERMITTENTLY - VEHICLES BUILT FROM 6/1/89 TO 1/15/90 FORD: 1989-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989-90 AEROSTAR This TSB article is being republished in its entirety to correct the fuel pump/sender part number listed for the 1989 Taurus/Sable. ISSUE: The electronic instrument cluster (EIC) fuel gauge may intermittently show an increase in the fuel level or display circuit open "CO". This happens when the fuel tank level is above 1/2 full. The condition is caused by either an intermittent high resistance contact or an open circuit internal to the fuel sender unit. ACTION: Perform the diagnostic procedures outlined in the appropriate Shop Manual, Sections 33-05 for Cars and 13-01A for the Aerostar to determine if a new fuel pump/sender is required. 1. Replace the fuel sender assembly. Refer to the appropriate Shop Manual, Sections 24-35 for cars and 13-03 for the Aerostar for service details. FUEL PUMP/SENDER APPLICATION CHART MODEL YEAR APPLICATION DESCRIPTION PART NUMBER 1989 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-C 1990 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-A 1989-90 Continental Fuel Pump/Sender E90Z-9H307-A 1989-90 Mark VII Fuel Pump/Sender E5LY-9275-A 1989 Town Car Fuel Pump/Sender E5VY-9275-A 1990 Town Car Fuel Pump/Sender F0VY-9H307-C 1989-90 Thunderbird/Cougar Fuel Pump/Sender F1SZ-9H307-B 1989-90 Aerostar Fuel Pump/Sender E99Z-9H307-A PART NUMBER PART NAME CLASS F0DZ-9H307-C Fuel Pump/Sender C E90Z-9H307-A Fuel Pump/Sender B F0DZ-9H307-A Fuel Pump/Sender B E5LY-9275-A Fuel Pump/Sender R E5VY-9275-A Fuel Pump/Sender BM F0VY-9H307-C Fuel Pump/Sender B F1SZ-9H307-B Fuel Pump/Sender B E99Z-9H307-A Fuel Pump/Sender B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-7-11 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level > Page 8977 OPERATION DESCRIPTION TIME 911304A Replace Fuel Pump/Sender 1.5 Hrs. - 1990 Town Car, Thunderbird, Cougar 911304A Replace Fuel Pump/Sender 1.2 Hrs. - Aerostar 911304A Replace Fuel Pump/Sender 1.0 Hr. - Continental, 1989 Town Car 911304A Replace Fuel Pump/Sender 0.9 Hr. - Taurus, Sable, Mark VII DEALER CODING BASIC PART NO. CONDITION CODE 9H307 28 OASIS CODES: 204000, 204100, 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Customer Interest: > 891411 > Jul > 89 > Fuel Gauge - Occasionally Sticks In FULL Position Fuel Gauge Sender: Customer Interest Fuel Gauge - Occasionally Sticks In FULL Position GAUGE-FUEL-OCCASIONALLY STICKS IN "FULL" POSITION Article No. 89-14-11 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A fuel gauge that ocassionally sticks in the "FULL" position may be caused by a binding fuel pump float assembly. The fuel pump float binds on the inner surface of the fuel tank and holds the float in the "FULL" position. This is most likely to occur when driving on unpaved or rough roads. ACTION: Modify the fuel pump float to prevent the binding condition. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 24-12 for removal and installation instructions. 1. Remove the fuel pump assembly. 2. Unscrew the nut from the end of the float rod assembly. 3. Remove the float from the rod. 4. Using a sharp knife, cut 3/8" to 1/2" (9.525 mm to 12.7 mm) off the end of the float. 5. Reinstall the shortened float on the float rod. 6. Install float retaining nut. NOTE: ALLOW CLEARANCE BETWEEN THE RETAINING NUT AND FLOAT SO THAT THE FLOAT SPINS FREELY. 7. Using diagonal cutters, trim the float rod so that it is flush with the retaining nut. 8. Reinstall the fuel sender. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891411A Modify Float 1.3 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 41 OASIS CODES: 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Intermittently Shows Increase In Fuel Level Article No. 91-13-4 06/26/91 GAUGE - FUEL - ELECTRONIC - SHOWS FUEL INCREASES OR DISPLAYS "CO" INTERMITTENTLY - VEHICLES BUILT FROM 6/1/89 TO 1/15/90 FORD: 1989-90 TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1989-90 CONTINENTAL, COUGAR, MARK VII, SABLE, TOWN CAR LIGHT TRUCK: 1989-90 AEROSTAR This TSB article is being republished in its entirety to correct the fuel pump/sender part number listed for the 1989 Taurus/Sable. ISSUE: The electronic instrument cluster (EIC) fuel gauge may intermittently show an increase in the fuel level or display circuit open "CO". This happens when the fuel tank level is above 1/2 full. The condition is caused by either an intermittent high resistance contact or an open circuit internal to the fuel sender unit. ACTION: Perform the diagnostic procedures outlined in the appropriate Shop Manual, Sections 33-05 for Cars and 13-01A for the Aerostar to determine if a new fuel pump/sender is required. 1. Replace the fuel sender assembly. Refer to the appropriate Shop Manual, Sections 24-35 for cars and 13-03 for the Aerostar for service details. FUEL PUMP/SENDER APPLICATION CHART MODEL YEAR APPLICATION DESCRIPTION PART NUMBER 1989 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-C 1990 Taurus/Sable Fuel Pump/Sender F0DZ-9H307-A 1989-90 Continental Fuel Pump/Sender E90Z-9H307-A 1989-90 Mark VII Fuel Pump/Sender E5LY-9275-A 1989 Town Car Fuel Pump/Sender E5VY-9275-A 1990 Town Car Fuel Pump/Sender F0VY-9H307-C 1989-90 Thunderbird/Cougar Fuel Pump/Sender F1SZ-9H307-B 1989-90 Aerostar Fuel Pump/Sender E99Z-9H307-A PART NUMBER PART NAME CLASS F0DZ-9H307-C Fuel Pump/Sender C E90Z-9H307-A Fuel Pump/Sender B F0DZ-9H307-A Fuel Pump/Sender B E5LY-9275-A Fuel Pump/Sender R E5VY-9275-A Fuel Pump/Sender BM F0VY-9H307-C Fuel Pump/Sender B F1SZ-9H307-B Fuel Pump/Sender B E99Z-9H307-A Fuel Pump/Sender B OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 90-7-11 WARRANTY STATUS: Eligible Under Basic Warranty Coverage, Major Component Warranty Coverage Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 91134 > Jun > 91 > Fuel Gauge - Intermittently Shows Increase In Fuel Level > Page 8987 OPERATION DESCRIPTION TIME 911304A Replace Fuel Pump/Sender 1.5 Hrs. - 1990 Town Car, Thunderbird, Cougar 911304A Replace Fuel Pump/Sender 1.2 Hrs. - Aerostar 911304A Replace Fuel Pump/Sender 1.0 Hr. - Continental, 1989 Town Car 911304A Replace Fuel Pump/Sender 0.9 Hr. - Taurus, Sable, Mark VII DEALER CODING BASIC PART NO. CONDITION CODE 9H307 28 OASIS CODES: 204000, 204100, 404000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return Technical Service Bulletin # RSB89170 Date: 891122 Remanufacturer Letter # 1 November 22, 1989 RSB # 89-170 To: All Ford Authorized Remanufacturers Subject: Sort and Return of Fuel & Send Assy. - E9DZ-9H307-C E5ZZ-9A407-A Gentlemen: Because certain fuel pump and sender assemblies may not meet Ford's high quality requirements, you are authorized to return unused parts for credit. Part Number Explanation E9DZ-9H307-C Action Required E5ZZ-9A407-A ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 - 1989; 0901 September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section, write "Returned per FPSD Purge 1079". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Returns restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Remanufacturer Letter # 2 November 22, 1989 RSB # 89-171 To: Ford Authorized Remanufacturers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1080". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 8992 ^ Return parts to your Facing PDC using least expensive trarisportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 1 December 7, 1989 To: Ford and Lincoln Mercury, Dealers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date ccde of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section Write "Returned per FPSD Purge # 1080". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 3 December 7, 1989 To: Ford and Lincoln Mercury Dealers Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 8993 Subject: Return of Fuel Pump & Sender Assy. - E9DZ-9H307-C and Fuel Pump & Bracket Assy. E5ZZ-9A407-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1079". ^ Return parts to your Facing PDC using-least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject part. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacemeut stock of the same part numbers is available for ordering immediately. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 8998 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Gauge Sender: > 891411 > Jul > 89 > Fuel Gauge - Occasionally Sticks In FULL Position Fuel Gauge Sender: All Technical Service Bulletins Fuel Gauge - Occasionally Sticks In FULL Position GAUGE-FUEL-OCCASIONALLY STICKS IN "FULL" POSITION Article No. 89-14-11 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A fuel gauge that ocassionally sticks in the "FULL" position may be caused by a binding fuel pump float assembly. The fuel pump float binds on the inner surface of the fuel tank and holds the float in the "FULL" position. This is most likely to occur when driving on unpaved or rough roads. ACTION: Modify the fuel pump float to prevent the binding condition. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 24-12 for removal and installation instructions. 1. Remove the fuel pump assembly. 2. Unscrew the nut from the end of the float rod assembly. 3. Remove the float from the rod. 4. Using a sharp knife, cut 3/8" to 1/2" (9.525 mm to 12.7 mm) off the end of the float. 5. Reinstall the shortened float on the float rod. 6. Install float retaining nut. NOTE: ALLOW CLEARANCE BETWEEN THE RETAINING NUT AND FLOAT SO THAT THE FLOAT SPINS FREELY. 7. Using diagonal cutters, trim the float rod so that it is flush with the retaining nut. 8. Reinstall the fuel sender. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891411A Modify Float 1.3 Hrs. DEALER CODING BASIC PART NO. CONDITION CODE 9H307 41 OASIS CODES: 2300, 2310, 2400 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return Technical Service Bulletin # RSB89170 Date: 891122 Remanufacturer Letter # 1 November 22, 1989 RSB # 89-170 To: All Ford Authorized Remanufacturers Subject: Sort and Return of Fuel & Send Assy. - E9DZ-9H307-C E5ZZ-9A407-A Gentlemen: Because certain fuel pump and sender assemblies may not meet Ford's high quality requirements, you are authorized to return unused parts for credit. Part Number Explanation E9DZ-9H307-C Action Required E5ZZ-9A407-A ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 - 1989; 0901 September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section, write "Returned per FPSD Purge 1079". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Returns restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Remanufacturer Letter # 2 November 22, 1989 RSB # 89-171 To: Ford Authorized Remanufacturers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1080". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 9008 ^ Return parts to your Facing PDC using least expensive trarisportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Sales Representative. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 1 December 7, 1989 To: Ford and Lincoln Mercury, Dealers Subject: Return of Fuel Pump and Sender Assemblies E8FZ-9H307-B E9TZ-9H307-B E9DZ-9H307-D E93Z-9H307-A E90Z-9H307-A E99Z-9H307-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date ccde of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section Write "Returned per FPSD Purge # 1080". ^ Return parts to your Facing PDC using least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject parts. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacement stock of the same part numbers is available for ordering immediately. Dealer Letter # 3 December 7, 1989 To: Ford and Lincoln Mercury Dealers Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > RSB89170 > Nov > 89 > Fuel Pump/Sender - Defective Parts Return > Page 9009 Subject: Return of Fuel Pump & Sender Assy. - E9DZ-9H307-C and Fuel Pump & Bracket Assy. E5ZZ-9A407-A Because the subject parts may not meet Ford's quality requirements, you are authorized to return unused parts for credit. Action Required ^ 100% sort all stock. ^ Okay stock has a date code of 890901 (89 = 1989; 0901 = September 1) or later. ^ Suspect stock has a date code prior to 890901. ^ Date code tag is located on fuel return line. ^ Complete separate FPS-340 claim for these parts. ^ Indicate Reason Code "J" on claim. ^ In Remarks Section write "Returned per FPSD Purge # 1079". ^ Return parts to your Facing PDC using-least expensive transportation. Limits ^ Returns must be received within 30 days from the date of letter. ^ Return restricted to subject part. Credit ^ Credit for parts and prepaid freight costs will be issued. Questions ^ Contact your Zone Manager. Special Note ^ Replacemeut stock of the same part numbers is available for ordering immediately. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement Fuel Gauge Sender: All Technical Service Bulletins Fuel Tank Sending Unit - Connector Replacement FUEL SYSTEM-FUEL TANK SENDING UNIT-WIRE HARNESS CONNECTOR REPLACEMENT WIRING-FUEL TANK SENDING UNIT-CONNECTOR REPLACEMENT Article No. 89-14-6 FORD: 1985-89 CROWN VICTORIA, ESCORT 1985-88 EXP 1985-89 MUSTANG, TEMPO, THUNDERBIRD 1986-89 TAURUS LINCOLN-MERCURY: 1985-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1985-87 LYNX 1985-89 MARK VII, TOPAZ, TOWN CAR 1986-89 SABLE LIGHT TRUCK: 1985-89 BRONCO II, ECONOLINE, F-150, F-250, F-350, RANGER Figure 1 ISSUE: Damaged fuel tank sending unit connectors can be serviced by splicing in a new wire harness connector. The new connector can be obtained by ordering the fuel tank sending unit wire harness and cutting off the connector. ACTION: Splice the new fuel tank sending unit connector to the existing wire harness. Refer to the following procedure for service details. 1. Disconnect the battery ground. 2. Cut the connector from the new harness. 3. Leave 6-8 inches of wiring lead on the connector. 4. Remove the old connector from the fuel tank sending unit. 5. Cut the connector off the vehicle's wire harness about 6-8 inches from the old connector. 6. Match the wire colors. 7. Install the new connector. Use a "Duraseal" butt splice connector, Figure 1. 8. Using a heat gun, seal the splice. CAUTION: DO NOT USE AN OPEN FLAME. 9. Connect the battery ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > All Other Service Bulletins for Fuel Gauge Sender: > 89146 > Jul > 89 > Fuel Tank Sending Unit - Connector Replacement > Page 9014 10. Check the operation of the fuel gauge. PART NUMBER PART NAME CLASS E9FZ-9A400-A Wire Harness - Fuel Pump C OTHER APPLICABLE ARTICLES: 86-3-11 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2300, 2310, 2400, 2770, 4500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Technical Service Bulletins > Page 9015 Fuel Gauge Sender: Locations On RH Frame Rail Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests Fuel Gauge Sender: Pinpoint Tests Fig. 1 Fuel Indicating System Diagnosis (Part 1 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 9018 Fig. 1 Fuel Indicating System Diagnosis (Part 2 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 9019 Fig. 1 Fuel Indicating System Diagnosis (Part 3 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 9020 Fig. 1 Fuel Indicating System Diagnosis (Part 4 Of 5). Models w/Magnetic Gauge Fig. 1 Fuel Indicating System Diagnosis (Part 5 Of 5). Models w/Magnetic Gauge Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 9021 Fig. 2 Fuel Indicating System Diagnosis (Part 1 Of 2) Fig. 2 Fuel Indicating System Diagnosis (Part 2 Of 2) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Fuel Gauge Sender > Component Information > Testing and Inspection > Pinpoint Tests > Page 9022 Fuel Gauge Sender: Component Tests and General Diagnostics Magnetic Type The required test equipment consists of a Rotunda Gauge Tester part No. 021-00055 or equivalent, a pair of 10 ohm and 75 ohm resistor or another fuel sender of known quality. 1. Perform test with resistors as follows: a. Disconnect wiring connector at sender unit, then connect resistor between gauge lead and a suitable ground. b. Turn ignition switch to On position. c. With 10 ohm resitor, the gauge pointer should contact the Full mark. d. With 75 ohm resistor, the gauge pointer should contact the Empty mark. 2. Perform test with fuel sender of known quality as follows: a. Turn ignition switch to Off position. b. Disconnect wiring connector from sender and connect it to test sender. c. Move float rod away from fuel filter against Full stop position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or above the Full mark. d. Move float rod toward fuel filter against Empty stop position. Turn ignition switch to Off position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or below the Empty mark. e. If gauge performs as indicated, perform fuel sender unit tests. Refer to DIAGNOSTIC CHARTS for fuel sender unit tests. f. If gauge is out of calibration at the Empty mark, or both the Empty and Full mark, replace gauge. Bimetal Type The required test equipment consists of a Rotunda Gauge Tester part No. 021-00055 or equivalent, a pair of 22 ohm and 145 ohm resistor or another fuel sender of known quality. 1. Perform test with resistors as follows: a. Disconnect wiring connector at sender unit, then connect resistor between gauge lead and a suitable ground. b. Turn ignition switch to On position. c. With 145 ohm resitor, the gauge pointer should contact the Full mark. d. With 22 ohm resistor, the gauge pointer should contact the Empty mark. 2. Perform test with fuel sender of known quality as follows: a. Turn ignition switch to Off position. b. Disconnect wiring connector from sender and connect it to test sender. c. Move float rod away from fuel filter against Full stop position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or above the Full mark. d. Move float rod toward fuel filter against Empty stop position. Turn ignition switch to Off position. Wait approximately 30 seconds, then turn ignition switch to On position. The gauge should read on or below the Empty mark. e. If gauge performs as indicated, perform fuel sender unit tests. Refer to DIAGNOSTIC CHARTS for fuel sender unit tests. f. If gauge is out of calibration at the Empty mark, or both the Empty and Full mark, replace gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Technical Service Bulletins > Ignition Key Warning Switch - Replacement Procedure Key Reminder Switch: Technical Service Bulletins Ignition Key Warning Switch - Replacement Procedure IGNITION SYSTEM-IGNITION KEY WARNING SWITCH-REPLACEMENT PROCEDURE SWITCH-IGNITION KEY WARNING-REPLACEMENT PROCEDURE Article No. 89-19-2 FORD: 1986-90 CROWN VICTORIA, TAURUS, THUNDERBIRD LINCOLN-MERCURY: 1986-90 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOWN CAR ISSUE: A new procedure for servicing the ignition key warning switch has been developed. The new procedure is not published in the shop manual. ACTION: Use the following service procedure to remove and install the ignition key warning switch. Figure 1 REMOVAL 1. Remove the ignition lock assembly from the steering column lock housing. Refer to the appropriate Car Shop Manual, Section 13-04 for service details. NOTE: LEAVE THE LOCK IN THE RUN POSITION. DO NOT TURN THE IGNITION KEY. 2. Remove the switch from the lock assembly using a screwdriver as shown in Figure 1. 3. Throw away the switch. Figure 2 INSTALLATION 1. Obtain a new key warning switch (11A127). 2. Place the switch halfway on the lock cylinder case. Note proper alignment as shown in Figure 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Technical Service Bulletins > Ignition Key Warning Switch - Replacement Procedure > Page 9027 Figure 3 3. While pressing down on the switch with the thumb, slide the switch into place making sure all tabs are in place, Figure 3. 4. Install the lock cylinder assembly. Refer to the procedure in Section 13-04 of the appropriate Car Shop Manual. PART NUMBER PART NAME CLASS E7DZ-11A127-A Key Warning Switch C (Continental, Taurus, Sable) E6SZ-11A127-A Key Warning Switch (All Other C Car Lines) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2500, 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Key Reminder Switch > Component Information > Technical Service Bulletins > Page 9028 Key Reminder Switch: Locations I/P Components Part Of Ignition Switch Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel > Parking Brake Warning Switch > Component Information > Locations Parking Brake Warning Switch: Locations Body & Chassis Components Top Of Parking Brake Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Technical Service Bulletins > Customer Interest for Shift Indicator: > 89139 > Jun > 89 > A/T - PRNDL Bulb Socket Melted Shift Indicator: Customer Interest A/T - PRNDL Bulb Socket Melted LAMP-TRANSMISSION PRNDL BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 TRANSMISSION-PRNDL LIGHT BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 Article No. 89-13-9 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Heat from the transmission "PRNDL" light bulb may soften and melt the plastic bulb socket. This is caused by the two (2) candlepower bulb. ACTION: Install a new bulb and socket assembly. The new assembly has a one (1) candlepower bulb which will operate cooler. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 17-02 for service details. NOTE: THE NEW BULB AND SOCKET ASSEMBLY ALSO HAS A LIGHTER GREEN FILTER SO THE LESS BRIGHT BULB WILL STILL SUPPLY THE CORRECT GREEN COLOR AND INTENSITY. PART NUMBER PART NAME CLASS E9SZ-15A808-C Bulb and Socket Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891309A Install Bulb & Socket 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 15A808 46 OASIS CODES: 2100, 2150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Shift Indicator > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Shift Indicator: > 89139 > Jun > 89 > A/T - PRNDL Bulb Socket Melted Shift Indicator: All Technical Service Bulletins A/T - PRNDL Bulb Socket Melted LAMP-TRANSMISSION PRNDL BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 TRANSMISSION-PRNDL LIGHT BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 Article No. 89-13-9 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Heat from the transmission "PRNDL" light bulb may soften and melt the plastic bulb socket. This is caused by the two (2) candlepower bulb. ACTION: Install a new bulb and socket assembly. The new assembly has a one (1) candlepower bulb which will operate cooler. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 17-02 for service details. NOTE: THE NEW BULB AND SOCKET ASSEMBLY ALSO HAS A LIGHTER GREEN FILTER SO THE LESS BRIGHT BULB WILL STILL SUPPLY THE CORRECT GREEN COLOR AND INTENSITY. PART NUMBER PART NAME CLASS E9SZ-15A808-C Bulb and Socket Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891309A Install Bulb & Socket 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 15A808 46 OASIS CODES: 2100, 2150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest: > 9128 > Jan > 91 > Analog Speedometer - Inaccurate At High Speeds Speedometer Head: Customer Interest Analog Speedometer - Inaccurate At High Speeds Article No. 91-2-8 January 23, 1991 SPEEDOMETER - ANALOG (CONVENTIONAL) - INACCURATE AT HIGH SPEEDS-VEHICLES BUILT BEFORE 4/01/90 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The base or performance analog speedometer may give inaccurate speed indications above 70 mph (112 km/h). This is caused by calibration tolerances within the speedometer head. ACTION: Install a new more accurate speedometer. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-10, for service details. SPEEDOMETER IDENTIFICATION Late model or improved speedometers can be identified by the white calibration dots located on the face of the speedometer at the 60 mph (100 km/h) graduation. Early production speedometers were not marked with calibration dots. NOTE: SPEEDOMETER PART NUMBERS WERE NOT CHANGED WHEN THE PRODUCTION CHANGES WERE IMPLEMENTED. PART NUMBERS FOR THE BASE AND PERFORMANCE SPEEDOMETERS ARE SHOWN IN THE PARTS BLOCK. PART NUMBER PART NAME CLASS FOSZ-17255-A Speedometer (English - Base B Analog) FOSZ-17255-B Speedometer (Metric - Base ZC Analog) FOSZ-17255-C Speedometer (English - B Performance Analog) FOSZ-17256-D Speedometer (Metric - ZC Performance Analog) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910208A Install Speedometer 1.2 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 17255 53 OASIS CODES: 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > Customer Interest: > 9128 > Jan > 91 > Analog Speedometer - Inaccurate At High Speeds > Page 9053 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 9128 > Jan > 91 > Analog Speedometer - Inaccurate At High Speeds Speedometer Head: All Technical Service Bulletins Analog Speedometer - Inaccurate At High Speeds Article No. 91-2-8 January 23, 1991 SPEEDOMETER - ANALOG (CONVENTIONAL) - INACCURATE AT HIGH SPEEDS-VEHICLES BUILT BEFORE 4/01/90 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: The base or performance analog speedometer may give inaccurate speed indications above 70 mph (112 km/h). This is caused by calibration tolerances within the speedometer head. ACTION: Install a new more accurate speedometer. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 33-10, for service details. SPEEDOMETER IDENTIFICATION Late model or improved speedometers can be identified by the white calibration dots located on the face of the speedometer at the 60 mph (100 km/h) graduation. Early production speedometers were not marked with calibration dots. NOTE: SPEEDOMETER PART NUMBERS WERE NOT CHANGED WHEN THE PRODUCTION CHANGES WERE IMPLEMENTED. PART NUMBERS FOR THE BASE AND PERFORMANCE SPEEDOMETERS ARE SHOWN IN THE PARTS BLOCK. PART NUMBER PART NAME CLASS FOSZ-17255-A Speedometer (English - Base B Analog) FOSZ-17255-B Speedometer (Metric - Base ZC Analog) FOSZ-17255-C Speedometer (English - B Performance Analog) FOSZ-17256-D Speedometer (Metric - ZC Performance Analog) OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 910208A Install Speedometer 1.2 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 17255 53 OASIS CODES: 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 9128 > Jan > 91 > Analog Speedometer - Inaccurate At High Speeds > Page 9059 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 8927 > Jan > 89 > Speedometer/Odometer - Inaccurate Readings Speedometer Head: All Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND ODOMETER READINGS Article No. 89-2-7 FORD: 1989 AND PRIOR ALL CAR LINES LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle components or systems. The information in this TSB article is intended to assist technicians in speedometer/odometer concern diagnosis. ACTION: Use the following supplemental information below to assist in speedometer/odometer diagnostics. OPERATION A mechanical analog speedometer displays vehicle speed and the odometer displays total distance traveled. The speedometer/odometer assembly is cable driven by either a transmission or a transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed so that all are identical and have no error in the speedometer head. Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the speedometer/odometer. An electronic signal is sent from a speed sensor to the digital speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle, similar to a cable. Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio and speedometer/odometer drive and driven gears. TIRES Improper tire rolling radius and inflation pressure, temperature and size may contribute to inaccurate system readings. System accuracy testing should be performed after the tires are set at the correct pressure as shown on the safety compliance certification label. The tires should be warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a constant speed within the posted speed limit. AXLE/TRANSAXLE RATIO The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios are available, but usually are not a concern when dealing with speedometer/odometer concerns unless the gear ratio has been changed. WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel drive vehicles have several driven gears with various numbers of teeth available to correct input to the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears for correction. GENERAL DESCRIPTION The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance traveled. Ford Motor vehicles are well within those limits. The speed indication is biased high, except on police vehicles with certified calibration speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the actual speed. This is intended to protect the consumer against violating speed laws. Most customer concerns are related to speedometers reading too high at true speeds between 50 MPH and 65 MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10% greater than true speed. The speedometer head is an instrument which processes information sent to it by the rotating speedometer cable. If the system components send the Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Speedometer Head: > 8927 > Jan > 89 > Speedometer/Odometer - Inaccurate Readings > Page 9064 wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the speedometer head odometer, start by checking the accuracy of the odometer even if the customer concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads established at mile increments or a known local course. If roads with mile markers are used, a five mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The odometer should be checked again to verify any corrective action. If the indicated speed error exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of drive gears, parts not splined or loose yoke nuts. If the vehicle has speed control, the speed accuracy can be checked using the verified odometer vs. time. The formula is as follows: 3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES: 60 MPH (96 Km/h) requires 60 seconds to cover one mile 55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile 50 MPH (80 Km/h) requires 72 seconds to cover one mile ARTICLE SUPERSEDED: 84-14-6, date 7/3/84 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2300, 2310, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speedometer Head: > 8927 > Jan > 89 > Speedometer/Odometer - Inaccurate Readings Speedometer Head: All Technical Service Bulletins Speedometer/Odometer - Inaccurate Readings SPEEDOMETER - MECHANICAL/ELECTRONIC - INACCURATE SPEED READINGS AND ODOMETER READINGS Article No. 89-2-7 FORD: 1989 AND PRIOR ALL CAR LINES LINCOLN-MERCURY: 1989 AND PRIOR ALL CAR LINES LIGHT TRUCK: 1989 AND PRIOR ALL TRUCK LINES ISSUE: The accuracy of speedometer/odometer readings may be influenced by several vehicle components or systems. The information in this TSB article is intended to assist technicians in speedometer/odometer concern diagnosis. ACTION: Use the following supplemental information below to assist in speedometer/odometer diagnostics. OPERATION A mechanical analog speedometer displays vehicle speed and the odometer displays total distance traveled. The speedometer/odometer assembly is cable driven by either a transmission or a transaxle. All speedometer/odometer assemblies, except for police vehicles are the same with respect to the speed accuracy tolerance used during calibration. The odometer gear ratio is fixed so that all are identical and have no error in the speedometer head. Electronic digital operation is similar. It could use a drive cable or a speed sensor to drive the speedometer/odometer. An electronic signal is sent from a speed sensor to the digital speedometer/ odometer assembly. The speed sensor is driven by a transmission or a transaxle, similar to a cable. Several areas of concern that may affect speedometer/ odometer readings are tires, axle gear ratio and speedometer/odometer drive and driven gears. TIRES Improper tire rolling radius and inflation pressure, temperature and size may contribute to inaccurate system readings. System accuracy testing should be performed after the tires are set at the correct pressure as shown on the safety compliance certification label. The tires should be warmed for a short period. Best results are obtained on smooth, dry pavement while driving at a constant speed within the posted speed limit. AXLE/TRANSAXLE RATIO The gear ratio of the rear axle or the final drive ratio of the transaxle must be known to select or check if the proper speedometer/odometer drive and driven gears are present. Various gear ratios are available, but usually are not a concern when dealing with speedometer/odometer concerns unless the gear ratio has been changed. WARNING: NEVER CORRECT SPEEDOMETER READINGS BY CHANGING GEARS UNLESS THE ODOMETER IS ALSO OFF. DRIVE/DRIVEN GEARS The speedometer/odometer drive gear is located inside the transmission, transaxle or transfer case and is not easily accessed for change. The driven gear rotates the speedometer cable. Rear wheel drive vehicles have several driven gears with various numbers of teeth available to correct input to the speedometer/odometer head. Front wheel drive vehicles generally do not offer different gears for correction. GENERAL DESCRIPTION The maximum allowable odometer system accuracy error is +/- 3.75% of the actual distance traveled. Ford Motor vehicles are well within those limits. The speed indication is biased high, except on police vehicles with certified calibration speedometers/ odometers. As a general rule, the indicated speed is equal to or greater than the actual speed. This is intended to protect the consumer against violating speed laws. Most customer concerns are related to speedometers reading too high at true speeds between 50 MPH and 65 MPH (80 - 105 Km/h). At that speed range, the worst case errors may indicate a speed that is 10% greater than true speed. The speedometer head is an instrument which processes information sent to it by the rotating speedometer cable. If the system components send the Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component Information > Technical Service Bulletins > All Other Service Bulletins for Speedometer Head: > 8927 > Jan > 89 > Speedometer/Odometer - Inaccurate Readings > Page 9070 wrong number of revolution per mile to the speedometer head, an inaccurate speed reading and amount of distanced traveled will be displayed. Since there is no error in the fixed gear ratio of the speedometer head odometer, start by checking the accuracy of the odometer even if the customer concern indicates a speed accuracy problem. Odometer accuracy can be checked by using roads established at mile increments or a known local course. If roads with mile markers are used, a five mile stretch is recommended to allow for inaccuracies. If an error is greater than 3.75%, a change to the transmission drive/driven gear selection, tire size, or tire inflation may need attention. The odometer should be checked again to verify any corrective action. If the indicated speed error exceeds 10% between 50 MPH and 60 MPH (80 - 105 Km/h), replace the speedometer/odometer assembly. Vehicles with transfer cases that have fluctuating readings may be due to slippage of drive gears, parts not splined or loose yoke nuts. If the vehicle has speed control, the speed accuracy can be checked using the verified odometer vs. time. The formula is as follows: 3600 divided by TIME (seconds to cover one mile) = TRUE MPH (Km/h) EXAMPLES: 60 MPH (96 Km/h) requires 60 seconds to cover one mile 55 MPH (88 Km/h) requires 65 and 3/4 seconds to cover one mile 50 MPH (80 Km/h) requires 72 seconds to cover one mile ARTICLE SUPERSEDED: 84-14-6, date 7/3/84 WARRANTY STATUS: "INFORMATION ONLY" OASIS CODES: 2300, 2310, 2400, 2500 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage Speedometer Module: Technical Service Bulletins Speedometer - Service Replacements With Pre-Set Mileage Article No. 93-12-9 06/09/93 SPEEDOMETER - ELECTRONIC INSTRUMENT CLUSTERS, PROGRAMMABLE SPEEDOMETER/ODOMETER MODULES - DIGITAL ELECTRONIC ODOMETERS - SERVICE REPLACEMENTS WITH PRE-SET VEHICLE MILEAGE FORD: 1985-92 THUNDERBIRD 1986-93 TAURUS 1989-92 PROBE 1992-93 CROWN VICTORIA LINCOLN-MERCURY: 1984-91 MARK VII 1984-93 CONTINENTAL 1985-92 COUGAR 1986-93 SABLE 1990-93 TOWN CAR 1992-93 GRAND MARQUIS LIGHT TRUCK: 1986-93 AEROSTAR 1992-93 ECONOLINE, F-150-350 SERIES 1993 VILLAGER ISSUE: Service replacement speedometer odometers, speedometer modules, electronic instrument clusters and PSOM (programmable speedometer/odometer module) clusters, with mileage preset to the mileage displayed on the removed cluster odometer, are now available. These components must be ordered through one of three Electronic Service Centers (Two (2) U.S.; One (1) Canadian). They will be provided on an exchange basis and will not be available through the parts depots. ACTION: If service is required, refer to the following ordering and shipping procedure. ORDERING PROCEDURE U.S. DEALERS The repair Form FPS 1878 must be filled out in sections 1A and 1B indicating the required vehicle information. A toll free phone call must be placed to the respective Electronic Service Center to relay the vehicle information: ^ Dealers who are normally serviced by the Detroit, New York and Atlanta Parts Distribution Centers should place their orders through the Eastern Electronic Service Center Call Line, 1-800-262-9606. ^ All other U.S. dealers should place their orders through the Western Electronic Service Center Call Line, 1-800-321-6969. CANADIAN DEALERS The repair Form 6125-2 must be filled out indicating the required vehicle information. To place an order through the Canadian Electronic Service Center, either fax the repair Form 6125-2 to FAX # 416-946-8975 or place a toll free phone call to 1-800-663-9974. ^ If the phone call or fax is placed to the Center before 4:00 p.m. on Monday through Thursday, the goal will be to provide the replacement cluster before close of business the following day. ^ If orders are placed on Friday or the day before a holiday, the cluster should be received on Monday or the day after the holiday. The clusters are shipped pre-paid freight. Assemblies shipped to Hawaii or Alaska should be received within forty-eight hours except on Fridays or the day before holidays. Saturday delivery is now available to dealers with Saturday operation hours. This service must be requested from the Service Center when placing the order. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 9075 SHIPPING PROCEDURES FOR REMOVED CLUSTER Service replacement assemblies will be shipped pre-paid freight. The return freight charge will be collect. Follow the Return Shipping Instructions enclosed in the container in which the assembly was received. The removed assembly must be returned to the Electronic Service Center in the same container. ^ Ensure that the original shipping label is completely removed from the outside of the shipping container. ^ Simply affix the collect return shipping label that is supplied. ^ Place the removed assembly in the container with a copy of the memo billing from the Electronic Service Center, and the completed manufacturer's copy of Form FPS 1878 (U.S.) or FPS 6125-2 (Canada). This will ensure proper procedure so that the core charge of $300.00 will not be billed. ^ The removed assembly must be returned to the Electronic Service Center within thirty calendar days or the core charge will be billed against the dealer parts account. HANDLING PROCEDURES FOR DIGITAL SPEEDOMETERS WITH UNKNOWN MILEAGE ACCUMULATION To comply with regulations pertaining to the accuracy of odometers, cores will be read to determine accuracy of the reported mileage. In nearly all instances, the mileage continues to accumulate in the odometer memory chip even though the odometer is non-functional. This mileage can be verified even though it is not visible on the removed odometer. The dealer must verify the mileage accumulated on the odometer. ^ If the mileage cannot be determined accurately, the dealer must indicate to the Electronic Service Center that the mileage is unknown. ^ In cases where the mileage is unknown, the law requires that we supply a replacement part with the mileage pre-set to "O" miles and the service odometer (circle "S") segment illuminated. ^ A sticker must be attached to the door indicating the mileage at the time of the service repair. COST AND WARRANTY INFORMATION The service assemblies will be billed on the monthly Dealer Parts Statement. Application is provided by part number, dealer cost and core charge. Refer to Dealer Service Manuals and the FPSD Parts and Accessories Price Listing. Repair Form FPS 1878 can be ordered from the Parts Distribution Center. Follow the normal parts allowance plus labor charge as shown in the Service Labor Time Standards Manual when requesting warranty reimbursement. The core charge should not be entered on the warranty claim form as there will not be a charge for the core if the removed assembly is returned to the Electronic Service Center within the specified 30-day period following receipt of the replacement assembly. DIGITAL ELECTRONIC ODOMETER REPLACEMENTS FOR UNSOLD NEW VEHICLES IN DEALER STOCK You must use a new digital odometer for unsold new vehicles in dealer stock. Simply enter the word "Stock" for the owner name on Form FPS 1878 and identify the order as a new unsold vehicle when placing the order. Dealer handling procedures will be the same as previously outlined. DEALER PARTS COUNTER RETAIL SALE There will be an occasion when it will be necessary to sell digital assemblies over the parts counter. Dealers must complete Form FPS 1878 (U.S.) or 6125-2 (Canada) and provide the same information as required for a service department repair. As with warranty repairs, the dealer must verify the mileage on the removed assembly. If the core is not received from the customer, you should charge the customer the core charge. You will be charged for the core if it is not returned. Orders will be processed the same day as received. SPECIFIC PART NUMBER ORDERING INFORMATION For 1984 thru 1987 Continental and all Mark VIII vehicles with an odometer concern, you can order just the NVM Module from the Service Centers (E4LY-17C269-A). If the concern is with the display, you can remove the NVM module from the cluster and order just the display (-10D922-), then install the NVM module into the replacement cluster. NOTE: ODOMETER MEMORY CONTROL ASSEMBLIES (-17C269-) HAVE TO BE RETURNED TO THE SERVICE CENTERS USING THE PROCEDURES AS PREVIOUSLY OUTLINED. THERE WILL BE A $300.00 CORE CHARGE IF YOU DO NOT RETURN THIS MODULE WITHIN 30 CALENDAR DAYS. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 9076 If a cluster is needed for a vehicle prior to the 1984 model year, order it from your FPSD Parts Distribution Center. Analog PSOM components (tachometers and gauges) may now be ordered from your FPSD Distribution Center. You no longer have to order the entire cluster for those type of concerns. For any cluster with a speedometer/odometer concern, the entire cluster must be ordered from the Electronic Service Center. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 9077 When ordering an Analog PSOM cluster or 1992-93 Aerostar EIC, refer to Figures 1 and 2. The Service Center will need additional information concerning the PSOM Conversion Constant. This constant is important for correct vehicle performance. Please refer to the following procedures in your 1993 Body/Chassis Service Manuals for determining or changing the PSOM conversion constant. These procedures apply to both 1992 and 1993 vehicles equipped with PSOM clusters. ^ 1993 Aerostar, Ranger, Explorer Body/Chassis Service Manual, Page 13-02B-7, Test Step C4 through Page 13-02B-9, Test Step C7. ^ 1993 Econoline, F-150,F-250, F350, Bronco, F-super Duty Body/Chassis Service Manual, Page 13-02A-7, Test Step C4 through Page 13-02A-8, Test Step C7. NOTE: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Module > Component Information > Technical Service Bulletins > Speedometer - Service Replacements With Pre-Set Mileage > Page 9078 IF A VEHICLE HAS EITHER HAD THE TIRE SIZE/TYPE CHANGED, OR HAS HAD MODIFICATIONS TO THE REAR AXLE, IT IS NECESSARY TO CHANGE THE PSOM CONVERSION CONSTANT. THIS CONVERSION CONSTANT CAN BE CHANGED AT THE DEALERSHIP SO IT IS NOT NECESSARY TO ORDER AN ENTIRE CLUSTER IN THESE CASES. TECHNICAL ASSISTANCE An Electronic Instrument Cluster Help Line is available at 1-800-461-6945 to assist with any technical concerns involving the digital electronic odometer or related wiring or hardware. A PSOM (Programmable Speedometer/Odometer Module) Cluster Help Line is available at 1-800-523-7763 to assist with any technical concerns involving the PSOM clusters or related wiring or hardware. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 91-8-14 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 204000, 204100, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Technical Service Bulletins > Conventional Tachometer - Manual Revision Tachometer: Technical Service Bulletins Conventional Tachometer - Manual Revision SHOP MANUAL - 1989 - PAGE 33-11-1 - SECTION 33-11 APPLIES TO CONVENTIONAL TACHOMETER ONLY Article No. 90-6B-37 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information > Technical Service Bulletins > Conventional Tachometer - Manual Revision > Page 9083 ISSUE: The Section 33-11 title shown on page 33-11-1 of the 1989 Thunderbird/Cougar Shop Manual should read Tachometer-Conventional. The Vehicle Application should be revised to read: Thunderbird/Cougar 3.8L Supercharged Engine Only. The illustration under Description and Operation has been modified to include updated information. ACTION: Refer to the pages following this TSB article for the revised material. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 9092 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 9093 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Gauge: > 90246 > Nov > 90 > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Gauge: > 90246 > Nov > 90 > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 9103 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Gauge: > 90246 > Nov > 90 > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 9104 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Gauge: > Page 9105 Suspension Main Relay: Locations Soft Ride Relay Body & Chassis Components Under Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Component Information > Locations > Hard Ride Relay Suspension Main Relay: Locations Hard Ride Relay Body & Chassis Components Under Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Component Information > Locations > Hard Ride Relay > Page 9110 Suspension Main Relay: Locations Soft Ride Relay Body & Chassis Components Under Rear Package Tray Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Component Information > Locations > Page 9111 Suspension Main Relay: Service and Repair 1. Turn ignition switch to Off or LOCK position. 2. Working from inside luggage compartment, disconnect push pin at left side of package tray. 3. Swing tray downward. 4. Disconnect control module or relay electrical connectors, then remove control module or relays. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 9119 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Component Information > Technical Service Bulletins > Customer Interest for Temperature Gauge: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 9120 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle Parking Brake Lever: All Technical Service Bulletins Parking Brake Release Button - Separates From Handle BRAKE - PARKING - RELEASE BUTTON SEPARATES FROM THE HANDLE Article No. 90-24-6 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: The console mounted parking brake release button may separate from the parking brake handle because its plastic tabs do not have enough retention force. The control will not latch in an up position; the handle will apply parking brake force but will return to the down position as the driver removes his/her hand. ACTION: Install a parking brake release button repair kit that consists of a button, spring and plastic sleeve. The sleeve improves release button retention. Refer to the following procedure for service details. REMOVAL 1. Remove the floor console. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 45-31, for service details. Figure 1 2. Disengage the shield tab. Lift and rotate the plastic wire shield out of the way to provide working room, Figure 1. Figure 2 3. Using a screwdriver, pry the release rod retaining tab .25" (6.35 mm) away from the release rod, Figure 2. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle > Page 9126 Figure 3 4. Disengage the release rod from the release pawl. Slide the release rod up through the handle, exposing the release button retaining barbs, Figure 3. Figure 4 5. Remove the button return spring from the handle by rotating the spring clockwise. Start the spring out of the handle with needle nose pliers, Figure 4. INSTALLATION 1. Position the new spring onto the release rod. Rotate the spring counterclockwise until it seats on the stop of the steel arm, Figure 4. CAUTION: DO NOT DAMAGE THE LEATHER ON THE BUTTON OPENING OF THE HANDLE. 2. Slide the release rod up through the parking brake handle exposing the barbs. a. Install the plastic sleeve onto the release rod. Figure 5 b. Make sure that the plastic sleeve enters the spring properly and seats on the stop of the steel arm, Figure 5. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle > Page 9127 Figure 6 3. Push the button onto the release rod until the tabs of the button slip over the barbs, Figure 6. Make sure that the tabs do not enter the sleeve until they have locked in place over the tabs. NOTE: A FAILURE TO PERFORM THIS STEP CORRECTLY MAY CAUSE DAMAGE TO THE BUTTON TABS. THE REMAINING LENGTH OF THE SPRING CAN BE PUSHED INTO THE HANDLE BY THE BUTTON DURING ASSEMBLY. 4. Push the release rod back into the assembly. Reconnect the release rod to the release rod pawl. Figure 7 5. Place .030" (.762 mm) feeler gauge stock between the release rod and the release rod retaining tab. Using pliers, squeeze the tab until .030" (.762 mm) clearance is obtained, Figure 7. 6. Move the handle several times to make sure of proper operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component Information > Testing and Inspection > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Parking Brake Lever: > 90246 > Nov > 90 > Parking Brake Release Button - Separates From Handle > Page 9128 Figure 8 7. Rotate the plastic wire shield back into its original position and snap it in place, Figure 8. 8. Install the console assembly. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 45-31, for service details. PART NUMBER PART NAME CLASS FOSZ-2L760-A Release Button Repair Kit C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902406A Install Parking Brake 0.7 Hr. Release Button Kit DEALER CODING BASIC PART NO. CONDITION CODE 2L760 33 OASIS CODES: 302000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic Temperature Sensor (Gauge): All Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic > Page 9137 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 9142 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Temperature Sensor (Gauge): > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 9143 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly Technical Service Bulletin # 902310 Date: 901107 Temperature Gauge - Not Functioning Correctly Article No. 90-23-10 GAUGE - TEMPERATURE - INOPERATIVE - 3.8L SUPERCHARGED ENGINES FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR ISSUE: The temperature gauge may be inoperative or not functioning correctly, This occurs because the coolant temperature sender assembly is improperly grounded or damaged. ACTION: Check to see if the coolant temperature sender is damaged or not properly grounded. If necessary, replace the sender assembly (10884). Refer to the following procedure for service details. Sender Ground Continuity & Damage Inspection Figure 1 1. Remove one (1) of the bolts that attaches the water outlet connection assembly (8594) to the intake manifold, Figure 1. 2. Remove the paint from under the bolt on the water outlet connection assembly to assure good grounding continuity. 3. Re-install the bolt. Tighten it to 15-22 lb.ft. (20-30 N-m). 4. Run the engine and check for coolant leaks. 5. If the coolant temperature gauge does not function properly, proceed to Step # 6. 6. Remove the water coolant temperature sender from the water outlet connection assembly. 7. Check the bulb end of the water coolant for damage. If the sending unit is not damaged, proceed to the following Undamaged Sending Unit Service Procedure. If the sending unit is damaged, proceed to Damaged Sending Unit Service Procedure of this article. Undamaged Sending Unit Service Procedure 1. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 2. Re-install the sender. Tighten it to 8-15 lb.ft. (10-20 N-m). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 9149 3. Start the engine and check for any coolant leaks. 4. If the coolant temperature gauge doesn't operate correctly, check for other causes that could effect the gauge operation. Damaged Sending Unit Service Procedure Figure 2 1. If the sender is damaged, check for an undersized hole in the hex fitting or a mismatch of the hex fitting and the bypass tube. 2. Drain the coolant below the level required to remove the water outlet connection. 3. Disconnect the upper radiator hose from the water outlet connection. 4. Remove the water outlet connection assembly (8594) from the intake manifold and remove the thermostat (8575). 5. Drill out the hole in the hex fitting or the mismatched bypass tube. Use a 3/8" (9.128-9.525 mm) diameter drill, Figure 2. CAUTION: USE CARE, DRILL POINT MAY DAMAGE THE OTHER SIDE OF THE BYPASS TUBE OR THREAD IN THE HEX FITTING. 6. Flush the water outlet connection to remove any metal chips. 7. Clean the gasket surface on the thermostat housing and on the intake manifold. 8. Position the thermostat, new gasket and thermostat housing on the manifold. a. Install the two (2) retaining bolts. b. Tighten the bolts to 15-22 lb.ft. (20-30 N-m). 9. Remove the paint from the first three (3) threads of the hole in which the sender was installed. The suggested method of removing the paint is to use a wire brush or any other suitable means that will not damage the threads. CAUTION: DO NOT USE A TAP TO REMOVE PAINT. 10. Install a new water coolant temperature sender. Tighten it to 8-15 lb.ft. (10-20 N-m). 11. Connect the upper radiator hose. 12. Fill (top off) the coolant system with the specified coolant. Refer to the 1989/91 Thunderbird/Cougar Shop Manual, Section 27-01 for the cooling system filling procedure. 13. Start the engine and check for any coolant leaks. 14. If the coolant gauge does not operate correctly, check for other causes that could effect the gauge operation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Customer Interest: > 902310 > Nov > 90 > Temperature Gauge - Not Functioning Correctly > Page 9150 Misc. Info. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902310A Ground Sending Unit 0.3 Hr. 902310B Remove Sender & Clean 0.3 Hr. Threads 902310C Service Damaged Sending 0.8 Hr. Unit DEALER CODING BASIC PART NO. CONDITION CODE 10884 46 OASIS CODES: 206000, 204000, 204200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic Temperature Sensor (Gauge): All Technical Service Bulletins Temperature Gauge - Reads Low/Erratic Article No. 95-13-2 07/03/95 ^ GAUGE - TEMPERATURE-READS IN LOW RANGE - ERRATIC READINGS ^ SERVICE PARTS - RETURN OF OBSOLETE TEMPERATURE SENDERS FORD: 1981-94 ESCORT 1981-95 MUSTANG, THUNDERBIRD 1983-95 CROWN VICTORIA 1984-94 TEMPO 1986-95 TAURUS LINCOLN-MERCURY: 1981-92 TOWN CAR 1981-95 COUGAR 1983-95 GRAND MARQUIS 1984-92 MARK VII 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1991-94 TRACER 1993-95 MARK VIII LIGHT TRUCK: 1982-95 BRONCO 1983-95 RANGER 1986-94 AEROSTAR 1990-95 F-150-350 SERIES 1991-95 EXPLORER 1992-95 ECONOLINE 1995 WINDSTAR ISSUE: Temperature Sender F1SZ-10884-A with a build date code prior to 2774 (277th day of 1994) should be purged from your inventory and returned to your facing PDC. These parts are being made obsolete because of an incorrect crimp during assembly. Installing these parts on a vehicle could result in early loss of temperature sender function. ACTION: Remove and return the suspect parts from your dealership's inventory. The obsolete parts should be withdrawn from your inventory and returned to your facing PDC within 30 days of this TSB. NOTE: USE TSB ARTICLE 93-24-8 FOR DIAGNOSIS PROCEDURE IN DETERMINING IF LOW GAUGE READINGS COULD BE ASSOCIATED WITH A TEMPERATURE SENDER CONCERN. 