THE LATEST SERVICE PCM CALIBRATION RELEASE FOR 2001 SUPERDUTY F-SERIES VEHICLES EQUIPPED WITH A 7.3L DIESEL ENGINE AND 4R100 TRANSMISSION CONTAIN ENHANCEMENTS FOR INCREASED LOW/REVERSE CLUTCH CAPACITY IN MANUAL 1.  THIS NEW SERVICE CALIBRATION RELEASE INCLUDES CATCHWORDS BRM0, CKS0, DMJ0, EJP0, FAV0 AND GMD0.  CALIBRATIONS WITH CATCHWORDS JLJ1, PMT3, BKA3, KRK3, NMC3 AND QHL3 CAN BE REPROGRAMMED WITH THIS NEW SERVICE CALIBRATION RELEASE.  REPROGRAM THE PCM WITH THE LATEST CALIBRATION AVAILABLE VIA FORDSTAR USING WDS RELEASE B24.3 OR LATER.  THE UPDATE FILE CAN ALSO BE OBTAINED AT WWW.WDSCENTRAL.COM.

NORMAL OPERATION - EXHAUST AIR RUSH NOISE AND LOWER POWER.  SOME 1994-2003 F-SUPER DUTIES, 1995-2003 ECONOLINE AND 2000-2003 EXCURSION WITH 7.3L ENGINE MAY EXHIBIT LOWER POWER WHEN COLD AND AN AIR RUSHING NOISE.  THE TURBO CHARGER EXHAUST IS RESTRICTED BY THE EBP TO HELP INCREASE ENGINE COOLANT TEMPERATURE QUICKER FOR CAB HEAT.  THIS IS CONTROLLED BY THE PCM & THE EBP REGULATOR LOCATED IN THE TURBOCHARGER PEDESTAL.  THE EBP DEVICE WILL OPEN WHEN THE ACCELERATOR PEDAL IS DEPRESSED CAUSING EXHAUST BACK PRESSURE TO INCREASE.  WHEN EXHAUST BACKPRESSURE DECREASES OR THE VEHICLE IS AT A STEADY STATE THE EBP REGULATOR CAN/WILL ACTIVATE THE EBP DEVICE AGAIN EVEN DURING HIGHWAY DRIVING AS LONG AS THE EOT TEMP IS BELOW SPECIFICATIONS.  PCM CONTROLLED ON THE FOLLOWING PARAMETERS: IAT BELOW 10C(50F) & EOT BELOW 70C(158F)

SOME VEHICLES EQUIPPED WITH THE ROMEO BUILT 4.6L 2V ENGINE OR 5.4L 2V WINDSOR AND 5.4L SUPERCHARGED ENGINE MAY EXHIBIT AN OIL LEAK OR OIL WEEPAGE FROM THE CYLINDER HEAD GASKET AT THE RIGHT HAND REAR OR THE LEFT HAND FRONT OF THE ENGINE.  OIL WEEPAGE IS NOT CONSIDERED DETRIMENTAL TO ENGINE PERFORMANCE OR DURABILITY.  AN OIL LEAK MAY BE CAUSED BY METAL CHIP DEBRIS LODGED BETWEEN THE HEAD GASKET AND THE BLOCK, CHIP DEBRIS BETWEEN THE CYLINDER HEAD AND THE HEAD GASKET, OR BY DAMAGE TO THE CYLINDER HEAD SEALING SURFACE THAT OCCURRED DURING THE MANUFACTURING PROCESS.  SEE TSB 03-06-02 ON OASIS, OR FMCDEALER.COM (U.S. ONLY) FOR DETAILS.

ATTENTION: LOAD THE B24 RELEASE CD ON WDS
THE WDS B24 RELEASE CD SHOULD BE LOADED NOW.  THE REASON FOR THIS NOTICE IS TO IDENTIFY THAT THE B24 CALIBRATION UPDATE MECHANISM HAS BEEN FIXED FOR B24.  INSTALL B24 AND PERFORM THE UPDATE TO RECEIVE THE LATEST CALIBRATION FILES.  THE B24 CD THAT WAS ORIGINALLY RECEIVED IS THE CORRECT CD TO LOAD ON THE WDS.  ONCE A FORDSTAR UPDATE OF FLOPPY DISK UPDATE FROM THE PTS WEBSITE IS PERFORMED ALL OF THE LATEST CALIBRATIONS WILL BE AVAILABLE.  FOR EXAMPLE THE LATEST 6.0L DIESEL, OR LINCOLN LS CALIBRATION FILES WILL BE AVAILABLE TO PERFORM VEHICLE CALIBRATION UPDATES.

ATTENTION: DO NOT LOAD THE WDS B24 RELEASE CD UNTIL FURTHER NOTICE
THE B24 CALIBRATION UPDATE MECHANISM HAS FAILED FOR B24.  LEAVE OR REINSTALL B23 AND PERFORM A CALIBRATION UPDATE TO RECEIVE THE LATEST CALIBRATION FILE.  THE B23 CALIBRATION UPDATE PROCESS IS WORKING PROPERLY.  SEE TECH TIPS ON WDS B23.0.12.  IF YOU HAVE ANY QUESTIONS, PLEASE CALL 800-826-4694 OPTION #1

SOME 2002-2003 F250-550 AND EXCURSIONS, MAY EXHIBIT A DIFFICULTY IN PROGRAMMING THE KEY FOB(S).  THIS MAY BE DUE TO A CHANGE IN THE PROGRAMMING PROCESS.  THE CONDITION MAY BE CORRECTED BY PERFORMING THE FOLLOWING STEPS: 1. THE PERIMETER ALARM (IF PRESENT) MUST BE DISARMED AND THE VEHICLE MUST BE UNLOCKED WITH THE DRIVER SIDE DOOR LOCK SWITCH (DO NOT MANUALLY UNLOCK THE DOORS).  2. CYCLE THE IGNITION FROM OFF TO RUN EIGHT TIMES WITHIN TEN SECONDS, (ENDING IN THE RUN POSITION).  3. THE DOOR LOCKS SHOULD CYCLE AT THIS POINT, SHOWING THAT THE MODULE IS IN THE PROGRAM MODE.  4. AT THIS POINT PRESSING ANY BUTTON ON A KEY FOB WILL ASSOCIATE THE KEY FOB TO THE VEHICLE, AND WILL CAUSE THE LOCKS TO CYCLE.  NOTE: UP TO FOUR KEY FOBS CAN BE PROGRAMMED TO THE MODULE.

SOME 1997-2003 F-SERIES, EXPEDITION, NAVIGATOR, ECONOLINE, AND ECONOLINE MOTOR HOME CHASSIS, MAY EXHIBIT A FALSE FAILURE OF THE VAPOR MANAGEMENT VALVE (VMV).  THIS MAY BE DUE TO THE USE OF THE ROTUNDA SMOKE MACHINE TOOL SMOKE TESTER (OR SIMILAR TYPE OF SMOKE TEST EQUIPMENT).  THESE VEHICLES ARE EQUIPPED WITH A VAPOR MANAGEMENT VALVE (VMV) WHICH BECOMES UNSEATED AT A PRESSURE OF 11 INCHES OF WATER.  THE ROTUNDA SMOKE MACHINE TOOL SMOKE TESTER IS CALIBRATED AT 13-14 INCHES OF WATER.  THE INCREASED PRESSURE MAY CAUSE THE VMV TO BECOME UNSEATED DURING SMOKE TESTING, RESULTING IN A VMV FALSE FAILURE.  TO PREVENT THIS FROM HAPPENING, DISCONNECT THE LARGE MANIFOLD VACUUM LINE TO VMV AND PLUG OR CAP THE PORT AT VMV BEFORE PERFORMING THE SMOKE TEST.