1. Perform 100% sort of all stock on hand. 2. Suspect stock has a build date code prior to 2774. Usable stock will have a build date code of 2774 or later. NOTE: DATE CODES ARE LOCATED ON THE SIDE OF THE SENDER HEX. 3. Usable stock can be returned to your inventory and released for normal sales. 4. Return suspect part (F1SZ-10884-A) to your facing PDC using the least expensive transportation. 5. If claim is processed electronically via DOES II, use return code "GB"; otherwise, complete a separate paper claim form FPS-340 using return code "J". Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > All Other Service Bulletins for Temperature Sensor (Gauge): > 95132 > Jul > 95 > Temperature Gauge - Reads Low/Erratic > Page 9156 6. In the Remarks Section, write "Returned per TSB 95-13-2". LIMITS ^ The returns must be received within 30 days from the date of this TSB. ^ Returns are restricted to the subject parts. ^ The parts returned must have been purchased from FCSD in accordance with Policy and Procedure Bulletin 4000. CREDIT Credit for parts and prepaid freight costs will be issued. Replacement stock is available for ordering PART NUMBER PART NAME F1SZ-10884-A Temperature Sender OTHER APPLICABLE ARTICLES: 93-24-8 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 203000, 203200, 204000, 204200, 402000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Technical Service Bulletins > Page 9157 Temperature Sensor (Gauge): Locations Engine Compartment. Top Front Of Engine Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Testing and Inspection > Pinpoint Tests Fig. 5 Temperature Indicating System Diagnosis Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) > Component Information > Testing and Inspection > Pinpoint Tests > Page 9160 Temperature Sensor (Gauge): Component Tests and General Diagnostics Magnetic Type 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 73 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace gauge. Bimetal Type The instrument voltage regulator (IVR) supplies a common regulated voltage for temperature, oil pressure and fuel gauges. The IVR is malfunctioning only if all gauges show similar problems. Test temperature gauge with Rotunda Gauge Tester 021-00055 or equivalent or with a 10 ohm resistor for high calibration and a 75 ohm resistor for low calibration as follows: 1. Turn ignition switch to On or ACC position. 2. Connect a 10 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the H mark. 3. Connect a 75 ohm resistor between gauge lead and ground. The centerline of pointer should fall within the band around the C mark. 4. If gauge tests within calibration, replace sender. 5. If gauge is out of calibration, replace IVR and retest. 6. If gauge is out of calibration, replace gauge. Refer to DIAGNOSTIC CHARTS for coolant temperature indicating system diagnosis. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Warning Lamp/Indicator, Engine Cooling > Component Information > Description and Operation Temperature Warning Lamp/Indicator: Description and Operation Bimetal Type The temperature lamp system provides the driver with an indication of engine coolant temperature by means of a switch mounted in the intake manifold and a red engine lamp mounted on the instrument panel. The temperature switch has a temperature sensitive bimetallic arm which completes the lamp circuit through the switch to engine ground. Magnetic Type The temperature indicating system is a magnetic type system, which consists only of the sending unit located in the engine block or cylinder head and a temperature gauge in the instrument cluster. The sending unit changes resistance according to the temperature of engine coolant, which varies the current flow through the gauge. The pointer position varies proportionally to the current flow. The sender resistance is high when coolant temperature is low, and low when coolant temperature is high. The pointer of the magnetic gauge remains in position when ignition is turned to the Off position. It will move to the correct indication whenever the ignition is turned back to On position. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation Volt Meter Gauge: Description and Operation The voltmeter indicates battery voltage when the ignition is in the Run position (engine off). After starting the engine, the pointer will move to indicate charging system voltage. Voltmeter is not adjustable and should be replaced if inoperative. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Volt Meter Gauge > Component Information > Description and Operation > Page 9167 Volt Meter Gauge: Testing and Inspection To test the voltmeter, turn the ignition switch On, turn headlamps On and set heater blower fan on High with engine stopped. The meter pointer should move toward the lower portion of the normal band (white portion of scale). If no movement of needle is observed, check battery to circuit breaker and circuit breaker to cluster wire connections. If connections are tight, and meter shows no movement, check fuse and wire continuity. If fuse and wire continuity are satisfactory, remove cluster from vehicle. Check for flex circuit to clip terminal continuity. If circuit is satisfactory, replace gauge. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor: Locations On Rear View Mirror Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations LH Rear Side Of Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions Brake Lamp: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9180 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9181 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Brake Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9182 Hazard, Stop and Turn Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations I/P Components On Brake Pedal Support Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9186 Brake Light Switch: Service and Repair When servicing any component on a vehicle equipped with anti-lock brakes it is necessary to discharge the hydraulic pressure in the system. Refer to Brakes and Traction Control/Brakes/Antilock Brake System/Service and Repair for procedure for procedure. 1. Disconnect battery ground cable. 2. Disconnect electrical connector from brake sensor switch. 3. Remove sensor switch from brake control valve body. 4. Reverse procedure to install. Torque brake sensor switch to 8-10 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions Cornering Lamp: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9191 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9192 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Cornering Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9193 Corning Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information > Locations Interior Light Switch: Locations Body & Chassis Components In Respective Door Jamb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations LH Front Of Engine Compartment, On Radiator Support Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Control Unit: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 9207 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 9208 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 9209 Daytime Running Lamp Control Unit: Electrical Diagrams Daytime Running Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 9210 Daytime Running Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Dimmer Switch > Component Information > Locations Dimmer Switch: Locations I/P Components LH Side Of Dash, Near Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Body & Chassis Components In Respective Door Latch Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Door Switch > Component Information > Locations > Page 9217 Door Switch: Service and Repair REMOVAL and INSTALLATION 1. Remove connector at switch. 2. Using an ohmmeter such as Rotunda Digital Volt Ohm Meter 007-00001, or an equivalent probe between switch terminal and ground (latch). 3. With door in latched (fully closed) position, switch should be open. 4. With door open, switch must be closed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Diagrams > Diagram Information and Instructions Fog/Driving Lamp: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9222 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9223 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9224 Fog Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component Information > Locations Hazard Warning Flasher: Locations Fuse panel is on LH side of lower instrument panel. Combination turn signal/hazard flasher is located to RH side of steering column opening reinforcement, mounted on a bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9233 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9234 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9235 Hazard Warning Switch: Electrical Diagrams Hazard, Horn And Memory Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9236 Hazard, Stop and Turn Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Headlamp Control Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9242 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9243 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9244 Headlamp Control Module: Electrical Diagrams Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9245 Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9246 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9247 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9248 Headlamps (Except Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Relay > Component Information > Locations Headlamp Dimmer Relay: Locations I/P Components RH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9257 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9258 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9259 Headlamp Dimmer Switch: Electrical Diagrams Headlamps (Except Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9260 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9261 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9262 Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9263 Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9264 Headlamp Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove lower LH finish panel retaining bolts and carefully pull to disengage retaining clips. 3. Remove lower LH reinforcement panel retaining bolts and remove panel. 4. Remove steering column lower shroud retaining screws and remove lower shroud. 5. Remove steering column retaining nuts, then remove column upper shroud. 6. Disconnect switch electrical connectors. 7. Remove switch retaining bolts, then remove switch. 8. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9270 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9271 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9272 Headlamp Switch: Electrical Diagrams Main Light Switch (Except Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9273 Main Light Switch (With Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams > Page 9274 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove two cluster trim panel retaining screws. 3. Pull off headlamp switch knob and snap off cluster trim panel. 4. Disconnect electrical connector to headlamp dimmer sensor assembly. 5. With headlamp switch in full On position, using opening in instrument panel, depress shaft release button on switch and remove shaft. 6. Remove headlamp switch retaining nut and pull switch through opening to disconnect wiring connector. 7. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Headlamp > High Beam Relay > Component Information > Locations High Beam Relay: Locations I/P Components RH Side Of Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Technical Service Bulletins > Customer Interest for Horn Switch: > 902510 > Dec > 90 > Horn Button - High Operation Effort Horn Switch: Customer Interest Horn Button - High Operation Effort HORN - HIGH EFFORTS TO DEPRESS PAD DURING LOW AMBIENT TEMPERATURES NON-SUPERCHARGED CARS Article No. 90-25-10 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: High effort may be required when depressing the horn pad to sound the horn. This is caused by a steering wheel horn pad that is too stiff in low ambient temperatures. The stiff horn pad may not allow the horn contacts to close. ACTION: Install a new horn pad made from urethane material. This improves low temperature flexibility and reduces the horn blowing effort. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 35-80, for service details. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902510A Install Horn Pad 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 13A805 99 OASIS CODES: 203000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Horn Switch: > 902510 > Dec > 90 > Horn Button - High Operation Effort Horn Switch: All Technical Service Bulletins Horn Button - High Operation Effort HORN - HIGH EFFORTS TO DEPRESS PAD DURING LOW AMBIENT TEMPERATURES NON-SUPERCHARGED CARS Article No. 90-25-10 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: High effort may be required when depressing the horn pad to sound the horn. This is caused by a steering wheel horn pad that is too stiff in low ambient temperatures. The stiff horn pad may not allow the horn contacts to close. ACTION: Install a new horn pad made from urethane material. This improves low temperature flexibility and reduces the horn blowing effort. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 35-80, for service details. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902510A Install Horn Pad 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 13A805 99 OASIS CODES: 203000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Technical Service Bulletins > Page 9292 Horn Switch: Service and Repair MODELS EQUIPPED w/TURN SIGNAL MOUNTED SWITCH Horn sounder is located on the turn signal, headlight dimmer and horn lever. Refer to Vehicle Lighting/Turn signals/Turn Signal Switch/Service and Repair when replacing switch. 1. Disconnect battery ground cable. 2. Pry switch cover off top. Use caution not to damage cover when removing. 3. Remove switch attaching screws, then lift switch from steering wheel. Use caution not to loose contact spring. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions Parking Lamp: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9297 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9298 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9299 Parking Lamp: Electrical Diagrams Rear Park Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Parking Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9300 Exterior Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Courtesy Lamp Relay > Component Information > Locations Courtesy Lamp Relay: Locations Body & Chassis Components Behind LH Rear Wheelwell Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Locations Daytime Running Lamp Control Unit: Locations LH Front Of Engine Compartment, On Radiator Support Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions Daytime Running Lamp Control Unit: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 9310 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 9311 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 9312 Daytime Running Lamp Control Unit: Electrical Diagrams Daytime Running Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Daytime Running Lamp Control Unit > Component Information > Diagrams > Diagram Information and Instructions > Page 9313 Daytime Running Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions Headlamp Control Module: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9318 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9319 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9320 Headlamp Control Module: Electrical Diagrams Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9321 Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9322 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9323 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module > Component Information > Diagrams > Diagram Information and Instructions > Page 9324 Headlamps (Except Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Dimmer Relay > Component Information > Locations Headlamp Dimmer Relay: Locations I/P Components RH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > High Beam Relay > Component Information > Locations High Beam Relay: Locations I/P Components RH Side Of Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Ambient Light Sensor > Component Information > Locations Ambient Light Sensor: Locations On Rear View Mirror Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Backup Lamp Switch > Component Information > Locations Backup Lamp Switch: Locations LH Rear Side Of Transmission Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations Brake Light Switch: Locations I/P Components On Brake Pedal Support Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 9341 Brake Light Switch: Service and Repair When servicing any component on a vehicle equipped with anti-lock brakes it is necessary to discharge the hydraulic pressure in the system. Refer to Brakes and Traction Control/Brakes/Antilock Brake System/Service and Repair for procedure for procedure. 1. Disconnect battery ground cable. 2. Disconnect electrical connector from brake sensor switch. 3. Remove sensor switch from brake control valve body. 4. Reverse procedure to install. Torque brake sensor switch to 8-10 ft. lbs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations Door Switch: Locations Body & Chassis Components In Respective Door Latch Assembly Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Door Switch > Component Information > Locations > Page 9345 Door Switch: Service and Repair REMOVAL and INSTALLATION 1. Remove connector at switch. 2. Using an ohmmeter such as Rotunda Digital Volt Ohm Meter 007-00001, or an equivalent probe between switch terminal and ground (latch). 3. With door in latched (fully closed) position, switch should be open. 4. With door open, switch must be closed. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions Hazard Warning Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9350 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9351 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9352 Hazard Warning Switch: Electrical Diagrams Hazard, Horn And Memory Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9353 Hazard, Stop and Turn Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Locations Headlamp Dimmer Switch: Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Dimmer Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9359 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9360 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9361 Headlamp Dimmer Switch: Electrical Diagrams Headlamps (Except Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9362 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9363 Automatic Lamps And Delayed Exit Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9364 Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9365 Automatic Headlamp Dimmer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch > Component Information > Diagrams > Page 9366 Headlamp Dimmer Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove lower LH finish panel retaining bolts and carefully pull to disengage retaining clips. 3. Remove lower LH reinforcement panel retaining bolts and remove panel. 4. Remove steering column lower shroud retaining screws and remove lower shroud. 5. Remove steering column retaining nuts, then remove column upper shroud. 6. Disconnect switch electrical connectors. 7. Remove switch retaining bolts, then remove switch. 8. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Locations Headlamp Switch: Locations I/P Components LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions Headlamp Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9372 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9373 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9374 Headlamp Switch: Electrical Diagrams Main Light Switch (Except Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9375 Main Light Switch (With Autolamps) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch > Component Information > Diagrams > Page 9376 Headlamp Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove two cluster trim panel retaining screws. 3. Pull off headlamp switch knob and snap off cluster trim panel. 4. Disconnect electrical connector to headlamp dimmer sensor assembly. 5. With headlamp switch in full On position, using opening in instrument panel, depress shaft release button on switch and remove shaft. 6. Remove headlamp switch retaining nut and pull switch through opening to disconnect wiring connector. 7. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Technical Service Bulletins > Customer Interest: > 902510 > Dec > 90 > Horn Button - High Operation Effort Horn Switch: Customer Interest Horn Button - High Operation Effort HORN - HIGH EFFORTS TO DEPRESS PAD DURING LOW AMBIENT TEMPERATURES NON-SUPERCHARGED CARS Article No. 90-25-10 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: High effort may be required when depressing the horn pad to sound the horn. This is caused by a steering wheel horn pad that is too stiff in low ambient temperatures. The stiff horn pad may not allow the horn contacts to close. ACTION: Install a new horn pad made from urethane material. This improves low temperature flexibility and reduces the horn blowing effort. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 35-80, for service details. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902510A Install Horn Pad 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 13A805 99 OASIS CODES: 203000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 902510 > Dec > 90 > Horn Button - High Operation Effort Horn Switch: All Technical Service Bulletins Horn Button - High Operation Effort HORN - HIGH EFFORTS TO DEPRESS PAD DURING LOW AMBIENT TEMPERATURES NON-SUPERCHARGED CARS Article No. 90-25-10 FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1989-90 COUGAR ISSUE: High effort may be required when depressing the horn pad to sound the horn. This is caused by a steering wheel horn pad that is too stiff in low ambient temperatures. The stiff horn pad may not allow the horn contacts to close. ACTION: Install a new horn pad made from urethane material. This improves low temperature flexibility and reduces the horn blowing effort. Refer to the 1989/90 Thunderbird/Cougar Shop Manual, Section 35-80, for service details. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 902510A Install Horn Pad 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 13A805 99 OASIS CODES: 203000, 205000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Technical Service Bulletins > All Other Service Bulletins for Horn Switch: > 89139 > Jun > 89 > A/T - PRNDL Bulb Socket Melted Shift Indicator: All Technical Service Bulletins A/T - PRNDL Bulb Socket Melted LAMP-TRANSMISSION PRNDL BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 TRANSMISSION-PRNDL LIGHT BULB SOCKET MELTED-VEHICLES BUILT BEFORE 5/13/89 Article No. 89-13-9 FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: Heat from the transmission "PRNDL" light bulb may soften and melt the plastic bulb socket. This is caused by the two (2) candlepower bulb. ACTION: Install a new bulb and socket assembly. The new assembly has a one (1) candlepower bulb which will operate cooler. Refer to the 1989 Thunderbird /Cougar Shop Manual, Section 17-02 for service details. NOTE: THE NEW BULB AND SOCKET ASSEMBLY ALSO HAS A LIGHTER GREEN FILTER SO THE LESS BRIGHT BULB WILL STILL SUPPLY THE CORRECT GREEN COLOR AND INTENSITY. PART NUMBER PART NAME CLASS E9SZ-15A808-C Bulb and Socket Assembly C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 891309A Install Bulb & Socket 0.5 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 15A808 46 OASIS CODES: 2100, 2150 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component Information > Technical Service Bulletins > Page 9400 Horn Switch: Service and Repair MODELS EQUIPPED w/TURN SIGNAL MOUNTED SWITCH Horn sounder is located on the turn signal, headlight dimmer and horn lever. Refer to Vehicle Lighting/Turn signals/Turn Signal Switch/Service and Repair when replacing switch. 1. Disconnect battery ground cable. 2. Pry switch cover off top. Use caution not to damage cover when removing. 3. Remove switch attaching screws, then lift switch from steering wheel. Use caution not to loose contact spring. 4. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch > Component Information > Locations Interior Light Switch: Locations Body & Chassis Components In Respective Door Jamb Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9408 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9409 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9410 Hazard, Stop and Turn Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch > Component Information > Diagrams > Page 9411 Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove trim shroud or shroud halves. 3. Remove turn signal switch lever from switch. Grasp lever and use a pulling and twisting motion while pulling lever straight out from switch. 4. Peel back foam shield from turn signal switch, then disconnect two electrical connectors from switch. 5. Remove turn signal switch attaching screws, then remove switch. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 9416 OASIS CODES: 201000, 201200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information > Locations Turn Signal Flasher: Locations Fuse panel is on LH side of lower instrument panel. Combination turn signal/hazard flasher is located to RH side of steering column opening reinforcement, mounted on a bracket. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Lamp: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9425 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9426 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Component Information > Diagrams > Diagram Information and Instructions > Page 9427 Hazard, Stop and Turn Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions Turn Signal Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9432 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9433 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9434 Hazard, Stop and Turn Lamps Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams > Page 9435 Turn Signal Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove trim shroud or shroud halves. 3. Remove turn signal switch lever from switch. Grasp lever and use a pulling and twisting motion while pulling lever straight out from switch. 4. Peel back foam shield from turn signal switch, then disconnect two electrical connectors from switch. 5. Remove turn signal switch attaching screws, then remove switch. 6. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised Underhood Lamp Switch: Technical Service Bulletins Hood Lamp Switch - Revised Article No. 01-21-6 10/29/01 ELECTRICAL - REVISED MECHANICAL HOOD LAMP SWITCH TO REPLACE OLD STYLE MERCURY HOOD LAMP SWITCH FORD: 1987-1995 TAURUS 1988-1991 CROWN VICTORIA 1989 THUNDERBIRD 1989-1996 MUSTANG 1994-1996 THUNDERBIRD 1990 BRONCO II 1990-1996 RANGER 1991-1996 BRONCO 1994-2001 EXPLORER 1997-2001 F-150 2000-2001 EXCURSION 2002 EXPEDITION LINCOLN: 1989-1994 CONTINENTAL 1990-1992 MARK VII 1990-1996 TOWN CAR 1993-1995 MARK VIII 2002 NAVIGATOR MERCURY: 1987-1995 SABLE 1988-1991 GRAND MARQUIS 1989 COUGAR 1994-1996 COUGAR 1997-2001 MOUNTAINEER ISSUE This article is to provide information on replacement hood lamp switches. The 27 degree Mercury style hood switches will no longer be available. Replacement 27 degree Mechanical switches will be available as a service replacement. ACTION For vehicles requiring hood lamp switch replacement, replace the 27 degree Mercury switch with new 27 degree Mechanical switch. Replace hood lamp switch per the appropriate model year Workshop Manual as needed. Parts Block OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Lighting and Horns > Underhood Lamp > Underhood Lamp Switch > Component Information > Technical Service Bulletins > Hood Lamp Switch - Revised > Page 9441 OASIS CODES: 201000, 201200 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Heated Glass Element > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates Technical Service Bulletin # 8918A1 Date: 890915 Heated Backlite Grid - Manual Updates SHOP MANUAL-1989-SECTION 36-86-HEATED BACKLITE GRID-SERVICE INFORMATION Article No. 89-18A-1 FORD: 1987-89 CROWN VICTORIA, ESCORT, TAURUS, TEMPO, THUNDERBIRD LINCOLN-MERCURY: 1987-89 CONTINENTAL, COUGAR, GRAND MARQUIS 1987 LYNX 1987-89 MARK VII, SABLE, TOPAZ, TOWN CAR ISSUE: Section 36-86, Window, Rear--Defroster, of 1989 and prior Car Shop Manuals, has been revised to include new service information on heated backlite grid repair. The statement which now reads: "Any break in the grid longer than 25 mm (1 inch) cannot be repaired." should be revised to read: "A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired." ACTION: Refer to the pages following this TSB article for revised material. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 2800 Continental 1989 Continental 36-86-1 Window, Rear-Defroster 36-86-1 SECTION 36-86 Window, Rear-Defroster SUBJECT PAGE SPECIAL SERVICE TOOLS 36-86-4 DESCRIPTON AND OPERATION 36-86-1 MAJOR SERVICE OPERATIONS Grid Wire Repair 36-86-2 Lead Wire Terminal Service 36-86-3 REMOVAL AND INSTALLATION Relay Control Assembly 36-86-4 Switch 36-86-3 SUBJECT PAGE REMOVAL AND INSTALLATION (Cont'd.) Window 36-86-4 TESTING Grid Wire Test 36-86-4 Relay Tests 36-86-4 Switch Assembly 36-86-4 VEHICLE APPLICATION 36-86-1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9451 VEHICLE APPLICATION Continental. DESCRIPTION AND OPERATION The heated rear window defroster system consists of a switch assembly and a relay control assembly mounted to the instrument panel, and a series of grid wires baked on the inside surface of the rear window. When the control switch is activated by the push button, current is directed to the grid wires on the rear window. The heated grid wires keep the rear window clear of fog or ice. The integral timer automatically turns off the heating grid after approximately 10 minutes of operation. If more than 10 minutes of use is needed, the grid can be reactivated for another 10 minutes by pushing the push button to the ON position. This operation can be repeated as required. Power for the control timer and relay coil comes from the RUN terminal of the ignition switch and from the high-current fuse panel. 1989 Continental 36-86-2 Window, Rear-Defroster 36-86-2 DESCRIPTION AND OPERATION (Continued) The rear window defrost grid is fed through the relay contacts from the high current fuse panel. The input to the rear defrost control assembly from the ignition switch determines if the relay contacts will stay closed when activated by the ON-OFF push button. When the ignition switch is in RUN position, moving the button to ON closes the relay contacts and also activates the timing circuit. The relay contacts will remain closed until they are opened by the timing circuit, the button is depressed to the OFF position, or the ignition switch is turned to the OFF position. The circuit is protected by a fuse located in the highcurrent fuse panel. The operating button is spring-loaded to return from ON or OFF to its center (normal) position. As soon as the switch is depressed to the ON position, it electrically connects power to energize the timer relay coil, thereby causing the normally open relay load contacts to close and provide power to the ON lamp and the rear window grid wires. The grid wires will continue to receive power for approximately 10 minutes. The control can be deactivated before automatic time out by momentarily depressing it to the OFF position, or by turning the ignition switch to the OFF position. For individual wiring harness applications, refer to Section 34-24. MAJOR SERVICE OPERATIONS Grid Wire Repair Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9452 NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The rear window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: Surface Preparations 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean entire grid line repair area with Ultra Clear Spray Glass Cleaner E4AZ-19C507-AA (ESRM1495-A) or equivalent, to remove all dirt, wax, grease, oil or other foreign matter, It is important that repair area be clean and dry. Mixing The bottle of Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent and touch-up paint must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. Application 1. Mark location of break on outside of window. 2. Using cellulose tape, mask off area directly above and below grid break. The break area should be at the center of mask, and tape gap must be no wider than existing grid line. 3. If both brown and silber layers of grid are broken or missing, apply a coating of the brown touchup paint across break area first. Two coats may be necessary to obtain proper color. Allow touch-up paint to dry, then apply three coats of silver grid repair compound, allowing three to five minutes drying time between coats. The coating of silver grid repair compound should extend at least 6.35 mm (1/4-inch) on both sides of break area. NOTE: If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the break. 4. Allow to dry for five minutes, then remove mask. 5. After removing mask, check outside appearance of grid repair. If silver repair compound is visible above or below grid, this excess should be removed. This can be done by placing a single-edge razor blade on the glass parallel to the grid and scraping gently toward grid. CAUTION: Be careful not to damage the grid line with the razor blade. Curing The repair coating will air dry in approximately one minute and can be energized within three to five minutes. Optimum hardness and adhesion occurs after approximately 24 hours. At that time, the repair area may be cleaned with a mild window cleaner. Mark VII 1989 Mark VII 36-86-2 Window, Rear-Defroster 36-86-2 TESTING Control Assembly Tests 1. Ground pin (G) and connect a jumper wire between pins (B) and (1). Connect a 12-volt test lamp between pin (L) and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9453 2. Apply power to pin (B). The test lamp should not light. 3. Apply power to pin S. The heated rear window symbol on the switch knob should light up. 4. Momentarily actuate rocker knob to the ON position. The test lamp should come on andstay on after rocker knob returns to othe normal position. 5. Test lamp should go off under any one or more of the following conditions: a. If rocker knob is moved to the OFF position. b. Jumper wire between pins I and B is removed. c. Approximately 10 minutes have elapsed. Grid Wire Test 1. Using a strong lamp inside the vehicle, visually inspect the wire grid from the outside. A broken grid wire will appear as a brown spot. 2. Run the engine at idle. Set the control switch to ON. The indicator lamp should come on. 3. Working inside the vehicle with a 12-volt DC voltmeter such as Rotunda Digital Volt Ohm Meter 007-00001 or equivalent, contact the broad red-brown strips of the rear window positive lead to battery side and negative lead to ground side. The meter should read 10-13 volts. A lower voltage reading indicates a loose ground wire (pigtail) connection at the ground attaching screw. 4. Contact a good ground point with the negative lead of the meter. The voltage reading should not change. 5. With the negative lead of the meter grounded, touch each grid line of the heated rear window at its midpoint with the positive lead. A reading of approximately 6-volts indicates that the line is good. A reading of 0-volts indicates that the line is broken between the midpoint and the B+ side of the grid line. A reading of 12-volts indicates that the circuit is broken between the midpoint of the grid line and ground. REMOVAL AND INSTALLATION Control Assembly Removal and Installation 1. Remove applique. 2. Remove two screws retaining control assembly. 3. To install, reverse Steps 1 and 2. Window Disconnect wire leads at each end of the glass. Remove window. Refer to Section 43-11. 1989 Mark VII 36-86-3 Window, Rear-Defroster 36-86-3 MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: NOTE: If the first layer of the heated rear window grid (brown color) is damaged or missing, it will be necessary to apply brown Acrylic Lacquer Touch-Up Paint AL81-5477-B (ESR-M2P100-B) or equivalent on the glass prior to applying the Ford Rear Window Defroster Repair D8AZ-19562-AA (ESB-M4J58-A) or equivalent. Inoperative grid wires on heated rear windows should be repaired by using Ford Rear Window Defroster Repair D8AZ-19562-AA (ESB-M4J58-A) or equivalent. Surface Preparation 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner D4AZ-19C507-AA (ESRM14P5-A) or equivalent to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. CAUTION: Do not use scrapers, sharp instruments, or abrasive cleaners on the interior surface of the rear window, as this may cause damage to the grid lines. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9454 Mixing The bottle of Rear Window Defroster Repair D8AZ- 19562-AA (ESB-M4J58-A) or equivalent and touchup paint (if needed) must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. Application 1. Mark location of break on the outside of the window. 2. Using cellulose tape, mask off the area directly above and below grid break. The break area should be at the center of mask, and tape gap must be no wider than the existing grid line. 3. Apply the repair coating in several smooth continuous strokes (allowing three to five minutes drying time between coats) across the break area using the brush applicator in the cap. Extend the service coating at least 6.35 mm (1/4 inch) on both sides of the break area. If both brown and silver layers of the grid are broken or missing, apply a coating of the brown touch-up paint across the break area first. Two coats may be necessary to obtain the proper color. Allow the touch-up paint to dry, then apply three coats of silver grid repair compound allowing three to five minutes drying time between coats. The coating of the silver grid repair compound should extend at least 6.35 mm (1/4 inch) on both sides of the break area. 4. Allow to dry for five minutes, then remove the mask. 5. After removing the mask, check the outside appearance of the grid repair. If the silver repair compound is visible above or below the grid, this excess should be removed. This can be done by placing a single-edge razor blade on the glass parallel to grid and scrape gently towards grid. CAUTION: Be careful not to damage grid line with the razor blade. Curing The service coating will air dry in approximately one minute and can be energized within three minutes. Optimum hardness and adhesion occurs after approximately 24 hours. At that time, the serviced area may be cleaned with a mild window cleaner. Lead Wire Terminal Repair 1. Allow the rear window to warm up to room temperature for one half hour to an hour. 2. Clean the bus bar in the area to be repaired using fine steel wool (3/0 to 4/0 grade). 3. Restore the area where the bus bar terminal was originally attached by applying three coats of Rear Window Defroster Repair D8AZ-19562- AA (ESB-M4J58-A) or equivalent. Allow approximately 10 minutes drying time between coats. 4. Working as quickly as possible to avoid overheating the glass, tin the bus bar with solder in the area where the terminal will be reattached. 5. Using Rotunda Heat Gun 107-00300 or equivalent, preheat the glass in the solder area to 67~-83~C (120~-150~F) just prior to soldering the terminal on. Thunderbird/Cougar 1989 Thunderbird/Cougar 36-86-2 Window, Rear-Defroster 36-86-2 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9455 DESCRIPTION AND OPERATION (Continued) TESTING Control Assembly Tests 1. Ground pin 4 and connect a jumper wire between pins 2 and 3. Connect a 12-volt test lamp between pin 1 and ground. 2. Apply power to pin 2. The test lamp should not light. 3. Apply power to pin 5. The heated rear window symbol on the switch should light up. 4. Momentarily actuate the rocker switch to the ON position. The test lamp should come on and stay on after rocker switch returns to the normal position. 5. Test lamp should go off under any one or more of the following conditions: a. If rocker switch is moved to the OFF position. b. Jumper wire between pins 2 and 3. c. Approximately 10 minutes have elapsed. 1989 Thunderbird/Cougar 36-86-3 Window, Rear-Defroster 36-86-3 TESTING (Continued) Grid Wire Test 1. Using a strong lamp inside the vehicle, visually inspect the wire grid from the outside. A broken grid wire will appear as a brown spot. 2. Run the engine at idle. Set the control switch to ON. The indicator lamp should come on. 3. Working inside the vehicle with a 12-volt DC voltmeter such as Rotunda Digital Volt Ohm Meter 007-00001 or equivalent, contact the broad red-brown strips on the rear window; positive lead to battery side and negative lead to ground side. The meter should read 10-13 volts. A lower voltage reading indicates a loose ground wire (pigtail) connection at the ground attaching screw. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9456 4. Contact a good ground point with the negative lead of the meter. The voltage reading should not change. 5. With the negative lead of the meter grounded, touch each grid line of the heated rear window at its midpoint with the positive lead. A reading of approximately 6-volts indicates that the line is good. A reading of 0-volts indicates that the line is broken between the midpoint and the B+ side of the grid line. A reading of 12-volts indicates that the circuit is broken between the midpoint of the grid line and ground. REMOVAL AND INSTALLATION Control Assembly Removal and Installation 1. Remove instrument panel trim panel. 2. Remove electrical connector from control assembly. 3. Push on connector base of control assembly to push control assembly out of trim panel. 4. To install, reverse Steps 1, 2 and 3. Window Disconnect wire leads at each end of the glass. Remove window. Refer to Section 43-11. MAJOR SERVICE OPERATIONS Grid Wire Repair Note: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: NOTE: If the first layer of the heated rear window grid (brown color) is damaged or missing, it will be necessary to apply brown Acrylic Lacquer Touch-Up Paint AL81-5477-B (ESR-M2P100-B) or equivalent on the glass prior to applying the silver Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent. Inoperative grid wires on heated rear windows should be repaired by using Ford Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent. Surface Preparation 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner E4AZ-19C507-AA (ESR-M14P5-A) or equivalent to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. CAUTION: Do not use scrapers, sharp instruments, or abrasive cleaners on the interior surface of the rear window, as this may cause damage to the grid lines. Mixing The bottle of Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent and touch-up paint (if needed) must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. Application 1. Mark location of break on the outside of the window. 2. Using cellulose tape, mask off the area directly above and below grid break. The break area should be at the center of mask, and tape gap must be no wider than the existing grid line. 3. Apply the repair coating in several smooth continuous strokes (allowing three to five minutes drying time between coats) across the break area using the brush applicator in the cap. Extend the service coating at least 6.35 mm (1/4-inch) on both sides of the break area. If both brown and silver layers of the grid are broken or missing, apply a coating of the brown touch-up paint across the break area first. Two coats may be necessary to obtain the proper color. Allow the touch-up paint to dry, then apply three coats of silver grid repair compound allowing three to five minutes drying time between coats. The coating of the silver grid repair compound should extend at least 6.35 mm (1/4-inch) on both sides of the break area. 4. Allow to dry for five minutes, then remove the mask. Lincoln Town Car - Ford (Crown Victoria) - Mercury (Grand Marquis) 1989 Lincoln Town Car - Ford (Crown Victoria) - Mercury (Grand Marquis) 36-86-3 Window, Rear-Defroster 36-86-3 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9457 REMOVAL AND INSTALLATION Control Assembly Removal and Installation 1. Remove knob from control lever. 2. Remove applique. 3. Remove screws retaining the climate control head to the instrument panel and remove the climate control head. 4. Remove control assembly from the climate control head assembly. 5. To install, reverse Steps 1 through 4. 1989 Lincoln Town Car - Ford (Crown Victoria) - Mercury (Grand Marquis) 36-86-4 Window, Rear-Defroster 36-86-4 REMOVAL AND INSTALLATION (Continued) Window Disconnect wire leads at each end of the glass. Remove window. Refer to Section 43-11. MAJOR SERVICE OPERATIONS Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9458 Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: NOTE: If the first layer of the heated rear window grid (brown color) is damaged or missing, it will be necessary to apply brown Acrylic Lacquer Touch-Up Paint AL81-5477-B (ESR-M2P100-B) or equivalent on the glass prior to applying the Ford Rear Window Defroster Repair D8AZ-19562-AA (ESB-M4J58-A) or equivalent. Inoperative grid wires on heated rear windows should now be repaired by using Ford Rear Window Defroster Repair D8AZ-19562-AA (ESB-M4J58-A) or equivalent. Surface Preparation 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner D4AZ-19C507-AA (ESR-M14P5-A) or equivalent to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. CAUTION: Do not use scrapers, sharp instruments, or abrasive window cleaners on the interior surface of the rear window as this may cause damage to the grid lines. Mixing The bottle of Rear Window Defroster Repair D8AZ- 19562-AA (ESB-M4J58-A) or equivalent and touchup paint (if needed) must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. Application 1. Mark location of break on the outside of the window. 2. Using cellulose tape, mask off the area directly above and below grid break. The break area should be at the center of mask, and tape gap must be no wider than the existing grid line. Tempo/Topaz - Escort 1989 Tempo/Topaz - Escort 36-86-5 Window, Rear-Defroster 36-86-5 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9459 DESCRIPTION AND OPERATION (Continued) Escort 2-Door and 4-Door Hatchback 1989 Tempo/Topaz - Escort 36-86-6 Window, Rear-Defroster 36-86-6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9460 DESCRIPTION AND OPERATION (Continued) 4-Door Wagon MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The rear window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: Surface Preparation 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean entire grid line repair area with Ultra Clear Spray Glass Cleaner E4AZ-19C507-AA (ESRM1495-A) or equivalent, to remove all dirt, wax, grease, oil or other foreign matter. It is important that repair area be clean and dry. Mixing The bottle of Rear Window Defroster Repair D8AZ- 19562-AA (ESB-M4J58-A) or equivalent and touchup paint must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. Application 1. Mark location of break on outside of window. 2. Using cellulose tape, mask off area directly above and below grid break. The break area should be at the center of mask, and tape gap must be no wider than existing grid line. Mustang 1989 Mustang 36-86-3 Window, Rear-Defroster 36-86-3 TESTING (Continued) Relay/Timer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9461 1. Ground pin G and connect a jumper wire between pins B and 1. Connect a 12-volt test lamp between pin L and ground. 2. Supply power to pin B. The test lamp should not light. 3. Momentarily connect pin S to B. The test lamp should come on. 4. The test lamp should go off under the following conditions: a. Terminal S is momentarily connected to pin B. b. Jumper wire between pins B and I is removed. c. Approximately 10 minutes have elapsed from the time the switch was turned on. Grid Wire Test 1. Using a strong lamp inside the vehicle, visually inspect the wire grid from the outside. A broken grid wire will appear as a brown spot. 2. Run the engine at idle. Set the control switch to ON. The indicator lamp should come on. 3. Working inside the vehicle with a 12-volt DC voltmeter such as Rotunda Digital Volt Ohm Meter 007-00001 or equivalent, contact the broad red-brown strips on the rear window positive lead to battery side and negative lead to ground side. The meter should read 10-13 volts. A lower voltage reading indicates a loose ground wire (pigtail) connection at the ground attaching screw. 4. Contact a good ground point with the negative lead of the meter. The voltage reading should not change. 5. With the negative lead of the meter grounded, touch each grid line of the heated rear window at its midpoint with the positive lead. A reading of approximately 6-volts indicates that the line is good. A reading of 0-volts indicates that the line is broken between the midpoint and the B+ side of the grid line. A reading of 12-volts indicates that the circuit is broken between the midpoint of the grid line and ground. REMOVAL AND INSTALLATION Control Assembly 1. Disengage the two locking tabs on the RH side of control by pushing the tabs in with a small screwdriver and pulling on the RH side of the control. 2. Using a screwdriver, pry the LH side of the control out of the instrument panel. 3. Pull the control completely out of the opening and disconnect the two connectors. 4. To install, install the two connectors to the control and insert control into opening in instrument panel until the locking tabs on both sides of the control snap in place. Relay/Timer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9462 1. Remove relay/timer assembly from under LH side of instrument panel, by rotating the ' assembly 90 degrees. 2. Disconnect electrical connector and remove assembly. 3. To install, reverse Steps 1 and 2. Window Disconnect wire leads at each end of the glass. Remove window. Refer to Section 43-11. 1989 Mustang 36-86-4 Window, Rear-Defroster 36-86-4 MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more an 25 mm (1 inch) in one grid cannot be repaired. The window must be replaced. For breaks less than 25 mm (1 inch) tong, use the following procedure: NOTE: If the first layer of the heated rear window grid (brown color) is damaged or missing, it will be necessary to apply brown Acrylic Lacquer Touch-Up Paint AL81-5477-B (ESR-M2P100-B) or equivalent on the glass prior to applying the silver Rear Window Defroster Repair D8AZ-19562-AA (ESB-M4J58-A) or equivalent. Inoperative grid wires on heated rear windows should be repaired by using Rear Window Defroster Repair D8AZ-19562-AA (ESB-M4J58-A) or equivalent. Surface Preparation 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean the entire grid line service area with Ultra Clear Spray Glass Cleaner D4AZ-19C507-AA (ESR-M14P5-A) or equivalent to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. CAUTION: Do not use scrapers, sharp instruments, or abrasive cleaners on the interior surface of the rear window, as this may cause damage to the grid lines. Mixing The bottle of Rear Window Defroster Repair D8AZ- 19562-AA (ESB-M4J58-A) or equivalent and touchup paint (if needed) must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. Application 1. Mark location of break on the outside of the window. 2. Using cellulose tape, mask off the area directly above and below grid break. The break area should be at the center of mask, and tape gap must be no wider than the existing grid line. 3. Apply the repair coating in several smooth continuous strokes (allowing three to five minutes drying time between coats) across the break area using the brush applicator in the cap. Extend the service coating at least 6.35 mm (1/4 inch) on both sides of the break area. If both brown and silver layers of the grid are broken or missing, apply a coating of the brown touch-up paint across the break area first. Two coats may be necessary to obtain the proper color. Allow the touch-up paint to dry, then apply three coats of silver grid repair compound allowing three to five minutes drying time between coats. The coating of the silver grid repair compound should extend at least 6.35 mm (1/4 inch) on both sides of the break area. 4. Allow to dry for five minutes, then remove the mask. 5. After removing the mask, check the outside appearance of the grid repair. If the silver repair compound is visible above or below the grid, this excess should be removed. This can be done by placing a single-edge razor blade on the glass parallel to grid and scrape gently towards grid. CAUTION: Be careful not to damage grid line with the razor blade. Curing The service coating will air dry in approximately one minute and can be energized within three minutes. Optimum hardness and adhesion occurs after approximately 24 hours. At that time, the serviced area may be cleaned with a mild window cleaner. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9463 Lead Wire Terminal Repair 1. Allow the rear window to warm up to room temperature for one half hour to an hour. 2. Clean the bus bar in the area to be repaired using fine steel wool (3/0 to 4/0 grade). 3. Restore the area where the bus bar terminal was originally attached by applying three coats of Rear Window Defroster Repair D8AZ-19562- AA (ESB-M4J58-A) or equivalent. Allow approximately 10 minutes drying time between coats. 4. Working as quickly as possible to avoid overheating the glass, tin the bus bar with solder in the area where the terminal will be reattached. 5. Using Rotunda Heat Gun 107-00300 or equivalent, preheat the glass in the solder area to 67~-83~C (120~-150~F) just prior to soldering the terminal on. Taurus/Sable 1989 Taurus/Sable 36-86-1 Window, Rear-Defroster 36-86-1 SECTION 36-86 Window, Rear-Defroster SUBJECT PAGE DESCRIPTION AND OPERATION 36-86-1 MAJOR SERVICE OPERATIONS Grid Wire Repair 36-86-2 Application 36-86-3 Curing 36-86-3 Mixing 36-86-2 Surface Preparation 36-86-2 Lead Wire Terminal Service 36-86-3 SUBJECT PAGE REMOVAL AND INSTALLATION Switch 36-86-4 Window 36-86-4 SPECIAL SERVICE TOOLS 36-86-4 TESTING Grid Wire Test 36-86-4 Relay Tests 36-86-4 VEHICLE APPLICATION 36-86-1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9464 VEHICLE APPLICATION Taurus/Sable. DESCRIPTION AND OPERATION The heated rear window defroster system consists of a switch and relay control assembly mounted to the instrument panel and a series of grid wires baked on the inside surface of the rear window. When the control switch is activated by the rocker or push button, current is directed to the grid wires on the rear window. The heated grid wires keep the rear window clear of fog or ice. The integral timer automatically turns off tile heating grid after approximately 10 minutes of operation. If more than 10 minutes of use is needed, the grid can be reactivated for another 10 minutes by pushing the rocker or push button to the ON position. This operation can be repeated as required. Power for the control timer and relay coil comes from the RUN terminal of the ignition switch and from a wire containing a fuse link connected to the starter relay. 1989 Taurus/Sable 36-86-2 Window, Rear-Defroster 36-86-2 DESCRIPTION AND OPERATION (Continued) The rear window defrost grid is fed through the relay contacts from the fuse link wire. The input to the rear defrost control assembly from the ignition switch determines if the relay contacts will stay closed when activated by the ON-OFF rocker or buttons. When the ignition switch is in RUN position, moving the rocker or button to ON closes the relay contacts and also activates the timing circuit. The relay contacts will remain closed until they are opened by Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9465 the timing circuit, the rocker or button is depressed to the OFF position, or the ignition is turned to the OFF position. The circuit is protected by a fuse located in tile ruse panel and a fuse link. The operating rocker (Taurus) or buttons (Sable) are spring-loaded to return from ON or OFF to its center (normal) position. As soon as the switch is depressed to the ON position, it electrically connects power to energize the timer relay coil, causing the normally open relay load contacts to close and provide power to the ON lamp and the rear window grid wires. The grid wires will continue to receive power for approximately 10 minutes. The control can be deactivated before automatic time out by momentarily depressing it to the OFF position or when the ignition switch is turned to the OFF position. For individual wiring liarness applications, refer to Section 34-20. MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The rear window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: Surface Preparation 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean entire grid line repair area with Ultra Clear Spray Glass Cleaner E4AZ-19C507-AA (ESRM1495-A) or equivalent, to remove all dirt, wax, grease, oil or other foreign matter. It is important that repair area be clean and dry. Mixing The bottle of Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent and touch-up paint must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. Continental 1988 Continental Window, Rear-Defroster 36-86-1 36-86-1 SECTION 36-86 Window, Rear-Defroster SUBJECT PAGE DESCRIPTION AND OPERATION 36-86-1 MAJOR SERVICE OPERATATIONS Grid Wire Repair 36-86-2 Lead Wire Terminal Service 36-86-3 REMOVAL AND INSTALLATION Relay Control Assembly 36-86-4 Switch 36-86-3 SUBJECT PAGE REMOVAL AND INSTALLATION (Cont'd.) Window 36-86-4 TESTING Grid Wire Test 36-86-5 Relay Tests 36-86-4 Switch Assembly 36-86-5 VEHICLE APPLICATION 36-86-1 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9466 VEHICLE APPLICATION Continental. DESCRIPTION AND OPERATION The heated rear window defroster system consists of a switch assembly and a relay control assembly mounted to the instrument panel, and a series of grid wires baked on the inside surface of the rear window, When the control switch is activated by the push button, current is directed to the grid wires on the rear window. The heated grid wires keep the rear window clear of fog or ice. The integral timer automatically turns off the heating after approximately 10 minutes of operation. If more than 10 minutes of use is needed, the grid can be reactivated for another 10 minutes by pushing the push button to the ON position. This operation can be repeated as required. Power for the control timer and relay coil comes from the RUN terminal of the ignition switch and from the high-current fuse panel. 1988 Continental 36-86-2 Window, Rear-Defroster 36-86-2 DESCRIPTION AND OPERATION (Continued) The rear window defrost grid is fed through the relay contacts from the high current fuse panel. The input to the rear defrost control assembly from the ignition switch determines if the relay contacts will stay closed when activated by the ON-OFF push button. When the ignition switch is in RUN position, moving the button to ON closes the relay contacts and also activates the timing circuit. The relay contacts will remain closed until they are opened by the timing circuit, the button is depressed to the OFF position, or the ignition switch is turned to the OFF position. The circuit is protected by a fuse located in the highcurrent fuse panel. The operating button is spring-loaded to return from ON or OFF to its center (normal) position. As soon as the switch is depressed to the ON position, it electrically connects power to energize the timer relay coil, thereby causing the normally open relay load contacts to close and provide power to the ON lamp and the rear window grid wires. The grid wires will continue to receive power for approximately 10 minutes. The control can be deactivated before automatic time out by momentarily depressing it to the OFF position, or by turning the ignition switch to the OFF position. For individual wiring harness applications, refer to Section 34-24. MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The rear window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: Surface Preparations 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean entire grid line repair area with Ford Glass Cleaner E4AZ-19C507-A (ESR-M 1495- A) or equivalent, to remove all dirt, wax, grease, oil or other foreign matter. It is important that repair area be clean and dry. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9467 Mixing The bottle of Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent and touch-up paint must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. Application 1. Mark location of break on outside of window. 2. Using cellulose tape, mask off area directly above and below grid break. The break area should be at the center of mask, and tape gap must be no wider than existing grid line. 3. If both brown and silver layers of grid are broken or missing, apply a coating of the brown touchup paint across break area first. Two coats may be necessary to obtain proper color. Allow touch-up paint to dry, then apply three coats of silver grid repair compound, allowing three to five minutes drying time between coats. The coating of silver grid repair compound should extend at least 6.35mm (1/4-inch) on both sides of break area. NOTE: If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the break. 4. Allow to dry for five minutes, then remove mask. 5. After removing mask, check outside appearance of grid repair. If silver repair compound is visible above or below grid, this excess should be removed. This can be done by placing a single-edge razor blade on the glass parallel to the grid and scraping gently toward grid. CAUTION: Be careful not to damage the-grid line with the razor blade. Curing The repair coating will air dry in approximately one minute and can be energized within three to five minutes, Optimum hardness and adhesion occurs after approximately 24 hours. At the time, the repair area may be cleaned with a mild window cleaner. Taurus/Sable 1988 Taurus/Sable 36-86-1 Window, Rear-Defroster 36-86-1 SECTION 36-86 Window, Rear-Defroster SUBJECT PAGE DESCRIPTION AND OPERATION 36-86-1 MAJOR SERVICE OPERATIONS Grid Wire Repair 36-86-2 Application 36-86-3 Curing 36-86-3 Mixing 36-86-2 Surface Preparation 36-86-2 Lead Wire Terminal Service 36-86-3 SUBJECT PAGE REMOVAL AND INSTALLATION Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9468 Switch 36-86-4 Window 36-86-4 SPECIAL SERVICE TOOLS 36-86-4 TESTING Grid Wire Test 36-86-4 Relay Tests 36-86-4 VEHICLE APPLICATION 36-86-1 VEHICLE APPLICATION Taurus/Sable. DESCRIPTION AND OPERATION The heated rear window defroster system consists of a switch and relay control assembly mounted to the instrument panel and a series of grid wires baked on the inside surface of the rear window. When the control switch is activated by the rocker or push button, current is directed to the grid wires on the rear window. The heated grid wires keep the rear window clear of fog or ice. The integral timer automatically turns off the heating grid after approximately 10 minutes of operation. If more than 10 minutes of use is needed, the grid can be reactivated for another 10 minutes by pushing the rocker or push button to the ON position. This operation can be repeated as required. Power for the control timer and relay coil comes from the RUN terminal of the ignition switch and from a wire containing a fuse link connected to the starter relay. 1988 Taurus/Sable 36-86-2 Window, Rear-Defroster 36-86-2 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9469 DESCRIPTION AND OPERATION (Continued) The rear window defrost grid is fed through the relay contacts from the fuse link wire. The input to the rear defrost control assembly from the ignition switch determines if the relay contacts will stay closed when activated by the ON-OFF rocker or buttons. When the ignition switch is in RUN position, moving the rocker or button to ON closes the relay contacts and also activates the timing circuit. The relay contacts will remain closed until they are opened by the timing circuit, the rocker or button is depressed to the OFF position, or the ignition is turned to the OFF position. The circuit is protected by a fuse located in the fuse panel and a fuse link. The operating rocker (Taurus) or buttons (Sable) are spring-loaded to return from ON or OFF to its center (normal) position. As soon as the switch is depressed to the ON position, it electrically connects power to energize the timer relay coil, thereby causing the normally open relay load contacts to close and provide power to the ON lamp and the rear window grid wires. The grid wires will continue to receive power for approximately 10 minutes. The control can be deactivated before automatic time out by momentarily depressing it to the OFF position or when the ignition switch is turned to the OFF position. For individual wiring harness applications, refer to Section 34-20. MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The rear window must be replaced, For breaks less than 25 mm (1 inch) long, use the following procedure: Surface Preparation 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean entire grid line repair area with Ford Glass Cleaner E4AZ-19C507-A (ESR-M1495A) or equivalent, to remove all dirt, wax, grease, oil or other foreign matter. It is important that repair area be clean and dry. Mixing The bottle of Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent and touch-up paint must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. Tempo/Topaz - Escort 1988 Tempo/Topaz - Escort 36-86-6 Window, Rear-Defroster 36-86-6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9470 DESCRIPTION AND OPERATION (Continued) Escort EXP 1988 Tempo/Topaz - Escort 36-86-7 Window, Rear-Defroster 36-86-7 DESCRIPTION AND OPERATION (Continued) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9471 4-Door Wagon MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The rear window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: Surface Preparation 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean entire grid line repair area with Ford Glass Cleaner E4AZ-19C507-A (ESR-M1495- A) or equivalent, to remove all dirt, wax, grease, oil or other foreign matter. It is important that repair area be clean and dry. Mixing The bottle of Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent and touch-up paint must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. Application 1. Mark location of break on outside of window. 2. Using cellulose tape, mask off area directly above and below grid break. The break area should be at the center of mask, and tape gap must be no wider than existing grid line. Lincoln Town Car - Ford (Crown Victoria) - Mercury (Grand Marquis) 1988 Lincoln Town Car - Ford (Crown Victoria) - Mercury (Grand Marquis) 36-86-1 Window, Rear-Defroster 36-86-1 SECTION 36-86 Window, Rear-Defroster SUBJECT PAGE DESCRIPTION AND OPERATION 36-86-1 MAJOR SERVICE OPERATIONS Grid Wire Repair 36-86-2 Lead Wire Terminal Repair 36-86-4 REMOVAL AND INSTALLATION Control Assembly 36-86-2 Window 36-86-2 SUBJECT PAGE SPECIAL SERVICE TOOLS 36-86-4 TESTING Control Assembly Tests 36-86-1 Grid Wire Test 36-86-2 VEHICLE APPLICATION 36-86-1 VEHICLE APPLICATION Lincoln Town Car, Ford Crown Victoria/Mercury Grand Marquis. DESCRIPTION AND OPERATION The heated rear window defroster system consists of a control assembly mounted on the climate control head, a series of grid lines baked on the inside surface of the rear window and system wiring. The grid lines consist of two layers. The first layer is brown in color as viewed from the exterior, and the second layer is silver in color as viewed from the interior. The control assembly has a lever spring-loaded to center position, to turn the system on or off, and a timercontrolled relay that turns off automatically after approximately 10 minutes of operation. If more than 10 minutes are required, the control can be reactivated for another 10 minutes by pushing the lever momentarily to the ON position. This operation can be repeated as required. When the lever is pushed to the ON position the normally open contacts in the control are mechanically closed, thus providing power from battery to the rear window grids, the indicator lamp, the heated outside mirror and also triggering the timing circuit. This contact will remain closed until the timer turns it off, the lever is pushed momentarily to the OFF position, or the ignition switch is turned to the OFF position. Power for the rear window grids, the outside rearview mirror and the indicator lamp is supplied directly from the battery side of the starter motor relay through a fuse link which protects the circuit. Power for the control timer comes from the accessory terminal of the ignition switch. This power is available whenever the ignition switch is in the RUN position. This circuit is protected by a fuse, located in the fuse panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9472 FIGURE 1 - Wiring Diagram, Heated Rear Window TESTING Control Assembly Tests 1. Ground pin 2 and connect a jumper wire between pins 4 and 3. Connect a 12-volt test lamp between pin 1 and ground (Fig. 1). 2. Apply power to pin 4. The test lamp should not light. 3. Momentarily actuate the lever to the ON position. The test lamp should come on and stay on after the lever returns to the normal position. 4. Test lamp should go off under any one or more of the following conditions: ^ If lever is moved to the OFF position. ^ Jumper wire between pins 3 and 4 is removed. ^ Approximately 10 minutes has elapsed. 1988 Lincoln Town Car - Ford (Crown Victoria) - Mercury (Grand Marquis) 36-86-2 Window, Rear-Defroster 36-86-2 Grid Wire Test 1. Using a strong lamp inside the vehicle, visually inspect the wire grid from the outside. A broken grid wire will appear as a brown spot. 2. Run the engine at idle. Set the control switch to ON. The indicator lamp should come on. 3. Working inside the vehicle with a 12-volt DC voltmeter such as Rotunda Digital Volt Ohm Meter 007-00001 or equivalent, contact the broad redbrown strips on the rear window (positive lead to battery side and negative lead to ground side). The meter should read 10-13 volts. A lower voltage reading indicates a loose ground wire (pigtail) connection at the ground side of the glass. 4. Contact a good ground point with the negative lead of the meter. The voltage reading should not change. 5. With the negative lead of the meter grounded, touch each grid line of the heated rear window at its midpoint with the positive lead. A reading of approximately 6-volts indicates that the line is good. A reading of zero volts indicates that the line is broken between the midpoint and the B+ side of the grid line. A reading of 12-volts indicates that the circuit is broken between the midpoint of the grid line and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9473 FIGURE 2 - Control Assembly Location REMOVAL AND INSTALLATION Control Assembly Removal and Installation Refer to Fig. 2 1. Remove knob from control lever. 2. Remove applique. 3. Remove screws retaining the climate control head to the instrument panel and remove the climate control head. 4. Remove control assembly from the climate control head assembly. 5. To install, reverse Steps 1 through 4. Window Disconnect wire leads at each end of the glass (Fig. 3). Remove window. Refer to Section 43-11. MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: Mark VII - Thunderbird/Cougar - Mustang Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9474 FIGURE 4 - Control Assembly Electrical Schematic 1988 Mark VII - Thunderbird/Cougar - Mustang 36-86-4 Window, Rear-Defroster 36-86-4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9475 FIGURE 5 - Control Assembly Electrical Schematic-Thunderbird/Cougar with EATC FIGURE 6 - Switch Assembly-Mark VII FIGURE 7 - Switch Assembly-Thunderbird/Cougar 1988 Mark VII - Thunderbird/Cougar - Mustang 36-86-5 Window, Rear-Defroster 36-86-6 1. Disengage the two locking tabs on the RH side of control by pushing the tabs in with a small screwdriver and pulling on the RH side of the control. 2. Using a screwdriver, pry the LH side of the control out of the instrument panel. 3. Pull the control completely out of the opening and disconnect the two connectors. 4. To install, install the two connectors to the control and insert control into opening in instrument panel until the locking tabs on both sides of the control snap in place. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9476 Window Disconnect wire leads at each end of the glass. Remove window. Refer to Section 43-11. MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: NOTE: If the first layer of the heated rear window grid (brown color) is damaged or missing, it will be necessary to apply brown Acrylic Lacquer Touch-Up Paint AL81-5477-B (ESR-M2P100-B) or equivalent on the glass prior to applying the silver Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent. Inoperative grid wires on heated rear windows should be repaired by using Ford Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent. Surface Preparation 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean the entire grid line service area with Ford Glass Cleaner DBAZ-19C507-A (ESR-M14P5-A) or equivalent to remove all dirt, wax, grease, oil or other foreign matter. It is important that the repair area be clean and dry. Taurus/Sable 1987 Taurus/Sable 36-86-2 Window, Rear-Defroster 36-86-2 DESCRIPTION AND OPERATION (Continued) The rear window defrost grid is fed through the relay contacts from the fuse link wire. The input to the rear defrost control assembly from the ignition switch determines if the relay contacts will stay closed when activated by the ON-OFF rocker or buttons. When the ignition switch is in RUN position, moving the rocker or button to ON closes the relay contacts and also activates the timing circuit. The relay contacts will remain closed until they are opened by the timing circuit, the rocker or button is depressed to the OFF position, or the ignition is turned to the OFF position. The circuit is protected by a fuse located in the fuse panel and a fuse link. The operating rocker (Taurus) or buttons (Sable) are spring-loaded to return from ON or OFF to its center (normal) position. As soon as the switch is depressed to the ON position, it electrically connects power to energize the timer relay coil, thereby causing the normally open relay load contacts to close and provide power to the ON lamp and the rear window grid wires. The grid wires will continue to receive power for approximately ten minutes. The control can be deactivated before automatic time out by momentarily depressing it to the OFF position or when the ignition switch is turned to the OFF position. For individual wiring harness applications refer to Section 34-20. MAJOR SERVICE OPERATIONS Grid Wire Repair Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9477 NOTE: A single break or any breaks that total more an 25 mm (1 inch) in one grid cannot be repaired. The rear window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: Surface Preparations 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean entire grid line repair area with Ford Glass Cleaner E4AZ-19C507-A (ESR-M 1495- A) or equivalent or other suitable cleaning solvent to remove all dirt, wax, grease, oil or other foreign matter. It is important that repair area be clean and dry. Mixing The bottle of Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent and touch-up paint must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. 1987 Taurus/Sable 36-86-3 Window, Rear-Defroster 36-86-3 MAJOR SERVICE OPERATIONS (Continued) Application 1. Mark location of break on outside of window. 2. Using cellulose tape, mask off area directly above and below grid break. The break area should be at the center of mask and tape gap must be no wider than existing grid line. 3. If both brown and silber layers of grid are broken or missing, apply a coating of the brown touchup paint across break area first. Two coats may be necessary to obtain proper color. Allow touch-up paint to dry, then apply three coats of silver grid repair compound, allowing three to five minutes drying time between coats. The coating of silver grid repair compound should extend at least 6.35 mm (1/4 inch) on both sides of break area. NOTE: If the brown layer of the grid is not broken or missing, apply only the silver grid repair compound to the break. 4. Allow to dry for five minutes, then remove mask. 5. After removing mask, check outside appearance of grid repair. If silver repair compound is visible above or below grid, this excess should be removed. This can be done by placing a single-edge razor blade on the glass parallel to grid and scrape gently toward grid. CAUTION: Be careful not to damage the grid line with the razor blade. Curing Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9478 The repair coating will air dry in approximately one minute and can be energized within three to five minutes. Optimum hardness and adhesion occurs after approximately 24 hours. At that time, the repair area may be cleaned with a mild window cleaner. Lead Wire Terminal Service 1. Allow rear window to warm up to room temperature for one-half hour to a hour. 2. Clean bus bar in area to be repaired using fine steel wool (3/0 to 4/0 grade). 3. Restore area where bus bar terminal was originally attached by applying three coats of Grid Repair Compound D8AZ-19562-A (ESBM4J58-A) or equivalent. Allow approximately ten minutes drying time between coats. 4. Work as quickly as possible to avoid overheating glass. Tin bus bar with solder in area where terminal will be reattached. 5. Using a heat gun or heat lamp, preheat glass in the solder area to 67~-83~C (120~-150~F), just prior to soldering terminal on. 6. Position terminal on bus bar in area that was tinned and hold it in place with an ice pick or screwdriver. 7. Apply soldering heat to pad of terminal until solder flows. CAUTION: To avoid damaging bus bar, remove soldering gun or Iron as soon as the solder flows. 8. Start the vehicle, turn heater rear window on, and leave it on for five minutes. Inspect terminal and apply Grid Repair Compound D8AZ-19562- A (ESB-M4J58-A) or equivalent to the required area. Tempo/Topaz - Escort/Lynx 1987 Tempo/Topaz - Escort/Lynx 36-86-6 Window, Rear-Defroster 36-86-6 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9479 DESCRIPTION AND OPERATION (Continued) EXP 1987 Tempo/Topaz - Escort/Lynx 36-86-7 Window, Rear-Defroster 36-86-7 DESCRIPTION AND OPERATION (Continued) 4-Door Wagon Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9480 MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The rear window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: Surface Preparations 1. The vehicle should be brought inside and permitted to come to room temperature of 16~C (60~F) or above. 2. Clean entire grid line repair area with Ford Glass Cleaner E4AZ-19C507-A (ESR-M1495- A) or equivalent or other suitable cleaning solvent to remove all dirt, wax, grease, oil or other foreign matter. It is important that repair area be clean and dry. Mixing The bottle of Grid Repair Compound D8AZ-19562-A (ESB-M4J58-A) or equivalent and touch-up paint must be at room temperature. Shake bottle for at least one minute for thorough mixing. Shake frequently during use. Application 1 Mark location of break on outside of window. 2. Using cellulose tape, mask off area directly above and below grid break. The break area should be at the center of mask, and tape gap must be no wider than existing grid line. Lincoln Town Car - Ford Crown Victoria - Mercury (Grand Marquis) 1987 Lincoln Town Car - Ford (Crown Victoria) - Mercury (Grand Marquis) 36-86-1 Window, Rear-Defroster 36-86-1 SECTION 36-86 Window, Rear-Defroster SUBJECT PAGE DESCRIPTION AND OPERATION 36-86-1 MAJOR SERVICE OPERATIONS Grid Wire Repair 36-86-2 Lead Wire Terminal Repair 36-86-4 REMOVAL AND INSTALLATION Control Assembly 36-86-2 SUBJECT PAGE REMOVAL AND INSTALLATION (Cont'd.) Window 36-86-2 TESTING Control Assembly Tests 36-86-1 Grid Wire Test 36-86-2 VEHICLE APPLICATION 36-86-1 VEHICLE APPLICATION Lincoln Town Car, Ford Crown Victoria/Mercury Grand Marquis. DESCRIPTION AND OPERATION The heated rear window defroster system consists of a control assembly mounted on the climate control head, a series of grid lines baked on the inside surface of the rear window and system wiring. The grid lines consist of two layers. The first layer is brown in color as viewed from the exterior, and the second layer is silver in color as viewed from the interior. The control assembly has a lever spring-loaded to center position, to turn the system on or off, and a timercontrolled relay that turns off automatically after approximately ten minutes of operation. If more than ten minutes are required, the control can be reactivated for another ten minutes by pushing the lever momentarily to the ON position. This operation can be repeated as required. When the lever is pushed to the ON position the normally open contacts in the control are mechanically closed, thus providing power from battery to the rear window grids, the indicator lamp, the heated outside mirror and also triggering the timing circuit. This contact will remain closed until the timer turns it off, or the lever is pushed momentarily to the OFF position, or the ignition switch is turned off. Power for the rear window grids, the outside rear view mirror, and the indicator lamp is supplied directly from the battery side of the starter motor relay through a fuse link which protects the circuit. Power for the control timer comes from the accessory terminal of the ignition switch. This power is available whenever the ignition switch is in RUN. This circuit is protected by a fuse, located in the fuse panel. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9481 FIGURE 1 - Wiring Diagram, Heated Rear Window TESTING Control Assembly Tests 1. Ground pin 2 and connect a jumper wire between pins 4 and 3. Connect a 12-volt test lamp between pin 1 and ground (Fig. 1). 2. Apply power to pin 4. The test lamp should not light. 3. Momentarily actuate the lever to the ON position. The test lamp should come on and stay on after the lever returns to the normal position. 4. Test lamp should go off under any one or more of the following conditions: ^ If lever is moved to the OFF position. ^ Jumper wire between pins 3 and 4 is removed. 1987 Lincoln Town Car - Ford (Crown Victoria) - Mercury (Grand Marquis) 36-86-2 Window, Rear-Defroster 36-86-2 ^ Approximately ten minutes has elapsed. Grid Wire Test 1. Using a strong lamp inside the vehicle, visually inspect the wire grid from the outside. A broken grid wire will appear as a brown spot. 2. Run the engine at idle. Set the control switch to ON. The indicator lamp should come on. 3. Working inside the vehicle with a 12-volt DC voltmeter, contact the broad red-brown strips on the rear window (positive lead to battery side and negative lead to ground side). The meter should read 10-13 volts. A lower voltage reading indicates a loose ground wire (pigtail) connection at the ground side of the glass. 4. Contact a good ground point with the negative lead of the meter. The voltage reading should not change. 5. With the negative lead of the meter grounded, touch each grid line of the heated rear window at its midpoint with the positive lead. A reading of approximately 6 volts indicates that the line is good. A reading of 0 volts indicates that the line is broken between the midpoint and the B+ side of the grid line. A reading of 12-volts indicates that the circuit is broken between the midpoint of the grid line and ground. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9482 FIGURE 2 - Control Assembly Location REMOVAL AND INSTALLATION Control Assembly Remove knob from control lever. Remove applique. Remove screws retaining the climate control head to the instrument panel and remove the climate control head. Remove control assembly from the climate control head assembly (Fig. 2). Window Disconnect wire leads at each end of the glass (Fig. 3). Remove window. Refer to Section 43-11. MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: NOTE: If the first layer of the rear window grid (brown color) is damaged or missing, it will be necessary to apply brown Acrylic Lacquer Touch-Up Paint AL81-5477-B (ESR-M2P100-B) or equivalent on the glass prior to applying the silver Grid Repair Compound D8AZ-19562- A (ESB-M4J58-A) or equivalent. Continental - Mark VII - Thunderbird/Cougar - Mustang Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9483 FIGURE 5 - Control Assembly Electrical Schematic 1987 Continental - Mark VII - Thunderbird/Cougar-Mustang 36-86-4 Window, Rear-Defroster 36-86-4 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9484 FIGURE 6 - Control Assembly Electrical Schematic Thunderbird/Cougar with EATC FIGURE 7 - Switch Assembly-Mark VII/Continental FIGURE 8 - Switch Assembly-Thunderbird/Cougar 1987 Continental - Mark VII - Thunderbird/Cougar - Mustang 36-86-5 Window, Rear-Defroster 36-86-5 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Rear Defogger > Component Information > Technical Service Bulletins > Heated Backlite Grid - Manual Updates > Page 9485 FIGURE 8 - Switch Assembly-Thunderbird/Cougar Thunderbird/Cougar The control assembly is mounted to the heater A/C control head. Remove the knob from the control lever. Remove the applique. Remove the screws retaining the heater A/C control head to the instrument panel and remove the control head from its opening. Remove the control assembly from the heater A/C control panel (Figs. 8 and 9). Mustang 1. Disengage the two locking tabs on the right side of control by pushing the tabs in with a small screwdriver and pulling on the right side of the control. 2. Using a screwdriver, pry the left side of the control out of the instrument panel. 3. Pull the control completely out of the opening and disconnect the two connectors. 4. To install, install the two connectors to the control and insert control into opening in instrument panel until the locking tabs on both sides of the control snap in place. Window Disconnect wire leads at each end of the glass. Remove window. Refer to Section 43-11. MAJOR SERVICE OPERATIONS Grid Wire Repair NOTE: A single break or any breaks that total more than 25 mm (1 inch) in one grid cannot be repaired. The window must be replaced. For breaks less than 25 mm (1 inch) long, use the following procedure: NOTE: If the first layer of the heated rear window grid (brown color) is damaged or missing, it will be necessary to apply brown Acrylic Lacquer Touch-Up Paint AL81- 5477-B (ESR-M2P100-B) or equivalent on the glass prior to applying the silver Grid Repair Compound D8AZ- 19562-A (ESB-M4J58-A) or equivalent. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions Power Window Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9491 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9492 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Relays and Modules - Windows and Glass > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9493 Power Windows Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Heated Glass Element Switch > Component Information > Locations Heated Glass Element Switch: Locations I/P Components Center Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9502 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9503 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9504 Power Windows Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 9505 Power Window Switch: Service and Repair Removal 1. Using a flat blade screwdriver, pry switch housing up. Rotate housing up and out of armrest to remove. 2. Remove two connector retaining screws from bottom of switch housing. 3. The switch is held in place by the electrical contact pins. To remove the switch, carefully pry the switch from the connector with a small screwdriver. Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch > Component Information > Diagrams > Page 9506 1. To install, position switch to the connector and press firmly into place. NOTE: The switch is keyed to connector and can only be installed one way. 2. Install connector to switch housing using two retaining screws. 3. Install switch housing to armrest. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Locations Power Window Circuit Breaker: Locations Circuit Location Amp Cigar Lighter Fuse Panel 20 Power Door Locks Fuse Panel 20 Power Moon Roof Fuse Panel 20 Power Seats Fuse Panel 20 Power Windows Fuse Panel 20 Windshield Wiper Fuse Panel 8.25 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions Power Window Circuit Breaker: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9513 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9514 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Circuit Breaker > Component Information > Diagrams > Diagram Information and Instructions > Page 9515 Power Windows Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Locations Power Window Motor: Locations In Respective Doors Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions Power Window Motor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9521 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9522 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9523 Power Windows Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Window Regulator Power Window Motor: Service and Repair Window Regulator Removal WARNING: IF THE REGULATOR COUNTERBALANCE SPRING MUST BE REMOVED OR REPLACED FOR ANY REASON, ENSURE THAT THE REGULATOR ARMS ARE IN A FIXED POSITION PRIOR TO REMOVAL TO PREVENT POSSIBLE INJURY DURING C-SPRING UNWIND. 1. Remove door trim panel and watershield. See: Body and Frame/Doors, Hood and Trunk/Doors 2. Lower glass to access holes in door inner panel. Remove two nut and washer assemblies retaining glass to glass bracket. 3. Prop the glass in the full-up position. 4. Disconnect the electric motor wiring. 5. Remove two nut and washer assemblies retaining regulator equalizer bracket. 6. Remove the four rivets attaching regulator to door inner panel as follows: - Remove the center pin from each rivet with a drift punch. - Using a 6mm drill, drill out the remaining of the rivet using care not to enlarge the sheet metal retaining holes. 7. Remove regulator through door access hole. Installation 1. With glass in full-up position, install window regulator through access hole in door inner panel. 2. Position regulator base plate to door inner panel and install four rivets. 3. Install regulator equalizer bracket to regulator and loosely assemble with two nut and washer assemblies. 4. Install regulator glass bracket drive channel to glass and secure with two nut and washer assemblies. Tighten nut and washer assemblies to 9-14 N-m (7-10 lb-ft). 5. Connect electric motor wiring. 6. Lower door glass approximately 75mm (3 inch) from full-up position. 7. With door open, place hands on each side of glass and pull glass fully into door glass run assembly at B-pillar. 8. Apply a downward pressure on the equalizer bracket and tighten two nuts and washer assemblies. Tighten to 9-14 N-m (7-10 lb-ft). 9. Cycle door glass to ensure proper operation. 10. Install door trim panel and watershield. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Component Information > Service and Repair > Window Regulator > Page 9526 Power Window Motor: Service and Repair Window Regulator Motor Removal 1. Raise the window to the full-up position, if possible. If the glass cannot be raised and is in a partially down position, it must be supported so that it will not fall into the door well during motor removal. 2. Disconnect battery ground cable. 3. Remove door trim panel and watershield. See: Body and Frame/Doors, Hood and Trunk/Doors 4. Disconnect window motor connector. 5. Position the motor wiring harness out of the way. Using a 19mm (3/4 inch) hole saw with a 1/4-inch pilot, drill three holes at the existing drill dimples located on the door inner panel adjacent to the motor. CAUTION: Prior to motor removal, ensure that the regulator arm is in a fixed position to prevent counterbalance spring unwind. 6. Remove the three window motor retaining screws and disengage the motor and drive assembly from the regulator quadrant gear. Installation 1. Position the motor and drive to the regulator and install the three screws snug-not tight. 2. Connect the motor wires at the connector and cycle the glass to ensure gear engagement. After the gears are engaged, tighten the three motor and drive retaining screws to 5.6-9.6 N-m (50-84 lb-in). 3. Install the door trim panel and watershield. NOTE: Appropriate plug buttons may be installed to cover the exposed hole at the trim panel edge, if necessary. 4. Connect battery ground cable. 5. Check the drain holes at the bottom of the doors to ensure that each is open to prevent water buildup over the motor. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions Power Window Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9531 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9532 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9533 Power Windows Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions Power Window Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9538 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9539 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9540 Power Windows Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 9541 Power Window Switch: Service and Repair Removal 1. Using a flat blade screwdriver, pry switch housing up. Rotate housing up and out of armrest to remove. 2. Remove two connector retaining screws from bottom of switch housing. 3. The switch is held in place by the electrical contact pins. To remove the switch, carefully pry the switch from the connector with a small screwdriver. Installation Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Diagrams > Page 9542 1. To install, position switch to the connector and press firmly into place. NOTE: The switch is keyed to connector and can only be installed one way. 2. Install connector to switch housing using two retaining screws. 3. Install switch housing to armrest. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim Window Glass: Customer Interest Windshield/Backlite - Sealer Drips on Interior Trim Article No. 95-5-2 03/13/95 ^ INTERIOR TRIM - SEALER FROM WINDSHIELD OR BACKLITE DRIPS ON INTERIOR TRIM VEHICLES BUILT THROUGH 10/93 ^ SEALER - WINDSHIELD OR BACKLITE - DRIPS ON INTERIOR TRIM - VEHICLES BUILT THROUGH 10/93 FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR ISSUE: The sealer from the windshield or backlite (Thunderbird only) may drip down onto the interior trim on some vehicles. This may be caused by the sealer not curing properly and softening in hot weather. ACTION: Install a foam seal around the windshield and/or backlite (Thunderbird only). The seal will act as a dam and keep the sealer from dripping onto the interior trim. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the A-pillar trim mouldings and headliner. On Thunderbird, also remove the rear seat and quarter trim mouldings. Refer to the appropriate Service Manual for removal procedures. NOTE: WHEN REMOVING THE TRIM ITEMS, THE SEALER MIGHT BE STUCK TO THEM MAKING IT NECESSARY TO CUT THE SEALER TO SEPARATE THE PARTS FROM THE VEHICLE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9551 2. Using a plastic or wood (non-metal) scraper, remove as much of the sealer from the inside of the front and/or rear glass (Thunderbird only) and side edges as possible. Use care not to scratch the glass or the ceramic paint on the glass. It is not necessary to remove all the sealer, just the large deposits that will interfere with the installation of the foam seal used in this procedure. Use mineral spirits to remove any residue from the glass. Refer to Figure 1. NOTE: CLEAN AFFECTED INTERIOR TRIM WITH FORD SPOT AND STAIN REMOVER (B7A-19521-AA OR EQUIVALENT). 3. Remove any heavy deposits of sealer from the interior trim components and then install the headliner, A-pillar trim mouldings and quarter trim mouldings (if removed), but do not tighten the attaching screws. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9552 4. Install the foam seal (F5SZ-6303037-A) around the windshield. Start at the RH or LH A-pillar and pull the A-pillar moulding and headliner slightly away from the windshield. Carefully push/tuck the seal between them and the glass, working toward the bottom of the opposite side A-pillar until the seal is positioned out of view. Refer to Figure 2. 5. Tighten the A-pillar trim screws. 6. To install the foam seal on the rear glass of the Thunderbird, follow the same procedure as used for the windshield. 7. Tighten the quarter trim panel attaching screws. 8. Reinstall the rear seat (Thunderbird only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9553 PART NUMBER PART NAME F5SZ-6303037-A Windshield Sealer B7A-19521-AA Spot And Stain Remover OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950502A Clean Sealer And Install 1.0 Hr. Foam Dam - Cougar 950502B Clean Sealer And Install 2.0 Hrs. Foam Dam - Thunderbird DEALER CODING BASIC PART NO. CONDITION CODE 7003100 49 ACES II DEALERS MUST CODE TO THE FULL BASE BODY PANEL NUMBER - DO NOT USE 70 OASIS CODES: 102000, 107000, 110000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 92112 > May > 92 > Front Door Glass - Separates From the Glass Bracket Window Glass: Customer Interest Front Door Glass - Separates From the Glass Bracket Article No. 92-11-2 May 20, 1992 GLASS - FRONT DOOR - SEPARATES FROM GLASS BRACKET FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1988-90 CONTINENTAL 1989-90 COUGAR ISSUE: The front door glass may separate from the glass bracket because of poor adhesive material. A procedure has been developed for refastening the door glass assembly when the bracket separates from the glass. Previously, replacement of the entire glass assembly was required. ACTION: Thoroughly clean the glass bracket and reattach it to the glass. Refer to the following procedure for service details. 1. Remove the glass assembly from the front door. Refer to the 1990 Thunderbird/Cougar Service Manual or the 1990 Continental Service Manual, Section 42-03, for the removal procedure. 2. Mark the glass for the bracket location before cleaning it. 3. Thoroughly remove all pink primer from the plastic bracket. a. Soak it in a tray filled with General Purpose Adhesive Cleaner (3M # 08984) for about twenty (20) minutes. b. Use a wire brush to clean the inside wall of the "U" channel plastic bracket. c. Clean glass at the bracket location with the same adhesive cleaner. NOTE: BE CAREFUL NOT TO REMOVE MARKED LINES FOR THE BRACKET LOCATION WHEN CLEANING GLASS. 4. Reinstall the front door glass assembly. Refer to the 1990 Thunderbird/Cougar Service Manual or the 1990 Continental Service Manual, Section 42-03, for the installation procedure. 5. Mix and apply 3M two part adhesive system Structural Adhesive (3M # 08101) to the inside wall of the "U" channel plastic bracket. NOTE: THE MIXED ADHESIVE HAS A FOUR (4) TO FIVE (5) MINUTE DRYING TIME. AFTER FOUR (4) HOURS OF CONTINUED CURING TIME AT ROOM TEMPERATURE, THE BRACKET ADHESION WILL MEET THE FORD SPECIFIED PULL TEST. FULL CURE TIME IS 48 HOURS. 6. Schedule the glass bracket repair for four (4) hours to accommodate the necessary curing time. Advise the customer to restrict use of the window system for a minimum of 48 hours so that full adhesive cure can take place. PART NUMBER PART NAME CLASS Obtain From 3M General Purpose Adhesive Supplier Cleaner (3M # 08984) Obtain From 3M Structural Adhesive - 2 Part Supplier System (3M # 08101) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 921102AT Thunderbird/Cougar - Both 2.2 Hrs. Doors 921102A Thunderbird/Cougar - One 1.2 Hrs. Door 921102BT Continental - Both Doors 2.6 Hrs. 921102B Continental - One Door 1.4 Hrs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 92112 > May > 92 > Front Door Glass - Separates From the Glass Bracket > Page 9558 DEALER CODING BASIC PART NO. CONDITION CODE 21410 33 OASIS CODES: 102000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > Customer Interest: > 9012 > Jan > 90 > Door Glass Run - Split or Cracked Window Glass: Customer Interest Door Glass Run - Split or Cracked Article No. 90-1-2 GLASS - FRONT DOOR - SPLITTING OR CRACKING DOOR GLASS RUN FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A door glass run that is not fully seated along the header of the glass run may split or crack. The splitting and cracking conditions are caused by excessive rotational stress on the molded joints at the "A" and "B" pillars. ACTION: Inspect the door glass run to determine if the split or crack can be repaired. Refer to the following procedure for service details. 1. Repair the door glass run with the new service Door Window Glass Repair Kit when the gap is 1-5 mm. If the gap is larger than 5 mm, proceed to Step 2. The Door Window Glass Repair Kit contains the following items: ^ A tube of sealant - EPDM ^ A tube of adhesive - "Loctite 414" ^ Two "B" pillar patches (marked "B") ^ One "A" pillar patch - RH (marked A-R) ^ One "A" pillar patch - LH (marked A-L) ^ An instruction sheet 2. Replace the front door glass run. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 42-03 for service details. PART NUMBER PART NAME CLASS E9SZ-63222B44-A Door Window Glass Run Kit C E9SZ-6321596-B Glass Run - RH C E9SZ-6321597-B Glass Run - LH C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 900102A Repair Both Glass Runs 0.3 Hr. 900102BT Replace Both Glass Runs 1.2 Hrs. 900102B Replace One Glass Run 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7021596 01 OASIS CODES: 1050, 1052, 1300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Window Glass: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 9568 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim Window Glass: All Technical Service Bulletins Windshield/Backlite - Sealer Drips on Interior Trim Article No. 95-5-2 03/13/95 ^ INTERIOR TRIM - SEALER FROM WINDSHIELD OR BACKLITE DRIPS ON INTERIOR TRIM VEHICLES BUILT THROUGH 10/93 ^ SEALER - WINDSHIELD OR BACKLITE - DRIPS ON INTERIOR TRIM - VEHICLES BUILT THROUGH 10/93 FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR ISSUE: The sealer from the windshield or backlite (Thunderbird only) may drip down onto the interior trim on some vehicles. This may be caused by the sealer not curing properly and softening in hot weather. ACTION: Install a foam seal around the windshield and/or backlite (Thunderbird only). The seal will act as a dam and keep the sealer from dripping onto the interior trim. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the A-pillar trim mouldings and headliner. On Thunderbird, also remove the rear seat and quarter trim mouldings. Refer to the appropriate Service Manual for removal procedures. NOTE: WHEN REMOVING THE TRIM ITEMS, THE SEALER MIGHT BE STUCK TO THEM MAKING IT NECESSARY TO CUT THE SEALER TO SEPARATE THE PARTS FROM THE VEHICLE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9573 2. Using a plastic or wood (non-metal) scraper, remove as much of the sealer from the inside of the front and/or rear glass (Thunderbird only) and side edges as possible. Use care not to scratch the glass or the ceramic paint on the glass. It is not necessary to remove all the sealer, just the large deposits that will interfere with the installation of the foam seal used in this procedure. Use mineral spirits to remove any residue from the glass. Refer to Figure 1. NOTE: CLEAN AFFECTED INTERIOR TRIM WITH FORD SPOT AND STAIN REMOVER (B7A-19521-AA OR EQUIVALENT). 3. Remove any heavy deposits of sealer from the interior trim components and then install the headliner, A-pillar trim mouldings and quarter trim mouldings (if removed), but do not tighten the attaching screws. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9574 4. Install the foam seal (F5SZ-6303037-A) around the windshield. Start at the RH or LH A-pillar and pull the A-pillar moulding and headliner slightly away from the windshield. Carefully push/tuck the seal between them and the glass, working toward the bottom of the opposite side A-pillar until the seal is positioned out of view. Refer to Figure 2. 5. Tighten the A-pillar trim screws. 6. To install the foam seal on the rear glass of the Thunderbird, follow the same procedure as used for the windshield. 7. Tighten the quarter trim panel attaching screws. 8. Reinstall the rear seat (Thunderbird only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9575 PART NUMBER PART NAME F5SZ-6303037-A Windshield Sealer B7A-19521-AA Spot And Stain Remover OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950502A Clean Sealer And Install 1.0 Hr. Foam Dam - Cougar 950502B Clean Sealer And Install 2.0 Hrs. Foam Dam - Thunderbird DEALER CODING BASIC PART NO. CONDITION CODE 7003100 49 ACES II DEALERS MUST CODE TO THE FULL BASE BODY PANEL NUMBER - DO NOT USE 70 OASIS CODES: 102000, 107000, 110000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 93211 > Oct > 93 > Glass - Iridescence or Mottling In Tempered Glass Window Glass: All Technical Service Bulletins Glass - Iridescence or Mottling In Tempered Glass Article No. 93-21-1 10/13/93 GLASS - "IRIDESCENCE" OR "MOTTLING" IN TEMPERED GLASS FORD: 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-88 EXP 1986-94 TAURUS 1989-93 FESTIVA LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1988-94 CONTINENTAL 1991-94 CAPRI, TRACER 1993-94 MARK VIII LIGHT TRUCK: 1984-90 BRONCO II 1984-94 ECONOLINE, F-150-350 SERIES, RANGER 1986-94 AEROSTAR 1991-94 EXPLORER 1993-94 VILLAGER ISSUE: Vehicles may exhibit iridescent spots or "mottling" in tempered glass under some lighting conditions. This condition is caused by the tempering process. ACTION: Explain to customers that "iridescence" or "mottling" of tempered glass is a normal condition and that glass replacement is neither warranted nor necessarily effective in resolving the condition. DESCRIPTION OF CONDITION The somewhat iridescent grayish or blueish and fairly geometric spots detected in side and rear window tempered glass are characteristic of tempered glass. The mottled appearance is noted only under certain conditions of lighting. The occurrence of mottling does not affect glass quality or durability and cannot be reduced by scouring the glass surface. The boldness of the mottled pattern in a given glass may vary, depending upon lighting conditions, but may appear intensified if viewed through polarized sunglasses. CAUSES OF CONDITION Atmospheric dust and other angular reflections can cause changes in the polarized properties of natural light. This polarization, combined with the light polarizing properties imparted to tempered glass by the forces of tension and compression (during the tempering process), cause the iridescent or mottled appearance. These are the same forces of compression and tension which make tempered glass so remarkably strong. Windshields, which are annealed rather than tempered, do not exhibit iridescence. OTHER APPLICABLE ARTICLES: 83-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 92112 > May > 92 > Front Door Glass - Separates From the Glass Bracket Window Glass: All Technical Service Bulletins Front Door Glass - Separates From the Glass Bracket Article No. 92-11-2 May 20, 1992 GLASS - FRONT DOOR - SEPARATES FROM GLASS BRACKET FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1988-90 CONTINENTAL 1989-90 COUGAR ISSUE: The front door glass may separate from the glass bracket because of poor adhesive material. A procedure has been developed for refastening the door glass assembly when the bracket separates from the glass. Previously, replacement of the entire glass assembly was required. ACTION: Thoroughly clean the glass bracket and reattach it to the glass. Refer to the following procedure for service details. 1. Remove the glass assembly from the front door. Refer to the 1990 Thunderbird/Cougar Service Manual or the 1990 Continental Service Manual, Section 42-03, for the removal procedure. 2. Mark the glass for the bracket location before cleaning it. 3. Thoroughly remove all pink primer from the plastic bracket. a. Soak it in a tray filled with General Purpose Adhesive Cleaner (3M # 08984) for about twenty (20) minutes. b. Use a wire brush to clean the inside wall of the "U" channel plastic bracket. c. Clean glass at the bracket location with the same adhesive cleaner. NOTE: BE CAREFUL NOT TO REMOVE MARKED LINES FOR THE BRACKET LOCATION WHEN CLEANING GLASS. 4. Reinstall the front door glass assembly. Refer to the 1990 Thunderbird/Cougar Service Manual or the 1990 Continental Service Manual, Section 42-03, for the installation procedure. 5. Mix and apply 3M two part adhesive system Structural Adhesive (3M # 08101) to the inside wall of the "U" channel plastic bracket. NOTE: THE MIXED ADHESIVE HAS A FOUR (4) TO FIVE (5) MINUTE DRYING TIME. AFTER FOUR (4) HOURS OF CONTINUED CURING TIME AT ROOM TEMPERATURE, THE BRACKET ADHESION WILL MEET THE FORD SPECIFIED PULL TEST. FULL CURE TIME IS 48 HOURS. 6. Schedule the glass bracket repair for four (4) hours to accommodate the necessary curing time. Advise the customer to restrict use of the window system for a minimum of 48 hours so that full adhesive cure can take place. PART NUMBER PART NAME CLASS Obtain From 3M General Purpose Adhesive Supplier Cleaner (3M # 08984) Obtain From 3M Structural Adhesive - 2 Part Supplier System (3M # 08101) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 921102AT Thunderbird/Cougar - Both 2.2 Hrs. Doors 921102A Thunderbird/Cougar - One 1.2 Hrs. Door 921102BT Continental - Both Doors 2.6 Hrs. 921102B Continental - One Door 1.4 Hrs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 92112 > May > 92 > Front Door Glass - Separates From the Glass Bracket > Page 9584 DEALER CODING BASIC PART NO. CONDITION CODE 21410 33 OASIS CODES: 102000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Window Glass: > 9012 > Jan > 90 > Door Glass Run - Split or Cracked Window Glass: All Technical Service Bulletins Door Glass Run - Split or Cracked Article No. 90-1-2 GLASS - FRONT DOOR - SPLITTING OR CRACKING DOOR GLASS RUN FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A door glass run that is not fully seated along the header of the glass run may split or crack. The splitting and cracking conditions are caused by excessive rotational stress on the molded joints at the "A" and "B" pillars. ACTION: Inspect the door glass run to determine if the split or crack can be repaired. Refer to the following procedure for service details. 1. Repair the door glass run with the new service Door Window Glass Repair Kit when the gap is 1-5 mm. If the gap is larger than 5 mm, proceed to Step 2. The Door Window Glass Repair Kit contains the following items: ^ A tube of sealant - EPDM ^ A tube of adhesive - "Loctite 414" ^ Two "B" pillar patches (marked "B") ^ One "A" pillar patch - RH (marked A-R) ^ One "A" pillar patch - LH (marked A-L) ^ An instruction sheet 2. Replace the front door glass run. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 42-03 for service details. PART NUMBER PART NAME CLASS E9SZ-63222B44-A Door Window Glass Run Kit C E9SZ-6321596-B Glass Run - RH C E9SZ-6321597-B Glass Run - LH C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 900102A Repair Both Glass Runs 0.3 Hr. 900102BT Replace Both Glass Runs 1.2 Hrs. 900102B Replace One Glass Run 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7021596 01 OASIS CODES: 1050, 1052, 1300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Window Glass: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Glass: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 9594 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Glass > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Glass: > 93211 > Oct > 93 > Glass - Iridescence or Mottling In Tempered Glass Window Glass: All Technical Service Bulletins Glass - Iridescence or Mottling In Tempered Glass Article No. 93-21-1 10/13/93 GLASS - "IRIDESCENCE" OR "MOTTLING" IN TEMPERED GLASS FORD: 1984-94 CROWN VICTORIA, ESCORT, MUSTANG, TEMPO, THUNDERBIRD 1986-88 EXP 1986-94 TAURUS 1989-93 FESTIVA LINCOLN-MERCURY: 1984-86 CAPRI 1984-87 LYNX 1984-92 MARK VII 1984-94 COUGAR, GRAND MARQUIS, TOPAZ, TOWN CAR 1986-94 SABLE 1988-89 TRACER 1988-94 CONTINENTAL 1991-94 CAPRI, TRACER 1993-94 MARK VIII LIGHT TRUCK: 1984-90 BRONCO II 1984-94 ECONOLINE, F-150-350 SERIES, RANGER 1986-94 AEROSTAR 1991-94 EXPLORER 1993-94 VILLAGER ISSUE: Vehicles may exhibit iridescent spots or "mottling" in tempered glass under some lighting conditions. This condition is caused by the tempering process. ACTION: Explain to customers that "iridescence" or "mottling" of tempered glass is a normal condition and that glass replacement is neither warranted nor necessarily effective in resolving the condition. DESCRIPTION OF CONDITION The somewhat iridescent grayish or blueish and fairly geometric spots detected in side and rear window tempered glass are characteristic of tempered glass. The mottled appearance is noted only under certain conditions of lighting. The occurrence of mottling does not affect glass quality or durability and cannot be reduced by scouring the glass surface. The boldness of the mottled pattern in a given glass may vary, depending upon lighting conditions, but may appear intensified if viewed through polarized sunglasses. CAUSES OF CONDITION Atmospheric dust and other angular reflections can cause changes in the polarized properties of natural light. This polarization, combined with the light polarizing properties imparted to tempered glass by the forces of tension and compression (during the tempering process), cause the iridescent or mottled appearance. These are the same forces of compression and tension which make tempered glass so remarkably strong. Windshields, which are annealed rather than tempered, do not exhibit iridescence. OTHER APPLICABLE ARTICLES: 83-16-4 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Regulator > Front Door Window Regulator > System Information > Service and Repair Front Door Window Regulator: Service and Repair Removal WARNING: IF THE REGULATOR COUNTERBALANCE SPRING MUST BE REMOVED OR REPLACED FOR ANY REASON, ENSURE THAT THE REGULATOR ARMS ARE IN A FIXED POSITION PRIOR TO REMOVAL TO PREVENT POSSIBLE INJURY DURING C-SPRING UNWIND. 