SOME 2003 F-SUPERDUTY AND EXCURSION ALL EQUIPPED WITH A 6.0L DI, MAY EXHIBIT AN OIL LEAK AT THE REAR OF THE ENGINE AT THE REAR MAIN SEAL.  ENGINEERING IS CURRENTLY INVESTIGATING.  IF DURING DIAGNOSIS AN ENGINE OIL LEAK IS VERIFIED AT THE REAR MAIN SEAL, AND LEAKAGE IS DISCOVERED THROUGH ONE OR MORE OF THE SIX BOLTS THAT ATTACH THE PRIMARY FLANGE TO THE CRANKSHAFT, DO NOT REMOVE ANY OF THE BOLTS.  PLEASE CONTACT FORD ENGINEERING AT 313-248-4029.  BE PREPARED TO LEAVE A MESSAGE INCLUDING YOUR NAME, DEALERSHIP NAME AND PHONE NUMBER.  IF YOU DO NOT RECEIVE A RETURN PHONE CALL WITHIN 15 MINUTES THEN CONTINUE WITH NORMAL SERVICE.

SOME 2003 SUPER DUTY F-SERIES/EXCURSION WITH A 6.0L DIESEL MAY EXHIBIT ROUGH, ROLLING IDLE, POOR IDLE RETURN, LOW POWER, INJECTOR FAULT CODES, OR INCREASED SMOKE.  THIS MAY BE CAUSED BY THE ICP SENSOR.  CAREFULLY INSPECT THE ICP SENSOR CONNECTOR/TERMINALS FOR DAMAGE.  VERIFY VREF & SIGNAL RETURN CIRCUITS.  IF NO ELECTRICAL ISSUES, USE SCAN TOOL TO MEASURE ICP WITH EOT ABOVE 180 F.  KEY OFF, WAIT 1 MINUTE MINIMUM FOR BLEED DOWN.  KEY ON, WAIT 30 SECONDS.  MONITOR ICP PID (READING SHOULD BE 0.18-0.24 V).  IF NOT IN RANGE, CHECK NEW SENSOR (3C3Z-9F838-DA) BEFORE REMOVING OLD SENSOR.  ON COOL ENGINE, CONNECT NEW SENSOR TO ICP HARNESS CONNECTOR & ENSURE NO CONTACT WITH ANY METAL COMPONENTS.  KEY ON, MEASURE ICP PID (READING SHOULD BE 0.16-0.21 V).  IF NOT IN RANGE, CHECK ANOTHER ICP.  IF IN RANGE, INSTALL NEW ICP.  CK ICP AGAIN ABOVE 180 F PER ABOVE.

SOME 1999-2003 SUPER DUTY/EXCURSION VEHICLES EQUIPPED WITH A 7.3 OR 6.0 FORD NAVISTAR DIESEL ENGINE MAY EXHIBIT LACK OF POWER, SMOKE, OR OIL LEAKS AROUND THE CHARGE AIR COOLER (CAC) TUBE ON THE HOT SIDE OF THE COOLER (DRIVERS SIDE OF THE VEHICLE NEAR THE INTERCOOLER).  THIS MAY BE DUE TO OIL CONTAMINATION IN THE CAC.  CLEAN THE CAC AND AIR DRY WITH SHOP AIR THOROUGHLY BEFORE REINSTALLING.  DO NOT REPLACE THE CHARGE AIR COOLER FOR THIS CONDITION.

SOME 2003 SUPER DUTY F-SERIES AND EXCURSIONS 6.0L DIESEL MAY EXHIBIT A COLD ROUGH/SURGING IDLE IN 'DRIVE' OR 'REVERSE,' POOR THROTTLE RESPONSE WHEN COLD, OR LOW POWER FOLLOWING A COLD START/EXTENDED IDLE (LOW POWER MAY BE CLEARED BY CYCLING THE IGNITION SWITCH).  VEHICLES WITH A TORQSHIFT AUTO. TRANS. MY ALSO EXHIBIT HARSH SHIFT ENGAGEMENTS, HARSH 2-3 UPSHIFTS, COASTING 5-3 DOWNSHIFTS, AND COLD 3-5 FLARE.  ENHANCED FICM, TCM, AND PCM CALIBRATIONS ARE AVAILABLE AND MUST BE FLASHED AS A MATCHED SET.  ALL PRIOR CALIBRATION LEVELS MAY BE UPDATED.  ADDITIONALLY, CALIBRATIONS INCLUDE MODIFIED TR DC VALUES AND ACTIVATION OF P0528 (COOLING FAN) DTC.  SEE PTS WEBSITE QUICK REFERENCE GUIDES SECTION AND FUTURE TSB COMMUNICATION FOR NEW TR DC DIAGNOSTIC CHART VALUES.  USE WDS RELEASE B23.0.8 OR LATER.

SOME 2003 SUPER DUTY F-SERIES & EXCURSION VEHICLES EQUIPPED WITH A 6.0L DIESEL ENGINE MAY EXHIBIT COMMUNICATION ERRORS WHILE TRYING TO PERFORM DIAGNOSTICS WITH THE WDS TOOL.  ENSURE WDS IS AT THE LATEST SOFTWARE RELEASE, B23.0.7 OR LATER.  WHEN PERFORMING ON-DEMAND SELF TESTS WAIT AT LEAST 4 SECONDS AFTER KEY ON BEFORE INITIATING EACH TEST.  IF TEST IS INITIATED TOO QUICKLY A 'FAIL PCM' MESSAGE CAN APPEAR.  VERIFY GROUND CONNECTIONS TO THE DIAGNOSTIC CONNECTOR (DLC), REFER TO PC/ED PINPOINT AE.  VERIFY CAN COMMUNICATION CIRCUITS AT DLC, BY MEASURING VOLTAGE, KOEO, FROM PINS 6 & 14 TO GROUND, EACH VOLTAGE SHOULD BE 2.5V + .5V.  IF WDS STILL FAILS TO COMMUNICATE, CONTACT TECHNICAL INFORMATION SUPPORT @ 800-826-4694 OPTION #1 FOR FURTHER ASSISTANCE.

SOME 2002 AND 2003 MODEL YEARS 5.4L, 6.8L AND 7.3L (ONLY) SUPER DUTY F-SERIES AND EXCURSION VEHICLES MAY EXHIBIT THE FOLLOWING CONDITIONS:  2002 MODEL YEAR: 5.4L/6.8L APPLICATIONS - "WAIT TO START" LAMP ILLUMINATES AND STAYS ON AND/OR FLASHES INTERMITTENTLY, 7.3L APPLICATIONS - "WAIT TO START" LAMP DOES NOT SHUT OFF WITHIN CALIBRATED TIME AFTER KEY-ON, 7.3L APPLICATIONS - "WAIT TO START" LAMP DOES NOT SHUT OFF WITHIN CALIBRATED TIME AFTER KEY-ON, 7.3L APPLICATIONS - "WAIT TO START" LAMP FLASHES INTERMITTENTLY WHILE DRIVING.  2003 MODEL YEAR: 7.3L APPLICATIONS - "WAIT TO START" LAMP FLASHES INTERMITTENTLY WHILE DRIVING.  THIS CONDITION REFERS TOT HE ILLUMINATION OF THE "WAIT TO START" LAMP ONLY AND DOES NOT AFFECT ENGINE STARTING AND/OR OPERATION.  SEE TSB 03-04-5 ON OASIS AND FMCDEALER.COM FOR DETAILS.

THE 2003 EXCURSION, F250-350 SUPERDUTY DIESEL ENGINE LIFTING BRACKET ADAPTERS CALLED OUT IN THE 2003 WORKSHOP MANUAL (303-D043-01 AND 303-D043-02) WERE NOT PART OF THE ORIGINAL 303-D043 DIESEL ENGINE LIFTING BRACKET KIT.  THESE ARE NEW ADAPTERS SPECIFICALLY DESIGNED FOR THE NEW 6.0L DIESEL ENGINE.  YOU CAN PURCHASE THESE ADAPTERS BY CONTACTING ROTUNDA AT 1-800-ROTUNDA.  SELECTION #4.

THIS TSB PROVIDES INFORMATION ON THE 4X4 SYSTEM, PARTICULARLY THE FRONT LOCKING HUBS.  SEE TSB 03-04-01 ON OASIS AND FMCDEALER.COM FOR DETAILS.

SOME 2003 SUPER DUTY F-SERIES AND EXCURSIONS EQUIPPED WITH A 6.0L DIT ENGINE MAY EXHIBIT A LEAK AT THE REAR FUEL RAIL PLUG IN THE CYLINDER HEAD(S).  THIS MAY BE DUE TO A MIS-ALIGNED PLUG SEAL.  TO SERVICE, REPLACE THE PLUG AND SEAL ASSEMBLY USING SERVICE PART NUMBER 3C3Z-9K042-AA.

SOME 2003 SUPER DUTY F-SERIES/EXCURSION VEHICLES EQUIPPED WITH A 6.0L DIT AND TORQSHIFT TRANSMISSION MAY EXHIBIT A NO CRANK/NO START.  DTC'S P1705 (TR CIRCUIT NOT INDICATING PARK/NEUTRAL DURING SELF TEST) P0706 (TR-P SENSOR FREQUENCY FAULT) AND P0707 (TR-P SENSOR CIRCUIT DUTY CYCLE LOW INPUT) MAY BE PRESENT.  IF LOW VOLTAGE IS FOUND AT THE TRANSMISSION RANGE POSITION SENSOR (TR-P) PIN 21 (3-4 VOLTS) CIRCUIT 371, ELECTRICALLY DISCONNECT THE COOLING FAN CLUTCH AND RETEST THE VOLTAGE.  IF THE VOLTAGE NOW READS 12 VOLTS AND THE VEHICLE CRANKS AND STARTS, VERIFY WITH A SHORT DRIVE THAT CODES DO NOT RETURN.  DO NOT SERVICE THE TRANSMISSION OR REPLACE THE TRANSMISSION RANGE POSITION SENSOR (TR-P) FOR THIS CONDITION.  REFER TO THE APPROPRIATE WIRING DIAGRAM AND PC/ED MANUAL SECTION TO DIAGNOSE AND SERVICE THE COOLING FAN.

THE 2003 SUPER DUTY F-SERIES/EXCURSION 6.0L DIESEL SUPPLEMENT TO THE OWNER GUIDE INCORRECTLY STATES AIR FILTER REPLACEMENT INTERVALS.  EVERY 7500 MILES OWNERS SHOULD INSPECT THE AIR FILTER MINDER TO DETERMINE IF THEIR AIR FILTER NEEDS TO BE REPLACED.  THERE IS NO MILEAGE REQUIREMENT FOR REPLACING THE AIR FILTER.  THE NEXT REVISION OF THE 6.0L OWNER GUIDE SUPPLEMENT WILL REFLECT THE CORRECT INFORMATION.

CUSTOMER SATISFACTION PROGRAM 03B03:  CERTAIN 2002/2003 MODEL YEAR F-SUPER DUTY AND EXCURSION VEHICLES BUILT WITH 7.3L DIESEL ENGINES - ADJUSTABLE ACCELERATOR PEDAL SENSOR REPLACEMENT
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THE DEALER BULLETIN FOR THE SUBJECT FIELD SERVICE ACTION HAS BEEN POSTED TO THE FCSD COMMUNICATOR WEBSITE (FMCDEALER.COM) AT THE FOLLOWING URL ADDRESS:
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HTTP://WWW.FMCDEALER.COM

THE NEW 6.0L DIESEL ENGINE USES A CARTRIDGE-TYPE OIL FILTER LOCATED ON TOP OF THE ENGINE.  THE OIL FILTER SHOULD BE REMOVED BEFORE DRAINING THE OIL FROM THE OIL PAN.  THIS ALLOWS THE OIL TO DRAIN FROM THE FILTER HOUSING INTO THE PAN.
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NOTE: THE OIL FILTER CAP IS TO BE REUSED AND A NEW OIL FILTER CAP O-RING IS TO BE INSTALLED (INCLUDED WITH THE REPLACEMENT FILTER).
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FOR ADDITIONAL INFORMATION REFER TO PTS 'SERVICE PUBLICATIONS, QUICK REFERENCE GUIDES' FOR COMPLETE OIL CHANGE PROCEDURE.

SOME 2003 F-SUPER DUTY AND EXCURSION WITH 6.0L DIESEL ENGINE MAY EXHIBIT A COOLANT LEAK A THE JOINT BETWEEN THE LOWER RADIATOR HOSE AND RADIATOR.  WHEN THE ENGINE IS AT NORMAL OPERATING TEMPERATURE (AND THERMOSTAT IS OPEN), REV THE ENGINE AND VISUALLY INSPECT THIS JOINT FOR A LEAK.  IF A LEAK IS PRESENT, LET THE SYSTEM COOL DOWN, AND MAKE SURE THAT THE HOSE IS PUSHED ALL THE WAY ONTO THE RADIATOR HOSE FITTING.  INSTALL 3C3Z-8287-EA SERVICE HOSE CLAMP RIGHT UP AGAINST THE EXISTING CLAMP ON THE HOSE (NO NEED TO REMOVE HOSE).

SOME 2003 SUPER DUTY F-SERIES/EXCURSION 6.0L, MAY EXHIBIT A LOW POWER CONDITION AND OR DTC P2263 (TURBO/SUPER CHARGER SYSTEM PERFORMANCE).  ENGINEERING IS INVESTIGATING.  PERFORM THE FOLLOWING:
1) DRIVE VEHICLE TO ENSURE THE CONDITION IS REPRODUCIBLE.
2) VERIFY THAT THE AIR TUBES ARE SECURE (CAC TUBE AND INTAKE HOSES).
3) VERIFY THAT THERE ARE NO CUTS OR HOLES IN THE CAC OR TURBO INLET TUBE.
4) VERIFY THAT THE EVRT CONTROL VALUE IS PROPERLY CONNECTED.
5) VERIFY THAT THERE ARE NO OIL LINE LEAKS.
6) PERFORM ICP SSM 16607
IF THE CONDITION IS STILL PRESENT AFTER COMPLETING THE ABOVE STEPS, CALL (734) 560-7946.  IF YOU ARE NOT CALLED BACK WITHIN 15 MINUTES, CONTINUE DIAGNOSIS.

SOME 2003 SUPER DUTY F-SERIES AND EXCURSIONS EQUIPPED WITH A 6.0L DIESEL ENGINE MAY EXHIBIT DRIVEABILITY CONDITIONS THAT CAN INCLUDE; ROUGH IDLE, ROLLING IDLE, POOR IDLE RETURN, LACKS POWER, INJECTOR FAULT CODES, OR INCREASED EXHAUST SMOKE.  THIS MAY BE CAUSED BY THE ICP SENSOR.  TO SERVICE, CAREFULLY INSPECT THE ICP SENSOR CONNECTOR AND TERMINALS FOR DAMAGE.  VERIFY VREF AND SIGNAL RETURN CIRCUITS AT THE ICP SENSOR.  IF NO ELECTRICAL CAUSE IS MEASURE ICP READING WITH A WDS AT NORMAL OPERATING TEMPERATURE (EOT ABOVE 180 F).  KEY OFF, VERIFY ENGINE HAS BEEN OFF FOR A MINIMUM OF 2 MINUTES TO ALLOW FOR BLEED DOWN.  TURN KEY ON AND WAIT FOR 30 SECONDS.  MONITOR ICP PID.  ICP READINGS SHOULD BE 0.16 - 0.28 V (LESS THAN 70 PSI).  IF ICP IS NOT WITHIN THIS RANGE, INSTALL NEW ICP SENSOR, PART NUMBER 3C3Z-9F838-DA.