1. Remove door trim panel and watershield. See: Body and Frame/Doors, Hood and Trunk/Doors 2. Lower glass to access holes in door inner panel. Remove two nut and washer assemblies retaining glass to glass bracket. 3. Prop the glass in the full-up position. 4. Disconnect the electric motor wiring. 5. Remove two nut and washer assemblies retaining regulator equalizer bracket. 6. Remove the four rivets attaching regulator to door inner panel as follows: - Remove the center pin from each rivet with a drift punch. - Using a 6mm drill, drill out the remaining of the rivet using care not to enlarge the sheet metal retaining holes. 7. Remove regulator through door access hole. Installation 1. With glass in full-up position, install window regulator through access hole in door inner panel. 2. Position regulator base plate to door inner panel and install four rivets. 3. Install regulator equalizer bracket to regulator and loosely assemble with two nut and washer assemblies. 4. Install regulator glass bracket drive channel to glass and secure with two nut and washer assemblies. Tighten nut and washer assemblies to 9-14 N-m (7-10 lb-ft). 5. Connect electric motor wiring. 6. Lower door glass approximately 75mm (3 inch) from full-up position. 7. With door open, place hands on each side of glass and pull glass fully into door glass run assembly at B-pillar. 8. Apply a downward pressure on the equalizer bracket and tighten two nuts and washer assemblies. Tighten to 9-14 N-m (7-10 lb-ft). 9. Cycle door glass to ensure proper operation. 10. Install door trim panel and watershield. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 92112 > May > 92 > Front Door Glass - Separates From the Glass Bracket Window Track: Customer Interest Front Door Glass - Separates From the Glass Bracket Article No. 92-11-2 May 20, 1992 GLASS - FRONT DOOR - SEPARATES FROM GLASS BRACKET FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1988-90 CONTINENTAL 1989-90 COUGAR ISSUE: The front door glass may separate from the glass bracket because of poor adhesive material. A procedure has been developed for refastening the door glass assembly when the bracket separates from the glass. Previously, replacement of the entire glass assembly was required. ACTION: Thoroughly clean the glass bracket and reattach it to the glass. Refer to the following procedure for service details. 1. Remove the glass assembly from the front door. Refer to the 1990 Thunderbird/Cougar Service Manual or the 1990 Continental Service Manual, Section 42-03, for the removal procedure. 2. Mark the glass for the bracket location before cleaning it. 3. Thoroughly remove all pink primer from the plastic bracket. a. Soak it in a tray filled with General Purpose Adhesive Cleaner (3M # 08984) for about twenty (20) minutes. b. Use a wire brush to clean the inside wall of the "U" channel plastic bracket. c. Clean glass at the bracket location with the same adhesive cleaner. NOTE: BE CAREFUL NOT TO REMOVE MARKED LINES FOR THE BRACKET LOCATION WHEN CLEANING GLASS. 4. Reinstall the front door glass assembly. Refer to the 1990 Thunderbird/Cougar Service Manual or the 1990 Continental Service Manual, Section 42-03, for the installation procedure. 5. Mix and apply 3M two part adhesive system Structural Adhesive (3M # 08101) to the inside wall of the "U" channel plastic bracket. NOTE: THE MIXED ADHESIVE HAS A FOUR (4) TO FIVE (5) MINUTE DRYING TIME. AFTER FOUR (4) HOURS OF CONTINUED CURING TIME AT ROOM TEMPERATURE, THE BRACKET ADHESION WILL MEET THE FORD SPECIFIED PULL TEST. FULL CURE TIME IS 48 HOURS. 6. Schedule the glass bracket repair for four (4) hours to accommodate the necessary curing time. Advise the customer to restrict use of the window system for a minimum of 48 hours so that full adhesive cure can take place. PART NUMBER PART NAME CLASS Obtain From 3M General Purpose Adhesive Supplier Cleaner (3M # 08984) Obtain From 3M Structural Adhesive - 2 Part Supplier System (3M # 08101) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 921102AT Thunderbird/Cougar - Both 2.2 Hrs. Doors 921102A Thunderbird/Cougar - One 1.2 Hrs. Door 921102BT Continental - Both Doors 2.6 Hrs. 921102B Continental - One Door 1.4 Hrs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 92112 > May > 92 > Front Door Glass - Separates From the Glass Bracket > Page 9611 DEALER CODING BASIC PART NO. CONDITION CODE 21410 33 OASIS CODES: 102000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > Customer Interest: > 9012 > Jan > 90 > Door Glass Run - Split or Cracked Window Track: Customer Interest Door Glass Run - Split or Cracked Article No. 90-1-2 GLASS - FRONT DOOR - SPLITTING OR CRACKING DOOR GLASS RUN FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A door glass run that is not fully seated along the header of the glass run may split or crack. The splitting and cracking conditions are caused by excessive rotational stress on the molded joints at the "A" and "B" pillars. ACTION: Inspect the door glass run to determine if the split or crack can be repaired. Refer to the following procedure for service details. 1. Repair the door glass run with the new service Door Window Glass Repair Kit when the gap is 1-5 mm. If the gap is larger than 5 mm, proceed to Step 2. The Door Window Glass Repair Kit contains the following items: ^ A tube of sealant - EPDM ^ A tube of adhesive - "Loctite 414" ^ Two "B" pillar patches (marked "B") ^ One "A" pillar patch - RH (marked A-R) ^ One "A" pillar patch - LH (marked A-L) ^ An instruction sheet 2. Replace the front door glass run. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 42-03 for service details. PART NUMBER PART NAME CLASS E9SZ-63222B44-A Door Window Glass Run Kit C E9SZ-6321596-B Glass Run - RH C E9SZ-6321597-B Glass Run - LH C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 900102A Repair Both Glass Runs 0.3 Hr. 900102BT Replace Both Glass Runs 1.2 Hrs. 900102B Replace One Glass Run 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7021596 01 OASIS CODES: 1050, 1052, 1300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92112 > May > 92 > Front Door Glass - Separates From the Glass Bracket Window Track: All Technical Service Bulletins Front Door Glass - Separates From the Glass Bracket Article No. 92-11-2 May 20, 1992 GLASS - FRONT DOOR - SEPARATES FROM GLASS BRACKET FORD: 1989-90 THUNDERBIRD LINCOLN-MERCURY: 1988-90 CONTINENTAL 1989-90 COUGAR ISSUE: The front door glass may separate from the glass bracket because of poor adhesive material. A procedure has been developed for refastening the door glass assembly when the bracket separates from the glass. Previously, replacement of the entire glass assembly was required. ACTION: Thoroughly clean the glass bracket and reattach it to the glass. Refer to the following procedure for service details. 1. Remove the glass assembly from the front door. Refer to the 1990 Thunderbird/Cougar Service Manual or the 1990 Continental Service Manual, Section 42-03, for the removal procedure. 2. Mark the glass for the bracket location before cleaning it. 3. Thoroughly remove all pink primer from the plastic bracket. a. Soak it in a tray filled with General Purpose Adhesive Cleaner (3M # 08984) for about twenty (20) minutes. b. Use a wire brush to clean the inside wall of the "U" channel plastic bracket. c. Clean glass at the bracket location with the same adhesive cleaner. NOTE: BE CAREFUL NOT TO REMOVE MARKED LINES FOR THE BRACKET LOCATION WHEN CLEANING GLASS. 4. Reinstall the front door glass assembly. Refer to the 1990 Thunderbird/Cougar Service Manual or the 1990 Continental Service Manual, Section 42-03, for the installation procedure. 5. Mix and apply 3M two part adhesive system Structural Adhesive (3M # 08101) to the inside wall of the "U" channel plastic bracket. NOTE: THE MIXED ADHESIVE HAS A FOUR (4) TO FIVE (5) MINUTE DRYING TIME. AFTER FOUR (4) HOURS OF CONTINUED CURING TIME AT ROOM TEMPERATURE, THE BRACKET ADHESION WILL MEET THE FORD SPECIFIED PULL TEST. FULL CURE TIME IS 48 HOURS. 6. Schedule the glass bracket repair for four (4) hours to accommodate the necessary curing time. Advise the customer to restrict use of the window system for a minimum of 48 hours so that full adhesive cure can take place. PART NUMBER PART NAME CLASS Obtain From 3M General Purpose Adhesive Supplier Cleaner (3M # 08984) Obtain From 3M Structural Adhesive - 2 Part - Supplier System (3M # 08101) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 921102AT Thunderbird/Cougar - Both 2.2 Hrs. Doors 921102A Thunderbird/Cougar - One 1.2 Hrs. Door 921102BT Continental - Both Doors 2.6 Hrs. 921102B Continental - One Door 1.4 Hrs. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 92112 > May > 92 > Front Door Glass - Separates From the Glass Bracket > Page 9621 DEALER CODING BASIC PART NO. CONDITION CODE 21410 33 OASIS CODES: 102000, 190000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Technical Service Bulletins: > 9012 > Jan > 90 > Door Glass Run - Split or Cracked Window Track: All Technical Service Bulletins Door Glass Run - Split or Cracked Article No. 90-1-2 GLASS - FRONT DOOR - SPLITTING OR CRACKING DOOR GLASS RUN FORD: 1989 THUNDERBIRD LINCOLN-MERCURY: 1989 COUGAR ISSUE: A door glass run that is not fully seated along the header of the glass run may split or crack. The splitting and cracking conditions are caused by excessive rotational stress on the molded joints at the "A" and "B" pillars. ACTION: Inspect the door glass run to determine if the split or crack can be repaired. Refer to the following procedure for service details. 1. Repair the door glass run with the new service Door Window Glass Repair Kit when the gap is 1-5 mm. If the gap is larger than 5 mm, proceed to Step 2. The Door Window Glass Repair Kit contains the following items: ^ A tube of sealant - EPDM ^ A tube of adhesive - "Loctite 414" ^ Two "B" pillar patches (marked "B") ^ One "A" pillar patch - RH (marked A-R) ^ One "A" pillar patch - LH (marked A-L) ^ An instruction sheet 2. Replace the front door glass run. Refer to the 1989 Thunderbird/Cougar Shop Manual, Section 42-03 for service details. PART NUMBER PART NAME CLASS E9SZ-63222B44-A Door Window Glass Run Kit C E9SZ-6321596-B Glass Run - RH C E9SZ-6321597-B Glass Run - LH C OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME 900102A Repair Both Glass Runs 0.3 Hr. 900102BT Replace Both Glass Runs 1.2 Hrs. 900102B Replace One Glass Run 0.7 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 7021596 01 OASIS CODES: 1050, 1052, 1300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake Wheel Hub: All Technical Service Bulletins Brakes - Roughness/Pulsation/Steering Wheel Shake Article No. 92-4-3 02/12/92 BRAKES - ROUGHNESS, PULSATION OR STEERING WHEEL SHAKE - ANTI-LOCK (4 WHEEL DISC) AND BASE BRAKE (REAR DRUMS) SYSTEMS FORD: 1989-92 THUNDERBIRD LINCOLN-MERCURY: 1989-92 COUGAR ISSUE: Brake roughness, pulsation and steering; wheel shake, may occur because of uneven rotor wear. Two major causes of uneven rotor wear are... ^ Abrasive brake pads (semi-metallic material) ^ Hub or rotor high and low spots (improper orientation during assembly) Usually these vehicles appear to be corrected by just installing new pads and rotors. However, they can repeat the condition after some time in service unless proper attention is given to... ^ Front Brake Pads ^ Hub/Rotor "Stacked" Runout ^ Tire Wear And Balance ^ Rear Brake Rotors Or Rear Brake Drums ACTION: Check the front brake pads, hub/rotor "stacked" runout, tire wear/balance and rear rotors/drums. Refer to the following procedure for service details. FRONT BRAKE PADS 1. Replace the front brake pads with ONLY the new asbestos pads (F1SZ-2001-A). CAUTION: USING METALLIC FRONT BRAKE PADS (FOSZ-2001-A) WILL CAUSE UNEVEN ROTOR WEAR. 2. Refer to the 1992 Thunderbird/Cougar Service Manual, Section 06-03, for service details. HUB/ROTOR "STACKED" RUNOUT CHECK If the assembled system (new rotor installed on hub) indicates more than .002" (.051 mm) total runout (TIR), it will cause excessive thickness variation in the rotor as mileage accumulates by wearing the high spots off the rotor. Excessive thickness variation in the rotor causes brake pulsation and steering wheel shake. High system runout (TIR) is caused by... ^ Rust/contamination trapped between the hub and rotor mounting surface ^ Rotor or hub (high and low spots) not being properly oriented during assembly 1. Clean the hub area that will contact the new rotor. Remove rust build-up and debris. 2. Install a new rotor (FOSZ-1L104-A for 1989/90 vehicles and F1SZ-1125-A for 1991/92 vehicles) on the hub. a. Secure it with at least four (4) lug nuts. b. Tighten the four (4) lug nuts to 10 Lb-Ft (13 N.m) for testing. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 9631 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 9632 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 90199 > Sep > 90 > Lug Nuts - Proper Torqueing Procedure Wheel Hub: All Technical Service Bulletins Lug Nuts - Proper Torqueing Procedure ^ BRAKE SHUDDER - ROTOR DISTORTED - OVERTIGHTENED LUG NUTS ^ WHEEL - NUT INSTALLATION - SERVICE TIP Article No. 90-19-9 FORD: 1986-91 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS, TEMPO, THUNDERBIRD 1988-91 FESTIVA 1989-91 PROBE LINCOLN-MERCURY: 1986 CAPRI 1986-87 LYNX 1986-91 CONTINENTAL, COUGAR, GRAND MARQUIS, MARK VII, SABLE, TOPAZ, TOPAZ, TOWN CAR 1987-89 TRACER 1991 CAPRI, TRACER MERKUR: 1985-88 XR4TI 1988-89 SCORPIO LIGHT TRUCK: 1986-90 BRONCO II 1986-91 AEROSTAR, BRONCO, ECONOLINE, F-150-350 SERIES, RANGER 1988-91 F SUPER DUTY 1991 EXPLORER ISSUE: The use of a power impact wrench to install wheel nuts provides minimal torque control. Undertightening may allow the lug nuts to loosen, and can result in the wheel separating from the vehicle. Overtightening of wheel nuts may cause brake rotor distortion that could result in a brake shudder. Overtightening may cause distortion of the wheel. This can result in a change in the diameter of the center (axle) hole and make it difficult to remove from the axle it is mounted on or difficult or impossible to install on another axle with a smaller center hole diameter. ACTION: Use a manual torque wrench to tighten wheel nuts. Refer to the approriate Shop Manual for specific torque values. OTHER APPLICABLE ARTICLES: None WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 306000, 301000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 9642 3. Using a dial indicator (TOOL-4201-C) or equivalent, determine the total runout of the system, Figure 1. The total system (rotor and hub) runout must not exceed .002" (.051 mm). 4. If the runout exceeds .002" (.051 mm), remove the rotor and rotate it clockwise until the next hole lines up with the stud. a. Secure the rotor in the new position, re-indexed, as in Step 2. b. Repeat the checking and rotation (re-indexing) process until the system measures .002" (.051 mm) or less total runout. 5. If .002" (.051 mm) or less runout can not be reached, replace the hub. Repeat Steps 2 through 4 when the new hub is installed. NOTE: BASED ON EXPERIENCE, WE RECOMMEND THAT NEW BRAKE ROTORS SHOULD NOT BE MACHINED. NEW OEM REPLACEMENT ROTORS ARE WELL WITHIN THE RUN OUT AND THICKNESS VARIATION SPECIFICATIONS. TIRE WEAR AND BALANCE Tire wear and balance can cause or add to a brake roughness concern. After the brake system is serviced, the tire wear and/or balance could cause enough input to be perceived as a brake roughness condition. 1. Place the best tires on the front. 2. High speed balance all the tires. REAR BRAKE ROTORS/DRUMS Rear brake rotors/drums can contribute to the complaint and feel as if the front brake concern was not fully corrected. In some cases vibration is found in the rear rotors/drums from an out of specification condition. 1. Use the parking brake moderately instead of the service brakes from 55 mph (89 km/h) to 45 mph (72 km/h) to determine if the rear brakes are contributing to the concern. 2. If the roughness is present, service the rear rotors/drums as necessary. PART NUMBER PART NAME CLASS F1SZ-2001-A Brake Shoe Lining BG FOSZ-1L104-A Rotor (1989/90 Vehicles) BG F1SZ-1128-A Rotor (1991/92 Vehicles) B Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windows > Window Track > Component Information > Technical Service Bulletins > All Other Service Bulletins for Window Track: > 9243 > Feb > 92 > Brakes - Roughness/Pulsation/Steering Wheel Shake > Page 9643 SUPERSEDES: 90-22-5, 91-24-4 WARRANTY STATUS: Eligible Under Basic Warranty Coverage For 1989-91 Models, Bumper To Bumper For 1992 Models OPERATION DESCRIPTION TIME 920403A Replace front pads 0.9 Hr. 920403B Clean hub surface and 0.4 Hr. check rotor runout 920403C High speed balance tires 1.0 Hr. 920403D Replace hub - one side 0.6 Hr. 920403E Replace hubs - both sides 0.9 Hr. DEALER CODING CONDITION BASIC PART NO. CODE 1125 13 OASIS CODES: 301000, 302000, 703000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim Windshield: Customer Interest Windshield/Backlite - Sealer Drips on Interior Trim Article No. 95-5-2 03/13/95 ^ INTERIOR TRIM - SEALER FROM WINDSHIELD OR BACKLITE DRIPS ON INTERIOR TRIM VEHICLES BUILT THROUGH 10/93 ^ SEALER - WINDSHIELD OR BACKLITE - DRIPS ON INTERIOR TRIM - VEHICLES BUILT THROUGH 10/93 FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR ISSUE: The sealer from the windshield or backlite (Thunderbird only) may drip down onto the interior trim on some vehicles. This may be caused by the sealer not curing properly and softening in hot weather. ACTION: Install a foam seal around the windshield and/or backlite (Thunderbird only). The seal will act as a dam and keep the sealer from dripping onto the interior trim. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the A-pillar trim mouldings and headliner. On Thunderbird, also remove the rear seat and quarter trim mouldings. Refer to the appropriate Service Manual for removal procedures. NOTE: WHEN REMOVING THE TRIM ITEMS, THE SEALER MIGHT BE STUCK TO THEM MAKING IT NECESSARY TO CUT THE SEALER TO SEPARATE THE PARTS FROM THE VEHICLE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9656 2. Using a plastic or wood (non-metal) scraper, remove as much of the sealer from the inside of the front and/or rear glass (Thunderbird only) and side edges as possible. Use care not to scratch the glass or the ceramic paint on the glass. It is not necessary to remove all the sealer, just the large deposits that will interfere with the installation of the foam seal used in this procedure. Use mineral spirits to remove any residue from the glass. Refer to Figure 1. NOTE: CLEAN AFFECTED INTERIOR TRIM WITH FORD SPOT AND STAIN REMOVER (B7A-19521-AA OR EQUIVALENT). 3. Remove any heavy deposits of sealer from the interior trim components and then install the headliner, A-pillar trim mouldings and quarter trim mouldings (if removed), but do not tighten the attaching screws. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9657 4. Install the foam seal (F5SZ-6303037-A) around the windshield. Start at the RH or LH A-pillar and pull the A-pillar moulding and headliner slightly away from the windshield. Carefully push/tuck the seal between them and the glass, working toward the bottom of the opposite side A-pillar until the seal is positioned out of view. Refer to Figure 2. 5. Tighten the A-pillar trim screws. 6. To install the foam seal on the rear glass of the Thunderbird, follow the same procedure as used for the windshield. 7. Tighten the quarter trim panel attaching screws. 8. Reinstall the rear seat (Thunderbird only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > Customer Interest: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9658 PART NUMBER PART NAME F5SZ-6303037-A Windshield Sealer B7A-19521-AA Spot And Stain Remover OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950502A Clean Sealer And Install 1.0 Hr. Foam Dam - Cougar 950502B Clean Sealer And Install 2.0 Hrs. Foam Dam - Thunderbird DEALER CODING BASIC PART NO. CONDITION CODE 7003100 49 ACES II DEALERS MUST CODE TO THE FULL BASE BODY PANEL NUMBER - DO NOT USE 70 OASIS CODES: 102000, 107000, 110000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Windshield: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 9664 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure Windshield: All Technical Service Bulletins Windshield - Material Usage Procedure Article No. 95-12-1 06/19/95 GLASS - WINDSHIELD - URETHANE MOUNTED GLASS MATERIAL USAGE PROCEDURE SERVICE TIP. FORD 1981-95 ESCORT 1983-95 THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1990-95 CROWN VICTORIA 1995-95 ASPIRE 1995 CONTOUR, MUSTANG LINCOLN-MERCURY 1982-95 CONTINENTAL 1983-95 COUGAR 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1990-95 GRAND MARQUIS, TOWN CAR 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE LIGHT TRUCK 1983-95 RANGER 1984-90 BRONCO II 1986-95 AEROSTAR 1987-95 BRONCO, F-150-350 SERIES, F-47 1992-95 ECONOLINE 1993-95 VILLAGER 1995 WINDSTAR ISSUE: Essex windshield replacement products have a limited shelf life. Products should be discarded if they have exceeded their shelf life. ACTION: Refer to the following text to decode the manufacturing (batch) date from the container. Also, refer to the Service Procedure for proper installation procedures. HOW TO READ ESSEX BATCH NUMBERS Example: JL158601AA Year: J Month: L Day: 15 Essex ARG: 8601 Batch: AA This batch was made December 15, 1995 at the Essex plant, batch sequence AA. Monthly Code Guide: ^ A - January ^ B - February ^ C - March ^ D - April Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9669 ^ E - May ^ F - June ^ G - July ^ H - August ^ I - September ^ J - October ^ K - November ^ L December Year Code Guide: ^ J - 1995 ^ K - 1996 ^ L - 1997 ^ M - 1998 URETHANE MOUNTED GLASS MATERIAL USAGE PROCEDURE REMOVAL 1. If necessary, remove the windshield wiper mounting arm, pivot shafts and leaf screen along cowl. Remove the inside rear view mirror, all windshield garnish mouldings, A-pillar mouldings and lower headliner. 2. Use Rotunda Interior Cut-Out Knife (164-R2450 or 164-R2451) or equivalent to cut urethane. Refer to the manufacturer's instructions when using tool. CAUTION: USE CARE WHEN CUTTING THROUGH SEAL TO AVOID DAMAGE TO THE INSTRUMENT PANEL, REAR PACKAGE TRAY, HEADLINER OR INTERIOR TRIM. 3. Remove glass from vehicle using a suitable glass removal tool. INSTALLATION 1. Trim the urethane left on the flange with a utility knife or razor blade until the surface is smooth and free of cuts. Even up the urethane remaining on the pinch weld so it is all at the same level (approximately 1/16" or 1.6 mm). 2. Apply Essex Urethane Pinchweld Primer U-413 to any sheet metal that has been exposed along the pinch weld. Let dry for a minimum of 6-10 minutes before proceeding. Do not apply primer to existing urethane bead. 3. Properly align glass to body. Place the glass in the opening and center it from top to bottom and side to side with about equal clearance on all sides. Using masking tape or crayon, make alignment points on each of the four (4) sides of the glass and body. 4. Remove the windshield from the vehicle and place it inside up, on a low stable work surface. 5. Clean the glass with a non-alcohol based glass cleaner such as Essex Glass And Surface Cleaner GC-800. 6. Install rear view mirror bracket. Refer to the appropriate Service Manual for installation details. 7. Apply two (2) coats of Urethane Glass Prep U-401 to inner edge of the windshield. Wipe off material immediately after each application. NOTE: WIPE OFF URETHANE GLASS PREP U-401 IMMEDIATELY AFTER EACH APPLICATION. 8. Apply Essex Primer U-402 to the same glass area as U-401. Allow to dry 5 minutes. 9. Install foam dam tape on pinch weld, if required. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9670 10. Cut the nozzle of the Essex Urethane Auto Glass Adhesive U-4OOHV (Figure 1) and apply a triangular bead of urethane 5/8" (16 mm) by 3/8" (9 mm) wide around the perimeter of the pinch weld. 11. Install the glass into the opening taking care to align the marks previously designated. Press glass into place until full contact is made with urethane adhesive. Glass must be installed before urethane skins over. NOTE: BEFORE INSTALLING GLASS, OPEN THE WINDOWS TO PREVENT THE GLASS FROM BEING PUSHED OUT BY AIR PRESSURE IF A DOOR IS CLOSED. 12. If necessary, reinstall all mouldings and trim previously removed. CAUTION: WHEN REPLACING URETHANE INSTALLED GLASS, THE VEHICLE SHOULD NOT BE DRIVEN UNTIL THE URETHANE HAS CURED. THIS WILL PREVENT THE GLASS FROM BEING JARRED OUT OF POSITION AND HELP ENSURE APPROPRIATE WINDSHIELD RETENTION TO MEET SAFETY AND STRUCTURAL REQUIREMENTS. NOTE: USE ONLY URETHANE FOR SERVICE OF AIR AND WATER LEAKS ON URETHANE INSTALLED GLASS. These products are required for urethane mounted glass replacement: To locate the nearest distributor of Essex glass replacement products, contact the following locations: For North America or other: ^ Essex ARG ^ 555 Gaddis Blvd. ^ Dayton, Ohio 45403 ^ Phone Within North America: (800) 453-3779 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9671 ^ Phone Outside North America: (513) 254-1550 ^ Fax: (513) 254-3779 For Europe: ^ Gurit-Essex AG ^ CH-8807 Freienbach ^ Phone: (055) 471121 ^ Fax: (055) 486738 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim Windshield: All Technical Service Bulletins Windshield/Backlite - Sealer Drips on Interior Trim Article No. 95-5-2 03/13/95 ^ INTERIOR TRIM - SEALER FROM WINDSHIELD OR BACKLITE DRIPS ON INTERIOR TRIM VEHICLES BUILT THROUGH 10/93 ^ SEALER - WINDSHIELD OR BACKLITE - DRIPS ON INTERIOR TRIM - VEHICLES BUILT THROUGH 10/93 FORD: 1989-94 THUNDERBIRD LINCOLN-MERCURY: 1989-94 COUGAR ISSUE: The sealer from the windshield or backlite (Thunderbird only) may drip down onto the interior trim on some vehicles. This may be caused by the sealer not curing properly and softening in hot weather. ACTION: Install a foam seal around the windshield and/or backlite (Thunderbird only). The seal will act as a dam and keep the sealer from dripping onto the interior trim. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the A-pillar trim mouldings and headliner. On Thunderbird, also remove the rear seat and quarter trim mouldings. Refer to the appropriate Service Manual for removal procedures. NOTE: WHEN REMOVING THE TRIM ITEMS, THE SEALER MIGHT BE STUCK TO THEM MAKING IT NECESSARY TO CUT THE SEALER TO SEPARATE THE PARTS FROM THE VEHICLE. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9676 2. Using a plastic or wood (non-metal) scraper, remove as much of the sealer from the inside of the front and/or rear glass (Thunderbird only) and side edges as possible. Use care not to scratch the glass or the ceramic paint on the glass. It is not necessary to remove all the sealer, just the large deposits that will interfere with the installation of the foam seal used in this procedure. Use mineral spirits to remove any residue from the glass. Refer to Figure 1. NOTE: CLEAN AFFECTED INTERIOR TRIM WITH FORD SPOT AND STAIN REMOVER (B7A-19521-AA OR EQUIVALENT). 