SOME 1999-2003 F-SUPER DUTY AND EXCURSION VEHICLES WITH 5.4L, 6.8L AND 7.3L ENGINES MAY EXHIBIT A COOLANT LEAK DUE TO A BROKEN LOWER RADIATOR HOSE CLAMP.  TO SERVICE, WHEN THE ENGINE TEMPERATURE IS COOL, VISUALLY INSPECT THE UPPER AND LOWER RADIATOR HOSE CLAMPS.  IF NECESSARY SQUEEZE WITH PLIERS TO DETERMINE IF A HOSE CLAMP IS BROKEN (PRIMARILY LOWER).  BROKEN CLAMPS CAN BE REMOVED BY USING A HEAT GUN TO RELEASE THE GLUE THAT LOCATES THE CLAMP ON THE RUBBER HOSE, OR BY CUTTING THE GLUE BEAD (USE CAUTION SO AS NOT TO CUT INTO THE RUBBER OF THE HOSE, IF DAMAGE TO THE HOSE OCCURS REPLACE THE HOSE).  REPLACE ANY BROKEN HOSE CLAMPS WITH F8HZ-8287-AA (WORM GEAR/SCREW CONSTANT TENSION TYPE HOSE CLAMP).  VERIFY THAT THERE IS NO LONGER A COOLANT LEAK WITH THE ENGINE AT NORMAL OPERATING TEMPERATURE.

SOME 1999-2003 SUPER DUTY F-SERIES/E-SERIES & 2000-2003 EXCURSIONS EQUIPPED WITH 7.3L/6.0L DIESEL ENGINE, OPERATING IN COLD CONDITIONS, MAY EXHIBIT A GRADUAL LOSS OF POWER AT CRUISE.  THIS MAY BE CAUSED BY FUEL GELLING OR FREEZING IN THE IN-TANK SCREEN OR FUEL PICKUP.  FUEL ADDITIVES MAY BE REQUIRED TO PREVENT THIS CONDITION.  PRODUCTS SUCH AS 'STANADYNE PERFORMANCE FORMULA' ARE THE MOST ACCEPTABLE ADDITIVES.  JOHN DEERE ALSO MARKETS AN ACCEPTABLE COLD WEATHER ADDITIVE.  'STANADYNE JR.' IS 'NOT' SUITABLE IN THIS APPLICATION.  OVER 100 PRODUCTS ARE AVAILABLE ON THE MARKET WITH VARYING QUALITY AND FEATURES.  DO NOT USE ANY ALCOHOL BASED ADDITIVE IN FORD DIESEL ENGINES.  STANADYNE CAN BE CONTACTED DIRECTLY 8AM-4PM AT (800)842-2496

SOME VEHICLES EQUIPPED WITH THE CATERPILLAR ENGINE AND SPICER 7 SPEED MANUAL TRANSMISSION, MAY EXHIBIT A CONDITION WITH THE ENGINE FLYWHEEL HOUSING CRACKING.  THIS MAY BE CAUSED BY EXCESSIVE STRAIN PUT ON THE FLYWHEEL HOUSING.  SEE TSB 03-03-03 ON OASIS AND FMCDEALER.COM FOR DETAILS.

WHEN PERFORMING DIAGNOSTICS ON POWERTRAIN OR TRANSMISSION SYSTEMS ON THE 2003 SUPER DUTY OR EXCURSION EQUIPPED WITH THE 6.0L DIESEL ONLY, 2003 FOCUS 2.3L PZEV ONLY OR 2003 LINCOLN LS AND THUNDERBIRD, THE WDS (WORLD DIAGNOSTIC SYSTEM) MUST BE USED.  THE CURRENT NGS CANNOT DIAGNOSE POWERTRAIN MODULES ON THESE VEHICLES DUE TO THE USE OF THE NEW CAN (CONTROLLER AREA NETWORK) DIAGNOSTIC COMMUNICATION LINK.  UPDATED NGS HARDWARE CAPABLE OF DIAGNOSING VEHICLES USING THE CAN COMMUNICATION LINK IS EXPECTED TO BE AVAILABLE LATE 2003.  NGS CAN BE USED FOR BODY/CHASSIS/ELECTRICAL DIAGNOSIS ON THESE VEHICLES.

SOME 2003 SUPER DUTY F-SERIES AND EXCURSION EQUIPPED WITH A 6.0L DIESEL ENGINE MAY EXHIBIT AN IDLE SURGE/INSTABILITY AFTER COLD START-UP IN PARK/NEUTRAL OR SURGE FOLLOWING A COLD RESTART IN PARK/NEUTRAL.  TO SERVICE, REPROGRAM THE PCM WITH THE LATEST CALIBRATION AVAILABLE VIA FORDSTAR USING WDS RELEASE B22N.7, B23.4 OR LATER.  THE UPDATE FILE CAN ALSO BE OBTAINED AT WWW.WDSCENTRAL.COM.  THE CALIBRATION UPDATE ALSO CONTAINS A COLD IDLE KICKER ENHANCEMENT TO IMPROVE ENGINE WARM-UP PERFORMANCE DURING EXTENDED IDLES AT EXTREME COLD TEMPERATURES.  THIS RELEASE INCLUDES TEAR TAG NUMBERS; HBF8, JEL8, MAT8, BKG8, KMA8, NFW8 AND PBD8.  CALIBRATIONS WITH CATCHWORDS; HBF7, JEL7, MAT7, BKG7, FFM7, KMA7, NFW7 AND PBD7 RESPECTIVELY CAN BE REPROGRAMMED WITH THIS RELEASE.

SOME 2003 SUPERDUTY F-SERIES AND EXCURSION VEHICLES EQUIPPED WITH 6.0L ENGINE AND TORQSHIFT TRANSMISSION, AT PRE-DELIVERY, MAY APPEAR TO HAVE A LOW TRANSMISSION FLUID LEVEL.  PRIOR TO ADDING TRANSMISSION FLUID, CHECK TO SEE IF THE CORRECT FLUID LEVEL INDICATOR IS INSTALLED.  THE CORRECT TRANSMISSION FLUID INDICATOR IS PART NUMBER 3C3Z-7A020-BB.  THE CORRECT TRANSMISSION FLUID IF REQUIRED IS MERCON SP AS INDICATED ON THE CORRECT FLUID LEVEL INDICATOR HANDLE.

SOME 2003 SUPER DUTY F-SERIES AND EXCURSION EQUIPPED WITH A 6.0L DIESEL ENGINE MAY EXHIBIT DRIVEABILITY CONDITIONS THAT CAN INCLUDE ROUGH IDLE CONDITION, ROLLING IDLE, POOR IDLE RETURN, LACKS POWER, INJECTOR FAULT CODES, OR INCREASED EXHAUST SMOKE.  THIS MAY BE CAUSED BY AN ICP SENSOR.  TO SERVICE, CAREFULLY INSPECT THE ICP SENSOR CONNECTOR AND TERMINALS FOR DAMAGE.  VERIFY VREF AND SIGNAL RETURN CIRCUITS AT ICP SENSOR.  IF NO ELECTRICAL CAUSE IS FOUND, MEASURE ICP READING WITH A SCAN TOOL AT NORMAL OPERATING TEMPERATURE.  KEY OFF, VERIFY ENGINE HAS BEEN OFF FOR MINIMUM OF 2 MINUTES TO ALLOW FOR BLEED DOWN.  TURN KEY ON AND WAIT FOR 30 SECONDS.  MONITOR ICP PID.  IF ICP IS ABOVE 0.5 MPA (.32 V) INSTALL ICP SENSOR - 3C3Z-9F838-AA AND RETEST.

SOME 2003 EXCURSION BUILT BETWEEN 11/18/2002 AND 01/17/2003, EQUIPPED WITH A 6.0L DIESEL ENGINE, WITH DVD AND WITHOUT EATC, MAY EXHIBIT A NO AUDIO CONDITION WHEN A DVD IS PLAYED.  THIS MAY BE DUE TO SOME OMITTED WIRING CIRCUITS.  TO SERVICE, CALL (502)429-2965, MONDAY THROUGH FRIDAY BETWEEN 8:00 AM AND 5:00 PM ET, TO OBTAIN A SERVICE WIRE HARNESS KIT.

SOME 2003 F250-550 SUPER DUTY AND EXCURSION VEHICLES EQUIPPED WITH A 6.0L POWERSTROKE ENGINE, MAY EXHIBIT A DIFFICULT TO REMOVE OR REPLACE AIR FILTER ASSEMBLY DURING SERVICE.  SEE TSB 03-01-09 ON OASIS AND FMCDEALER.COM FOR DETAILS.

SOME 2000-2003 F-350 DUAL REAR WHEEL, F-450/550 VEHICLES, ALL EQUIPPED WITH 7.3L ENGINE, MAY EXHIBIT A LOUD SQUEALING NOISE FROM THE ENGINE AREA WHEN THE ENGINE FAN CLUTCH IS ENGAGED WHILE OPERATED IN HOT DUSTY CLIMATES.  THIS MAY BE DUE TO AN ACCUMULATION OF DUST ON THE BACKSIDE OF THE ACCESSORY DRIVE BELT CAUSING THE BELT TO SLIP.  THIS CONDITION HAS BEEN MISDIAGNOSED AS A TURBO CHARGER OR FAN CLUTCH ASSEMBLY DUE TO NOISE AND/OR FAST FAN CLUTCH CYCLING.  TO SERVICE THE SINGLE ALTERNATOR APPLICATION USE SERVICE KIT 2C3Z-8620-AA AND FOR DUAL ALTERNATOR APPLICATION USE 2C3Z-8620-BA.

SOME 1994-2003 SUPER DUTY F-SERIES, 1995-2003 E-SERIES AND 2000-2003 EXCURSION EQUIPPED WITH 7.3L DIT ENGINE MAY EXHIBIT OIL LEAKAGE FROM THE HIGH-PRESSURE PUMP AREA.  THE LEAK MAY BE FROM THE FITTINGS WHICH THE LINES ATTACH TO, AND/OR THE PLUG AT THE REAR OF THE PASSAGE WHERE THE LINE FITTINGS ARE.  THESE LEAKS CAN BE SERVICED WITHOUT REPLACING THE PUMP ASSEMBLY.  LEAKS FROM THESE JOINTS USUALLY RESULT FROM THE FITTINGS OR PLUG LOOSENING OVER TIME.  THE PROCEDURE INVOLVES REMOVING THE LINE FROM THE FITTING, THEN REMOVING THE FITTING OR PLUG FROM THE BODY OF THE PUMP.  CLEAN THE THREADS AND REPLACE THE O-RING FROM THE KIT 2C3Z-9G804-AA.  ADD ONE DROP OF LIQUID THREAD SEALANT (SUPPLIED WITH KIT) TO THE THREADS PRIOR TO RE-INSTALLATION.  TIGHTEN TO 23-28 LB-FT (31-38 NM).

SOME 2003 SUPER DUTY F-SERIES AND EXCURSION, ALL EQUIPPED WITH A 6.0L DIESEL ENGINE ARE BEING OVER-FILLED WITH ENGINE OIL AFTER DELIVERY.  THE NEW 6.0L ENGINE SHOULD BE SERVICED AS THE 7.3L ENGINE.  FOLLOW OWNER'S MANUAL OIL CHECK REFILL PROCEDURE.  MAKE SURE DIPSTICK IS FULLY SEATED AND MEASURE FILL LEVEL ONLY AFTER THE RECOMMENDED 20 MINUTE SHUTDOWN: REMOVE DIPSTICK, WIPE CLEAN AND REINSERT FULLY.  READ OIL LEVEL AND USE HIGHEST LEVEL READING FOR ACTUAL ENGINE OIL LEVEL.  DO NOT ADD OIL IF INDICATION IS ANYWHERE WITHIN THE HASH MARKS.

SOME 2003 SUPER DUTY F-SERIES AND EXCURSION, BUILT PRIOR TO 12/16/2002, EQUIPPED WITH A 6.0L DIESEL AND TORQSHIFT TRANSMISSION MAY EXHIBIT A SHIFT FLARE WHEN UPSHIFTING FROM 3RD GEAR.  IN ORDER TO FIX THIS CONDITION ENGINEERING HAS RELEASE A REVISED CALIBRATION.  ONLY VEHICLES WITH THE FOLLOWING TEAR TAG CODES ARE AFFECTED; BKG6, FFM6, KMA6, NFW6 OR PBD6.  CALIBRATIONS ARE IMMEDIATELY AVAILABLE VIA FORD STAR.  REPROGRAM TO THE LATEST LEVEL USING WDS ONLY WITH WDS RELEASE B22N.3 OR LATER.

SOME 1999-2003 F-SERIES SUPER DUTY AND EXCURSION VEHICLES MAY EXHIBIT AN ABS LIGHT ON, B2141/B2477, AND/OR AN INACCURATE SPEEDOMETER.  THIS MAY BE DUE TO AN INACCURATELY OR NON-PROGRAMMED ABS MODULE.  TO SERVICE, USE NGS ONLY TO PROGRAM ABS MODULE USING THE FOLLOWING PROCEDURE.  SELECT SERVICE BAY FUNCTIONS, ABS, TIRE SIZE/AXLE RATIO CONFIGURE, SELECT VEHICLE, ENTER CORRECT REVS/MILE AND AXLE SIZE.  TO DETERMINE CORRECT REVS/MILE FOR A TIRE, DIVIDE THE ACTUAL CIRCUMFERENCE OF THE TIRE IN INCHES INTO 6330.  FOR EXAMPLE, A 91 INCH TIRE CIRCUMFERENCE WOULD EQUAL 696.  YOU THEN ADD TWO ZEROS IN FRONT OF IT FOR NGS TO EQUAL 00696.  FOR AXLE SIZE, SCROLL THROUGH OPTIONS AND SELECT THE APPROPRIATE ENTRY.  SELECT 'N/A' FOR ABS OPTION.  PRESS DONE.

SOME 1999-2003 SUPER DUTY/EXCURSION VEHICLES MAY EXHIBIT A DTC B1871 OR B1935 AFTER THE ELECTRONIC CRASH SENSOR/RESTRAINT CONTROL MODULE (ECS/RCM) IS REPLACED.  THIS MAY BE DUE TO AN UNCONFIGURED/MISCONFICURED MODULE.  TH ECS/RCM MUST BE CONFIGURED IF THE VEHICLE IS EQUIPPED WITH DUAL FRONT AIR BAGS.  WHEN CONFIGURING FOR DUAL FRONT AIR BAGS, THERE WILL ALSO BE A SCAN TOOL OPTION FOR PASSENGER AIR BAG DISABLE (PAD) SWITCH, IF THE VEHICLE IS EQUIPPED.  WDS LEVEL B20.0 AND HIGHER CAN PROPERLY CONFIGURE ALL 1999-2003 SUPER DUTY F-SERIES AND NGS 11.0 OR HIGHER CAN PROPERLY CONFIGURE ALL 1999-2003 MODELS.

SOME 2003 SUPER DUTY F-SERIES AND EXCURSION EQUIPPED WITH THE 6.0L ENGINE MAY EXHIBIT A ROUGH/SURGING IDLE, EXCESSIVE SMOKE, OR POOR THROTTLE RESPONSE UPON DRIVE AWAY.  ENGINEERING IS INVESTIGATING.  PERFORM ONLY BASIC DIAGNOSIS INCLUDING VISUAL INSPECTION AND DTC RETRIEVAL.  THERE IS NO EFFECTIVE REPAIR FOR RESOLVING THE CONDITIONS AT THIS TIME.  DO NOT REPLACE ANY PARTS, PCM OR IDM UNLESS INDICATED BY DTC.  CONTINUE TO MONITOR OASIS.

SOME 2003 F-SUPER DUTY & EXCURSION EQUIPPED WITH 6.0L DIESEL ENGINE, MAY EXHIBIT A LACK OF POWER, HARD/NO START, OR RUNS ROUGH CONDITION AT DELIVERY.  THIS MAY BE CAUSED BY AIR IN THE FUEL/OIL SYSTEM.  TO PURGE THE AIR, DRIVE THE VEHICLE APPROX 30 MILES USING VARYING DRIVE CYCLES (PART AND WIDE OPEN THROTTLE).  IF CONCERN IS STILL PRESENT AFTER DRIVING, USE THE WDS AND COMMAND THE VGT TO CYCLE.  IF THE CONCERN IS STILL PRESENT DIAGNOSE USING NORMAL SERVICE PROCEDURES.