3. Remove any heavy deposits of sealer from the interior trim components and then install the headliner, A-pillar trim mouldings and quarter trim mouldings (if removed), but do not tighten the attaching screws. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9677 4. Install the foam seal (F5SZ-6303037-A) around the windshield. Start at the RH or LH A-pillar and pull the A-pillar moulding and headliner slightly away from the windshield. Carefully push/tuck the seal between them and the glass, working toward the bottom of the opposite side A-pillar until the seal is positioned out of view. Refer to Figure 2. 5. Tighten the A-pillar trim screws. 6. To install the foam seal on the rear glass of the Thunderbird, follow the same procedure as used for the windshield. 7. Tighten the quarter trim panel attaching screws. 8. Reinstall the rear seat (Thunderbird only). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 9552 > Mar > 95 > Windshield/Backlite - Sealer Drips on Interior Trim > Page 9678 PART NUMBER PART NAME F5SZ-6303037-A Windshield Sealer B7A-19521-AA Spot And Stain Remover OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage For 1992-94 Model Years, Basic Warranty Coverage For All Other Model Years OPERATION DESCRIPTION TIME 950502A Clean Sealer And Install 1.0 Hr. Foam Dam - Cougar 950502B Clean Sealer And Install 2.0 Hrs. Foam Dam - Thunderbird DEALER CODING BASIC PART NO. CONDITION CODE 7003100 49 ACES II DEALERS MUST CODE TO THE FULL BASE BODY PANEL NUMBER - DO NOT USE 70 OASIS CODES: 102000, 107000, 110000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 89113 > Jun > 89 > Windshield - Revised Installation Procedure Windshield: All Technical Service Bulletins Windshield - Revised Installation Procedure WINDSHIELD-URETHANE INSTALLATION-REVISED SERVICE PROCEDURE Article No. 89-11-3 FORD: 1981-88 ESCORT 1982-88 EXP 1983-89 THUNDERBIRD 1984-89 TEMPO LINCOLN-MERCURY: 1981-85 LYNX 1983-89 COUGAR 1984-89 MARK VII, TOPAZ LIGHT TRUCK: 1983-89 RANGER 1984-89 BRONCO II 1987-89 BRONCO, F-150, F-250, F-350 Figure 1 ISSUE: A revised procedure for installing urethane adhesive held windshields is used in production. It eliminates the need for spacers between the glass and the flange. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Windshield: > 89113 > Jun > 89 > Windshield - Revised Installation Procedure > Page 9683 ACTION: When installing windshields, refer to Section 43-11 of the appropriate Shop Manual and use the following service procedure. 1. Remove the glass and spacers from the flange. 2. Clean all excess hardened urethane from the flange. 3. Clean the underside edge of the glass outer edge with glass cleaner, Figure 1. Wipe it off immediately after application. 4. Apply urethane primer, Figure 1. Allow five minutes drying time. 5. Where appropriate, apply a strip of polyvinyl chloride foam tape (ESB-M3G137-A) around the outer area of the glass about 8.0 +/- 1.0 mm in from edge. Figure 2 NOTE: FOAM TAPE IS NOT REQUIRED FOR ALL VEHICLES. REFER TO THE APPROPRIATE SHOP MANUALS, SECTION 43-11 FOR SPECIFIC REQUIREMENTS. 6. Apply a bead of urethane sealer on the primer between the edge of the glass and the foam tape. The bead should be about 12.0 mm high and 8.0 mm wide, Figure 2. 7. Install the windshield on the cleaned and preped flange without spacers. 8. Follow the instructions in the appropriate Shop Manual for the finishing steps. PART NUMBER PART NAME CLASS EOAZ-19562-A Kit, Windshield Sealer (Cleaner, RM Urethane Primer and Sealer) E4AZ-19627-C Foam Tape A OTHER APPLICABLE ARTICLES: None SUPERSEDES: 84-18-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film Windshield: All Technical Service Bulletins Windshield/Interior Glass - Fog/Film Article No. 96-22-1 10/21/96 WINDSHIELD AND INTERIOR GLASS - FOG/FILM FORD: 1984-86 LTD 1984-88 EXP 1984-94 TEMPO 1984-97 CROWN VICTORIA, ESCORT, MUSTANG, THUNDERBIRD 1986-97 TAURUS 1988-93 FESTIVA 1989-97 PROBE 1994-97 ASPIRE 1995-97 CONTOUR LINCOLN-MERCURY: 1984-86 MARQUIS 1984-87 LN7, LYNX 1984-92 MARK VII 1984-94 TOPAZ 1984-97 CONTINENTAL, COUGAR, GRAND MARQUIS, TOWN CAR 1986-97 SABLE 1987-89 TRACER 1991-94 CAPRI 1991-97 TRACER 1993-97 MARK VIII 1995-97 MYSTIQUE MERKUR: 1985-89 XR4TI 1988-90 SCORPIO LIGHT TRUCK: 1984-97 F-150-350 SERIES 1986-90 BRONCO II 1986-96 BRONCO 1986-97 AEROSTAR, ECONOLINE, RANGER 1988-97 F SUPER DUTY 1991-97 EXPLORER 1993-97 VILLAGER 1995-97 WINDSTAR This TSB article is being republished in its entirety to update the model years. ISSUE: Customers with concerns of glass fogging (film) and with the chemicals that cause this fog can be advised that Ford Motor Company has extensively tested this material and found that it is not a health hazard. The film is caused by some of the chemicals used during the manufacture of the interior trim. ACTION: At the present time, there is no known field fix to prevent the window fogging, however, glass cleaner such as Ford Glass Cleaner (E4AZ-19C507-AA) has been found to be the best for film removal. PART NUMBER PART NAME E4AZ-19C507-AA Ford Glass cleaner Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 96221 > Oct > 96 > Windshield/Interior Glass - Fog/Film > Page 9689 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 86-13-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000, 107000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure Windshield: All Technical Service Bulletins Windshield - Material Usage Procedure Article No. 95-12-1 06/19/95 GLASS - WINDSHIELD - URETHANE MOUNTED GLASS MATERIAL USAGE PROCEDURE SERVICE TIP. FORD 1981-95 ESCORT 1983-95 THUNDERBIRD 1984-94 TEMPO 1986-95 TAURUS 1988-93 FESTIVA 1989-95 PROBE 1990-95 CROWN VICTORIA 1995-95 ASPIRE 1995 CONTOUR, MUSTANG LINCOLN-MERCURY 1982-95 CONTINENTAL 1983-95 COUGAR 1984-94 TOPAZ 1986-95 SABLE 1987-89 TRACER 1990-95 GRAND MARQUIS, TOWN CAR 1991-95 TRACER 1993-95 MARK VIII 1995 MYSTIQUE LIGHT TRUCK 1983-95 RANGER 1984-90 BRONCO II 1986-95 AEROSTAR 1987-95 BRONCO, F-150-350 SERIES, F-47 1992-95 ECONOLINE 1993-95 VILLAGER 1995 WINDSTAR ISSUE: Essex windshield replacement products have a limited shelf life. Products should be discarded if they have exceeded their shelf life. ACTION: Refer to the following text to decode the manufacturing (batch) date from the container. Also, refer to the Service Procedure for proper installation procedures. HOW TO READ ESSEX BATCH NUMBERS Example: JL158601AA Year: J Month: L Day: 15 Essex ARG: 8601 Batch: AA This batch was made December 15, 1995 at the Essex plant, batch sequence AA. Monthly Code Guide: ^ A - January ^ B - February ^ C - March ^ D - April Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9694 ^ E - May ^ F - June ^ G - July ^ H - August ^ I - September ^ J - October ^ K - November ^ L December Year Code Guide: ^ J - 1995 ^ K - 1996 ^ L - 1997 ^ M - 1998 URETHANE MOUNTED GLASS MATERIAL USAGE PROCEDURE REMOVAL 1. If necessary, remove the windshield wiper mounting arm, pivot shafts and leaf screen along cowl. Remove the inside rear view mirror, all windshield garnish mouldings, A-pillar mouldings and lower headliner. 2. Use Rotunda Interior Cut-Out Knife (164-R2450 or 164-R2451) or equivalent to cut urethane. Refer to the manufacturer's instructions when using tool. CAUTION: USE CARE WHEN CUTTING THROUGH SEAL TO AVOID DAMAGE TO THE INSTRUMENT PANEL, REAR PACKAGE TRAY, HEADLINER OR INTERIOR TRIM. 3. Remove glass from vehicle using a suitable glass removal tool. INSTALLATION 1. Trim the urethane left on the flange with a utility knife or razor blade until the surface is smooth and free of cuts. Even up the urethane remaining on the pinch weld so it is all at the same level (approximately 1/16" or 1.6 mm). 2. Apply Essex Urethane Pinchweld Primer U-413 to any sheet metal that has been exposed along the pinch weld. Let dry for a minimum of 6-10 minutes before proceeding. Do not apply primer to existing urethane bead. 3. Properly align glass to body. Place the glass in the opening and center it from top to bottom and side to side with about equal clearance on all sides. Using masking tape or crayon, make alignment points on each of the four (4) sides of the glass and body. 4. Remove the windshield from the vehicle and place it inside up, on a low stable work surface. 5. Clean the glass with a non-alcohol based glass cleaner such as Essex Glass And Surface Cleaner GC-800. 6. Install rear view mirror bracket. Refer to the appropriate Service Manual for installation details. 7. Apply two (2) coats of Urethane Glass Prep U-401 to inner edge of the windshield. Wipe off material immediately after each application. NOTE: WIPE OFF URETHANE GLASS PREP U-401 IMMEDIATELY AFTER EACH APPLICATION. 8. Apply Essex Primer U-402 to the same glass area as U-401. Allow to dry 5 minutes. 9. Install foam dam tape on pinch weld, if required. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9695 10. Cut the nozzle of the Essex Urethane Auto Glass Adhesive U-4OOHV (Figure 1) and apply a triangular bead of urethane 5/8" (16 mm) by 3/8" (9 mm) wide around the perimeter of the pinch weld. 11. Install the glass into the opening taking care to align the marks previously designated. Press glass into place until full contact is made with urethane adhesive. Glass must be installed before urethane skins over. NOTE: BEFORE INSTALLING GLASS, OPEN THE WINDOWS TO PREVENT THE GLASS FROM BEING PUSHED OUT BY AIR PRESSURE IF A DOOR IS CLOSED. 12. If necessary, reinstall all mouldings and trim previously removed. CAUTION: WHEN REPLACING URETHANE INSTALLED GLASS, THE VEHICLE SHOULD NOT BE DRIVEN UNTIL THE URETHANE HAS CURED. THIS WILL PREVENT THE GLASS FROM BEING JARRED OUT OF POSITION AND HELP ENSURE APPROPRIATE WINDSHIELD RETENTION TO MEET SAFETY AND STRUCTURAL REQUIREMENTS. NOTE: USE ONLY URETHANE FOR SERVICE OF AIR AND WATER LEAKS ON URETHANE INSTALLED GLASS. These products are required for urethane mounted glass replacement: To locate the nearest distributor of Essex glass replacement products, contact the following locations: For North America or other: ^ Essex ARG ^ 555 Gaddis Blvd. ^ Dayton, Ohio 45403 ^ Phone Within North America: (800) 453-3779 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 95121 > Jun > 95 > Windshield - Material Usage Procedure > Page 9696 ^ Phone Outside North America: (513) 254-1550 ^ Fax: (513) 254-3779 For Europe: ^ Gurit-Essex AG ^ CH-8807 Freienbach ^ Phone: (055) 471121 ^ Fax: (055) 486738 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 102000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 89113 > Jun > 89 > Windshield - Revised Installation Procedure Windshield: All Technical Service Bulletins Windshield - Revised Installation Procedure WINDSHIELD-URETHANE INSTALLATION-REVISED SERVICE PROCEDURE Article No. 89-11-3 FORD: 1981-88 ESCORT 1982-88 EXP 1983-89 THUNDERBIRD 1984-89 TEMPO LINCOLN-MERCURY: 1981-85 LYNX 1983-89 COUGAR 1984-89 MARK VII, TOPAZ LIGHT TRUCK: 1983-89 RANGER 1984-89 BRONCO II 1987-89 BRONCO, F-150, F-250, F-350 Figure 1 ISSUE: A revised procedure for installing urethane adhesive held windshields is used in production. It eliminates the need for spacers between the glass and the flange. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Windows and Glass > Windshield > Component Information > Technical Service Bulletins > All Other Service Bulletins for Windshield: > 89113 > Jun > 89 > Windshield - Revised Installation Procedure > Page 9701 ACTION: When installing windshields, refer to Section 43-11 of the appropriate Shop Manual and use the following service procedure. 1. Remove the glass and spacers from the flange. 2. Clean all excess hardened urethane from the flange. 3. Clean the underside edge of the glass outer edge with glass cleaner, Figure 1. Wipe it off immediately after application. 4. Apply urethane primer, Figure 1. Allow five minutes drying time. 5. Where appropriate, apply a strip of polyvinyl chloride foam tape (ESB-M3G137-A) around the outer area of the glass about 8.0 +/- 1.0 mm in from edge. Figure 2 NOTE: FOAM TAPE IS NOT REQUIRED FOR ALL VEHICLES. REFER TO THE APPROPRIATE SHOP MANUALS, SECTION 43-11 FOR SPECIFIC REQUIREMENTS. 6. Apply a bead of urethane sealer on the primer between the edge of the glass and the foam tape. The bead should be about 12.0 mm high and 8.0 mm wide, Figure 2. 7. Install the windshield on the cleaned and preped flange without spacers. 8. Follow the instructions in the appropriate Shop Manual for the finishing steps. PART NUMBER PART NAME CLASS EOAZ-19562-A Kit, Windshield Sealer (Cleaner, RM Urethane Primer and Sealer) E4AZ-19627-C Foam Tape A OTHER APPLICABLE ARTICLES: None SUPERSEDES: 84-18-7 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 1300 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9708 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9709 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9710 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations I/P Components LH Side Of Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9718 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9719 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9720 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Engine Compartment Component Locations In Bottom Of Reservoir Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9729 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9730 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9731 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9736 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9737 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9738 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9739 Wiper Switch: Testing and Inspection Continuity Test Fig. 40 Wiper Switch Continuity Test When testing a non-intermittent wiper switch, a self-powered test lamp or an ohmmeter can be used to check continuity. When testing an intermittent wiper switch, use only an ohmmeter to check continuity. When taking test readings move the switch lever to detect marginal switch operation. Refer to Fig. 40 for switch terminal identification and continuity readings. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9740 Wiper Switch: Service and Repair 1. Disconnect battery ground cable. 2. Remove four steering column shroud attaching screws, then grasp top and bottom of shroud and separate. 3. Using a screwdriver, disconnect wire connector from wiper switch. 4. Remove two wiper switch attaching screws, then remove switch. 5. Reverse procedure to install. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Diagrams > Diagram Information and Instructions Washer Fluid Level Indicator: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9745 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9746 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Indicator > Component Information > Diagrams > Diagram Information and Instructions > Page 9747 Fig. 10 Wiper System Wiring Schematic (Intermittent) Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information > Locations Washer Fluid Level Switch: Locations Engine Compartment Component Locations In Bottom Of Reservoir Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations Windshield Washer Motor: Locations Engine Compartment. In Bottom Of Reservoir Applicable to: V6-232/3.8L Except Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Locations > Page 9754 Engine Compartment Component Locations In Bottom Of Reservoir Applicable to: V6-232/3.8L Supercharged Engine Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Motor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9757 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9758 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9759 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Pump: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 9764 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 9765 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information > Diagrams > Diagram Information and Instructions > Page 9766 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9771 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9772 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9773 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions Windshield Washer Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9778 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9779 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9780 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Wiper Arm - Adjustment Procedure Wiper Arm: Technical Service Bulletins Wiper Arm - Adjustment Procedure Article No. 91-5-4 WINDSHIELD WIPER ARMS - ADJUSTMENT PROCEDURE FORD: 1989-91 THUNDERBIRD LINCOLN-MERCURY: 1989-91 COUGAR 1990-91 TOWN CAR ISSUE: The wiper arms are located and installed by a key in the arm and a keyway in the pivot shaft. This type of installation does not allow for adjustment, when required. ACTION: This article provides procedures and illustrations so adjustments can be performed. Refer to the following procedure for service details. Figure 1 ALL VEHICLES 1. Remove the arm and blade assembly from vehicle. Refer to the appropriate year Car Shop Manual, Section 35-60 for removal procedure. 2. Using a small flat end screwdriver, pry out the plastic key from the arm as shown in figure 1. NOTE: WINDSHIELD WIPER SYSTEM MUST BE CYCLED AND IN THE PARKED POSITION BEFORE THE ARMS AND BLADES ARE INSTALLED. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Wiper Arm - Adjustment Procedure > Page 9785 Figure 2 LINCOLN TOWN CAR 1. Locate the arm to the specified installation position, lay the arm over the wiper stop of the leaf screen assembly as shown in figure 2. 2. Install the arm while maintaning contact with the arm stop. Lock arm onto pivot shaft by applying downward pressure on the arm head. To ensure full seating, raise the other end of the arm high enough to allow the latch to slide under the pivot shaft into the latched position using finger pressure only to slide the latch. 3. Leave arm positioned above the leaf screen ramp stop, until arm on opposite side is installed as in steps 3 through 4 and similarly positioned. Then push both arms down and rearward so that the front of the arm bumpers rest against the ramp stops (park position). Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Wiper Arm - Adjustment Procedure > Page 9786 Figure 3 THUNDERBIRD/COUGAR 1. Locate the blade assembly to the specified installation position as shown in figure 3. 2. Install and lock arm on pivot shaft by applying downward pressure on the arm head and raising the blade end enough to allow the latch to slide under the pivot shaft. Use finger pressure only to slide latch. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage OPERATION DESCRIPTION TIME Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Technical Service Bulletins > Wiper Arm - Adjustment Procedure > Page 9787 910504A Adjust Wiper Arms 0.3 Hr. DEALER CODING BASIC PART NO. CONDITION CODE 17527 07 OASIS CODES: 202000, 290000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Control Module > Component Information > Locations Wiper Control Module: Locations I/P Components LH Side Of Steering Column Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Wiper Motor - Upgraded Service Kits Wiper Motor: Technical Service Bulletins Wiper Motor - Upgraded Service Kits Article No. 95-8-2 04/24/95 ^ WIPER MOTOR - REPLACEMENT - UPGRADED SERVICE KITS ^ WINDSHIELD WIPER MOTOR - UPGRADED SERVICE REPAIR KITS FORD: 1986-94 TEMPO 1987-91 CROWN VICTORIA 1987-93 MUSTANG, TAURUS 1989-92 PROBE 1989-93 THUNDERBIRD 1991-94 ESCORT LINCOLN-MERCURY: 1986-94 TOPAZ 1987-89 TOWN CAR 1987-91 GRAND MARQUIS 1987-93 SABLE 1988-94 CONTINENTAL 1989-93 COUGAR 1991-94 TRACER 1993 MARK VIII LIGHT TRUCK: 1987-94 BRONCO, F SUPER DUTY, F150-350 SERIES MEDIUM/HEAVY TRUCK: 1980-94 L SERIES 1988-95 F SERIES This TSB is being republished in its entirety to include F-150-350 Series, Bronco, F-Super Duty and F/B-Series, revise application chart, and to include production dates for L-Series vehicles. ISSUE: A revised service windshield wiper motor is now available if the windshield wiper motor requires replacement. ACTION: Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Wiper Motor - Upgraded Service Kits > Page 9795 Replace the wiper motor with a revised wiper motor and use a Windshield Wiper Motor Service Kit to complete the installation. Refer to the Application Chart listed in this article for the proper application. Follow the detailed instructions included in the service kit. 1. Inspect the vehicle to see if the new Wiper Motor (-17508-) is already installed. If so, the latest level of wiring is already installed and the Wiper Motor Wiring Kit (-14A411-) is not required. 2. Install a new Wiper Motor Assembly. Refer to appropriate Service Manual for installation details. 3. Use the Wiper Motor Wiring Kit (-14A411-) to complete the installation. The Wiring Kit (-14A411-) consists of: ^ One (1) Wiring and Connector Assembly ^ Seven (7) 5/16" (8 mm) Heat Shrink Tubing - 2" (51 mm) long ^ One (1) 37/63 (lead/tin) Solder 0.032" (0.80 mm) diameter x 12" (305 mm) long ^ One (1) Adhesive Label ^ Instruction Sheets Not included in the kit is the Wiper Motor (-17508-). Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 94-11-20, 95-4-6 WARRANTY STATUS: INFORMATION ONLY OASIS CODES: 202000 Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service Bulletins > Page 9796 Wiper Motor: Locations On LH Side Of I/P Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions Wiper Motor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9799 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9800 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Diagrams > Diagram Information and Instructions > Page 9801 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures Wipers And Washers Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 9804 Wiper Motor: Component Tests and General Diagnostics Parking Test The ignition switch must be in RUN for all tests. Verify proper operation of wiper system in LOW. With system operating in LOW, turn wiper system switch to OFF when wiper blades are in vertical (straight up) position. Wipers should complete cycle and park. If the wiper blades do not park, refer to appropriate condition of system below and test and service as indicated. Motor stops when wiper switch is turned to OFF (does not complete cycle). 1. Remove motor park switch connector and check for battery voltage on circuit 63 (red). If battery voltage is not present, service circuit as required. If voltage is present, go to Step 2. 2. Check motor housing for ground. If ground is not present (or poor), check cup screw for tightness. If screws are tight, check motor ground strap. Service as required. If ground is OK, go to Step 3. 3. With wiper motor connector disconnected, use an ohmmeter to verify continuity (less than one ohm) between circuits 28 and 58 in the wiring harness. If continuity is not present, trace and service as required. If continuity is OK, leave connectors disconnected and go to Step 4. 4. Check for ground at circuit terminal 28 on wiper motor. If open, replace wiper motor. If ground is present, leave connector disconnected and go to Step 5. 5. Verify continuity (less than one ohm resistance) between circuits G2 and 63 in the wiring harness. If continuity is not present, trace and service as required. If lack of continuity is traced to interval governor, check wiper switch for continuity between terminals P and G. Replace switch if continuity is not present between terminals P and G. If continuity is present between terminals P and G on wiper switch, and lack of continuity has been traced to interval governor, replace governor. Wiper blades complete cycle, but continue to wipe for part of another cycle and park on windshield, or Wiper blades run continuously in OFF or INTERVAL. Perform the following. 1. Perform wiper switch continuity test. If continuity test fails, replace switch. If continuity test is OK on standard wiper system, replace motor. If continuity test is OK on interval wiper system, go to Step 2. 2. Check wash circuit 941 for no voltage. Refer to illustration. If any voltage is present, service as required. If no voltage is present, go to Step 3. 3. Disconnect connectors at wiper motor and check for continuity between circuits G2 and 63 going to interval governor. If open, replace governor. If continuity is present, replace motor. Wiper Motor Current Draw Test Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Symptom Related Diagnostic Procedures > Page 9805 Fig. 39 Wiper Motor Current Draw Test Disconnect the negative battery cable. Remove wiper module from vehicle as outlined. With wiper module on bench disconnect wiper linkage from wiper motor. Connect the green lead from the Rotunda Starting and Charging Tester or equivalent to battery positive post. Connect positive (red) lead from tester first to low-speed connection and then to high- speed connections at connector plug as shown in the illustration. In either case, the current draw should not exceed 3.5 amperes. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Testing and Inspection > Page 9806 Wiper Motor: Service and Repair Fig. 6 Wiper Motor Replacement 1. Disconnect battery ground cable. 2. With wipers in Park position, remove arm and blade assemblies. 3. Remove LH cowl vent screen. 4. Remove vacuum manifolds from wiper module, Fig. 6. 5. Disconnect wiring connectors, then remove five bolts and one nut from wiper module and remove module. 6. Remove crankpin clip, then disconnect linkage drive arm from motor crankpin. 7. Remove three motor attaching screws, pull motor from opening. 8. Reverse procedure to install, ensuring that wiper motor is in the park position prior to installation. Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions Interval Governor: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions > Page 9811 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions > Page 9812 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Interval Governor <--> [Wiper Motor Timer] > Component Information > Diagrams > Diagram Information and Instructions > Page 9813 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions Wiper Relay: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9818 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9819 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Diagrams > Diagram Information and Instructions > Page 9820 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions Wiper Switch: Diagram Information and Instructions Symbol Identification Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9825 Symbol Identification Wire Color Code Identification NOTE: Whenever a wire is labeled with two colors; the first color listed is the basic color of the wire, and the second color is the tracer marking of the wire. If the second color is followed by by a D, the tracer is dots. If the second color is followed by an H, the tracer is hash marks. For example: BR/O is a brown wire with an orange stripe, R/Y D is a red wire with yellow dots and BK/W H is a black wire with white hash marks. BL: Blue Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9826 BK: Black BR: Brown DB: Dark Blue DG: Dark Green GR: Green GY: Gray LB: Light Blue LG: Light Green N: Natural O: Orange PK: Pink R: Red P: Purple T: Tan V: Violet W: White Y: Yellow Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Diagram Information and Instructions > Page 9827 Wiper And Washer Ford Thunderbird Workshop Manual (V6-232 3.8L SC (1989)) Ford Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Diagrams > Page 9828 Wiper Switch: Testing and Inspection Continuity Test Fig. 40 Wiper Switch Continuity Test When testing a non-intermittent wiper switch, a self-powered test lamp or an ohmmeter can be used to check continuity. When testing an intermittent wiper switch, use only an ohmmeter to check continuity. When taking test readings move the switch lever to detect marginal switch operation. Refer to Fig. 40 for switch terminal identification and continuity readings.

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