SOME 1994-2002 F-SERIES SUPER DUTY, EXCURSION, ECONOLINE, ALL EQUIPPED WITH 7.3 DIT DIESEL ENGINE MAY EXHIBIT A FALSE P0340 (DTC).  A VALID P0340 SETS WHEN A CMP FAULT CAUSES A NO-START CONDITION.  IF A P0340 IS PRESENT WITHOUT A NO-START CONDITION BEING ENCOUNTERED AND NO OTHER CMP DTCS (P0341, P0344) SET, DO NOT REPLACE THE CMP SENSOR.  CLEAR THE P0340 DTC AND VERIFY PROPER ENGINE OPERATION.  IF THE P0340 IS PRESENT IN COMBINATION WITH OTHER CMP SENSOR CODES, DIAGNOSE THE CMP CIRCUIT AS INSTRUCTED IN THE PCED.

SOME 2000-2003 F650/750 DIESEL DUAL FUEL TANK SYSTEM EQUIPPED VEHICLES MAY EXHIBIT DEGRADED ENGINE PERFORMANCE, LACK/LOSS OF POWER.  THIS MAY BE DUE TO FUEL TANK FUEL LEVEL.  IF BOTH FUEL TANKS ARE NEAR EMPTY AND ONLY ONE TANK IS FILLED, IT COULD TAKE UP TO 96 MINUTES FOR THE FUEL LEVEL TO EQUALIZE BETWEEN THE TANKS.  THE FUEL PUMP DRAWS FROM BOTH TANKS.  IF ONE TANK IS LEFT EMPTY, AIR WILL BE INGESTED RESULTING IN DEGRADED ENGINE PERFORMANCE.
FILLING BOTH FUEL TANKS WHEN REFUELING WILL CORRECT THE CONDITION.

SOME 1994-2003 F-SERIES SUPERDUTY AND EXCURSIONS EQUIPPED WITH A 7.3L DI DIESEL ENGINE MAY EXHIBIT AN IDLE ROLL/LOPE WITHIN THE FIRST 10 SECONDS UPON COLD STARTUP, WITH NO ASSOCIATED DTC'S.  TO SERVICE, FOLLOW THE PCED DIAGNOSTIC SYMPTOM CHART FOR RUNS ROUGH: IDLE.  IF THE CONDITION IS STILL PRESENT CHANGE TO A 10W30 ENGINE OIL RATED CG4/SH OR BETTER (MOTORCRAFT NUMBER XO-10W30-QSD) FOR VEHICLES OPERATED IN AMBIENT TEMPERATURES LESS THAN 90 DEGREES F ONLY.  SOME VEHICLES MAY STILL EXHIBIT THIS CONCERN AFTER USING 10W30 ENGINE OIL.  ENGINEERING IS CURRENTLY INVESTIGATING THIS CONCERN.

TO IMPROVE THE QUALITY OF INFORMATION PROVIDED TO SERVICE DEPARTMENT PERSONNEL DURING THE 6.0L DIESEL NEW MODEL TECHNICIAN TRAINING FORDSTAR COURSE, PLEASE BE AWARE THAT THE COURSE HAS BEEN CHANGED TO A TWO-PART COURSE.  THE CONTENT OF THE COURSE HAS NOT CHANGED, ONLY THE LENGTH.  THE MODIFIED SCHEDULE FOR DECEMBER IS IN STARS2 AS FOLLOWS:
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DIESEL ENG 6.0L 2003 NMDL PART 1-2 12/12/2002 09:00-12:00EST C107 HOST 32
DIESEL ENG 6.0L 2003 NMDL PART 2-2 12/16/2002 09:00-11:00EST C107 HOST 32
DIESEL ENG 6.0L 2003 NMDL PART 1-2 12/17/2002 17:00-20:00EST C107 HOST 32
DIESEL ENG 6.0L 2003 NMDL PART 2-2 12/19/2002 17:00-19:00EST C107 HOST 32
THERE WILL BE ONE FINAL SINGLE DAY COURSE PRESENTED ON 01/03/2003.

SOME 1997-2003 E-SERIES, F-150, EXPEDITION, 1998-199 NAVIGATOR AND 1999-2003 SUPER DUTY F-SERIES EQUIPPED WITH A 5.4L-2V NON SUPERCHARGED ENGINE MAY EXHIBIT BROKEN EXHAUST MANIFOLD STUD(S).  IF THIS CONDITION EXISTS, REPLACE THE EXHAUST MANIFOLD AND MANIFOLD GASKET(S) AND REPLACE ALL EXHAUST MANIFOLD STUDS AND NUTS ON THE AFFECTED BANK WITH STAINLESS STEEL STUD W703902-S403, AND NUT W701706-S2.

SOME 2000-2003 SUPER DUTY F-SERIES AND EXCURSION MAY EXHIBIT AND INTERMITTENT, INACCURATE FUEL GAUGE INDICATION (INDICATES LESS FUEL THAN WHAT IS ACTUALLY IN THE TANK).  THIS MAY BE DUE TO SLOW FUEL GAUGE NEEDLE RESPONSE VERSUS ACTUAL FUEL LEVEL DUE TO SLOSH CONDITIONS IN THE TANK.  IF THE GAUGE READING IS SUSPECTED TO BE INACCURATE, TURN THE IGNITION KEY TO THE 'ON' POSITION WHILE THE VEHICLE IS ON A LEVEL SURFACE AND WAIT 15 MINUTES.  FUEL INDICATION SHOULD CHANGE TO THE CORRECT FUEL LEVEL.  IF IT CHANGES TO THE CORRECT READING, NO SERVICE IS NECESSARY.  THE TEMPORARY INACCURACY IS DUE TO THE FILTERING OF THE FUEL SLOSH.  CUSTOMERS CAN MINIMIZE THIS OCCURRENCE BY MAKING SURE TO TURN THE IGNITION KEY TO 'OFF' DURING REFUELING AND/OR CYCLING THE KEY TO OFF WHEN AN INACCURATE READING IS SUSPECTED.

SOME 2002 7.3L DIT F-SUPER DUTY, ECONOLINE & EXCURSION MAY EXHIBIT THE OCCURRENCE OF P0340 CAMSHAFT POSITION SENSOR FALSE DIAGNOSTIC TROUBLE CODE (DTC).  F-SUPER DUTY & EXCURSION MAY EXHIBIT A LATE 4R100 3-4 SHIFT (HANGING IN 3RD GEAR) AT LIGHT THROTTLE DUE TO POTENTIAL LACK OF CONVERTER LOCK-UP OCCURRING AFTER 2-3 SHIFT (MOST PREVALENT ON 3.73:1 AXLE RATIO VEHICLES).  THIS MAY BE CAUSED BY THE POWERTRAIN CONTROL MODULE (PCM) CALIBRATION.  SEE TSB 02-24-04 ON OASIS AND FMCDEALER.COM FOR DETAILS.

THIS PROCEDURE IS TO BE USED FOR 2000-2001 FORD F-650 AND F-750 TRUCKS THAT ARE EQUIPPED WITH AIR BRAKES AND UTILIZE THE BENDIX E-14 FOOT VALVE.  THE SUPPLIER BENDIX, HAS DISCONTINUED THE E-14 SERIES FOOT VALVE IN WHICH THE E-7 SERIES FOOT VALVE HAS BEEN IDENTIFIED TO MEET FORD APPLICATION CRITERIA.  SEE TSB 02-23-05 ON OASIS AND QCDEALER.COM FOR DETAILS.

SOME 2003 SUPER DUTY F SERIES AND EXCURSIONS EQUIPPED WITH A 6.0L DIESEL ENGINE MAY EXHIBIT DTC P0148 (FUEL ERROR/ENGINE SPEED HIGHER THAN EXPECTED).  P0148 MAY BE SET DUE TO ENGINE RPM EXCEEDING DIESEL ENGINE POWER MONITOR (DEPM) LIMITS OR IN CONJUNCTION WITH P2552 IN THE EVENT THE FUEL INJECTOR CONTROL MODULE MONITOR (FICMM) IS SHORTED OR OPEN.  THE DEPM IS PART OF THE TCM/PCM CONTROL STRATEGY SOFTWARE.  THE DEPM IS USED IN ALL AUTOMATIC AND MANUAL TRANSMISSION APPLICATIONS.  THE FUNCTION OF THE DEPM IS TO MONITOR ENGINE RPM WHEN THERE IS NO POWER DEMAND FROM THE APP SENSOR.  WHEN DTC P0148 IS SET, DTC P2614 (CMPO FAILURE) AND P2617 (CKPO FAILURE) MAY ALSO SET.  IF DTCS P2614 AND P2617 ARE SET WITH P0148, DO NOT ATTEMPT TO DIAGNOSE THE CMPO OR CKPO CIRCUITS.  REFER TO THE WEB VERSION OF THE PC/ED FOR THE LATEST INFO.

SOME 2002-2003 E-SERIES EQUIPPED WITH A 7.3L DIESEL ENGINE BUILT BETWEEN 12/01/2001 AND 10/30/2002 MAY EXHIBIT WATER PUMP PULLEY BOLTS LOOSENING.  IF THIS CONDITION OCCURS REPLACE THE WATER PUMP PULLEY WITH PART NUMBER F81Z-8509-AA AND VERIFY THERE IS NO SECONDARY DAMAGE TO RELATED COMPONENTS.  UPON RE-ASSEMBLY, APPLY LOCTITE 270, 243, OR 242 TO THE THREADS AND TORQUE THE WATER PUMP PULLEY BOLTS TO 22 LB-FT (30NM) USING A SUITABLE TORQUE WRENCH.

SOME VEHICLES EQUIPPED WITH THE ROMEO BUILT 4.6L 2V ENGINE OR 5.4L 2V WINDSOR ENGINE MAY EXHIBIT AN OIL LEAK OR OIL WEEPAGE FROM THE THE CYLINDER HEAD GASKET AT THE RIGHT HAND REAR OR THE LEFT HAND FRONT OF THE ENGINE.  OIL WEEPAGE IS NOT CONSIDERED DETRIMENTAL TO ENGINE PERFORMANCE OR DURABILITY.  AN OIL LEAK MAY BE CAUSED BY METAL CHIP DEBRIS LODGED BETWEEN THE HEAD GASKET AND THE BLOCK, CHIP DEBRIS BETWEEN THE CYLINDER HEAD AND THE HEAD GASKET, OR BY DAMAGE TO THE CYLINDER HEAD SEALING SURFACE THAT OCCURRED DURING THE MANUFACTURING PROCESS.  SEE TSB 02-22-07 ON OASIS AND QCDEALER.COM FOR DETAILS.

SOME 1999-2003 F-SUPER DUTY 250-550 VEHICLES MAY EXHIBIT AN INOPERATIVE CLUTCH PEDAL DUE TO THE CLUTCH MASTER/SLAVE CYLINDER.  IF NORMAL DIAGNOSTICS LEADS TO THE CLUTCH MASTER/SLAVE CYLINDER, REPLACE IT WITH ONE OF THE FOLLOWING PARTS: 2C3Z-7C522-DA FOR GAS APPLICATIONS
2C3Z-7C522-CA FOR DIESEL APPLICATIONS
NOTE: DO NOT REPLACE THE CLUTCH MASTER/SLAVE CYLINDER JUST BECAUSE THE FLUID HAS CHANGED TO A PINK COLOR OR HAS A WHITE FILM FLOATING IN THE RESERVOIR.  THE PINK COLOR IS DUE TO THE DYE USED ON THE CENTER FEED VALVE SPRING AND THE WHITE FILM IS DUE TO LUBRICANT USED IN THE ASSEMBLY PROCESS OF THE PART.

STARTING OCTOBER 30, 2002, 6:00 P.M. EST THROUGH CLOSE OF BUSINESS FRIDAY, NOVEMBER 1, ESP SYSTEM MAINTENANCE WILL BE PERFORMED WHICH WILL RESULT IN A SMALL PERCENTAGE OF ACTIVE ESP CONTRACTS (LESS THAN 35,000) TO REPORT NO COVERAGE ON OASIS.
IN THE UNLIKELY EVENT THAT YOU ENCOUNTER A CUSTOMER WITH PROOF OF AN ESP CONTRACT BUT OASIS DOES NOT REPORT COVERAGE, PLEASE CALL OUR ESP ADMINISTRATIVE HOTLINE (800-521-4144) TO VERIFY COVERAGE.  YOU MAY ALSO HAVE YOUR BUSINESS OFFICE CONFIRM COVERAGE DIRECTLY ON THE ESP SYSTEM, SCREEN 43.
WE APOLOGIZE FOR THIS INCONVENIENCE.  ESP HEADQUARTERS

SOME MEDIUM DUTY VEHICLES EQUIPPED WITH THE 7.3L POWERSTROKE DIESEL ENGINE MAY EXHIBIT A NOISE ABOVE THE NORMAL SOUND OF THE DIESEL COMBUSTION.  THIS NOISE MAY SOUND LIKE A ROD KNOCK, BUT IS INTERMITTENT AND INCREASES IN INTENSITY AS THE ENGINE WARMS UP TO OPERATING TEMPERATURE.  THE "CACKLE" NOISE DOES NOT DAMAGE THE ENGINE, OR DECREASE THE ENGINE'S PERFORMANCE OR FUEL ECONOMY.  SEE TSB 02-22-06 ON OASIS AND QCDEALER.COM FOR DETAILS.

EFFECTIVE IMMEDIATELY, UNITED AMERICAN FREIGHT SERVICES HAS BEEN DESIGNATED AS THE NEW CARRIER/PROVIDER FOR ALL ENGINE AND TRANSMISSION PLANT, NO COST EXCHANGE PROGRAM, CORE RETURNS.  THESE RETURNS WERE BEING HANDLED BY CONSOLIDATED FREIGHTWAYS.  DEALERS ARE TO CALL (866) 322-1768 TO SCHEDULE AN APPOINTMENT FOR PICKUP BY UNITED AMERICAN.  UNITED AMERICAN WILL SCHEDULE A PICKUP AND PROVIDE ALL THE NECESSARY SHIPPING DOCUMENTATION.  IF AVAILABLE, AT TIME OF PICKUP, DEALERS ARE TO PROVIDE THE ORIGINAL DOCUMENTATION (I.E. TRACKING NUMBER) THAT ACCOMPANIED THE UNIT WHEN DELIVERED TO THE DEALER.  UNITED AMERICAN WILL MAKE EVERY EFFORT TO SCHEDULE A PICKUP AS FAST AS POSSIBLE.  HOWEVER, DUE TO THE BACKLOG OF UNITS IN THE FIELD, THERE MAY BE A SLIGHT DELAY IN THE SCHEDULING OF APPOINTMENTS.

SPECIAL FIELD ACTION 02L11: CERTAIN 1999 THROUGH 2002 MODEL YEAR F-SUPER DUTY VEHICLES, 1999 THROUGH 2002 F-53 STRIPPED CHASSIS VEHICLES AND 2000 THROUGH 2003 EXCURSION VEHICLES - WHEEL LUG NUT TORQUE SPECIFICATION AND PROCEDURE LABEL
.
THE DEALER BULLETIN FOR THE SUBJECT FIELD SERVICE ACTION HAS BEEN POSTED TO THE FCSD COMMUNICATOR WEBSITE (QCDEALER.COM) AT THE FOLLOWING URL ADDRESS:
.
HTTP://WWW.QCDEALER.COM

SOME 2003 SUPER DUTY F-SERIES AND EXCURSION VEHICLES EQUIPPED WITH A 6.0L DIESEL ENGINE AND 5R110W TORQSHIFT AUTOMATIC TRANSMISSION HAVE A STICKER APPLIED TO THE TRANSMISSION BOTTOM PAN.  PRIOR TO MARCH 31, 2003, DO NOT DISASSEMBLE OR ATTEMPT INTERNAL TRANSMISSION REPAIRS.  CHECK THE TRANSMISSION FLUID LEVEL AND PERFORM ELECTRONIC TRANSMISSION DIAGNOSIS.  IF NORMAL DIAGNOSIS INDICATES THAT THERE IS A TRANSMISSION CONCERN OR IF THERE IS AN EXTERNAL LEAK, PRIOR TO REMOVING OR SERVICING THE TRANSMISSION, COMPLETE THE TECHNICAL SERVICE HOTLINE CALL DATA SHEET AND CONTACT THE NATIONAL HOTLINE FOR AN EXCHANGE TRANSMISSION.  AFTER MARCH 31, 2003, FOLLOW THE APPROPRIATE WORKSHOP MANUAL FOR DIAGNOSTIC OR SERVICE INFORMATION.

SOME 2001-2003 F-650/750, EQUIPPED WITH AN ALLISON ELECTRONIC TRANSMISSION, MAY EXHIBIT AN INTERMITTENT SPEEDOMETER INOPERATIVE WITH A DTC C1752 (VEHICLE SPEED SENSOR OUTPUT CIRCUIT SHORT TO GROUND) IN MEMORY.  THIS MAY BE CAUSED BY A POOR GROUND ON THE PCM AND/OR ON THE ALLISON CONTROL UNIT.  TO SERVICE, VERIFY ALL PCM AND ALLISON CONTROL UNIT GROUNDS, CLEAR CODES AND RETEST AFTER ROAD TESTING THE VEHICLE.

SOME 2003 SUPERDUTY F-SERIES AND EXCURSION VEHICLES BUILT BETWEEN 07/15/2002 AND 08/16/2002 EQUIPPED WITH A 7.3L DIT (ENGINE S/N 1967000 TO 1995586) MAY EXHIBIT A NO START, HARD START, HESITATION/SURGE, RUNS ROUGH, AND/OR OTHER DRIVEABILITY CONDTITION WITH A MIL LAMP ON AND DTC'S P0340 (CMP SENSOR CIRCUIT MALFUNCTION) OR P0344 (CMP SENSOR CIRCUIT INTERMITTENT).  THIS MAY BE DUE TO EXCESSIVE CAMSHAFT END PLAY OR EXCESSIVE CAM POSITION SENSOR AIR GAP.  IF THIS CONDITION OCCURS, CALL THE INTERNATIONAL TECHNICAL HOTLINE FOR FURTHER DIAGNOSIS AND SERVICE INSTRUCTIONS AT (317) 352-4857.  MONDAY THROUGH FRIDAY BETWEEN THE HOURS OF 9:00-5:00 CENTRAL TIME.

ALUMINUM CYLINDER HEADS AND BLOCKS REQUIRE FLATNESS CHECKS PRIOR TO GASKET INSTALLATION TO ENSURE THE COMPONENT PART IS NOT OUT OF FACTORY SPECIFICATION.  THE SURFACE QUALITY (FINISH) OF THE CYLINDER HEAD GASKET SURFACE IS MACHINED TO CLOSE TOLERANCES WHICH ENABLE AN EFFECTIVE SEALING JOINT FOR THE MLS (MULTI-LAYERED STEEL) GASKET.  SEE TSB 02-21-13 ON OASIS AND QCDEALER.COM FOR DETAILS.

SOME 2002-2003 E-SERIES EQUIPPED WITH A 7.3L DIESEL ENGINE MAY EXHIBIT WATER PUMP PULLEY BOLTS LOOSENING.  WHEN THIS OCCURS THE WATER PUMP PULLEYS MAY HAVE ELONGATED HOLES, OR THE PULLEY BOLTS MAY SHEAR OFF IN THE WATER PUMP.  THE WATER PUMP AND/OR THE WATER PUMP PULLEY MAY NEED TO BE REPLACED.  IF NO DAMAGE IS FOUND ON THE PULLEY OR THE PUMP, OR IF THE PUMP AND/OR PULLEY ARE REPLACED, APPLY LOCTITE 270, OR 243 OR 242 TO THE THREADS AND TORQUE THE WATER PUMP PULLEY BOLTS TO 22 LB-FT (30 NM).  NO REPEAT SERVICE HAS BEEN REPORTED AFTER USING LOCTITE AND TIGHTENING THE WATER PUMP BOLTS TO THE  PROPER TORQUE SPECIFICATION.  ENGINEERING IS CURRENTLY INVESTIGATING.  PLEASE CONTINUE TO SUBMIT EDSR'S ON ANY VEHICLE THAT EXHIBITS THIS CONDITION.

SOME 1994-2003 SUPER DUTY F-SERIES, 1995-2003 E-SERIES AND 2000-2003 EXCURSION EQUIPPED WITH A 7.3L DIT ENGINE MAY EXHIBIT OIL LEAKAGE FROM THE HIGH-PRESSURE PUMP AREA.  THE LEAK MAY BE FROM THE FITTINGS WHICH THE LINES ATTACH TO, AND NOT THE PUMP.  THESE LEAKS CAN BE SERVICED WITHOUT REPLACING THE PUMP ASSEMBLY.  LEAKS FROM THESE JOINTS USUALLY RESULT FROM THE FITTING LOOSENING OVER TIME.  THE PROCEDURE INVOLVES REMOVING THE LINE FROM THE FITTING, THEN REMOVING THE FITTING FROM THE BODY OF THE PUMP.  CLEAN THE THREADS OF BOTH THE FITTING AND THE PUMP BODY, AND REPLACE THE O-RING ON THE FITTING FROM THE KIT 2C3Z-9G804-AA.  ADD ONE DROP OF LIQUID THREAD SEALANT (SUPPLIED IN KIT) TO THE THREADS ON THE FITTING PRIOR TO RE-INSTALLATION.  TIGHTEN THE FITTING TO 23-28 LB-FT (31-38 NM)

WHEN ADDING ADDITIONAL BULBS TO THE TURN SIGNAL OR HAZARD FLASHER CIRCUITS, ISOLATION RELAYS MUST BE USED IN ORDER TO PREVENT DAMAGE TO THE FLASHER RELAY MODULE AND OR THE MULTI FUNCTION SWITCH, AND TO PREVENT ERRATIC OPERATION.  SEE TSB 02-21-09 ON OASIS AND QCDEALER.COM FOR DETAILS.

2003 EXPEDITION/NAVIGATOR, CROWN VICTORIA/GRAND MARQUIS, TOWN CAR AND AVIATOR, AND 2002-2003 EXPLORER 4DR/MOUNTAINEER AND E-SERIES VEHICLES ARE EQUIPPED WITH A FIXED SCROLL TYPE A/C COMPRESSOR.  AIR CONDITIONING SYSTEMS WITH THIS TYPE OF COMPRESSOR MAY EXHIBIT RAPID REFRIGERANT HIGH-SIDE PRESSURE FLUCTUATIONS UPON COLD START-UPS AND/OR AFTER REFRIGERANT SYSTEM RECHARGES.  THESE HIGH-SIDE FLUCTUATIONS ARE CHARACTERISTIC OF THE FIXED SCROLL COMPRESSOR AND ARE NOT AN INDICATION OF A FAILING, FAILED, OR MALFUNCTIONING A/C COMPRESSOR.  DO NOT REPLACE A/C SYSTEM COMPONENTS IN AN ATTEMPT TO SERVICE THIS NORMAL CONDITION.

2003 ECONOLINE, EXPEDITION/NAVIGATOR, EXCURSION, WINDSTAR, ESCAPE, RANGER, F-150 AND SUPER DUTY F-SERIES VEHICLES EQUIPPED WITH A PREMIUM CD-6 RADIO DO NOT INCLUDE THE FEATURE OF SHUFFLING BETWEEN DISCS.  IF A VEHICLE COMES IN WITH A REPORT OF 'CD PLAYER WILL NOT SHUFFLE BETWEEN DISCS', DO NOT ATTEMPT SERVICE - THE RADIO IS FUNCTIONING AS INTENDED.  CD-6 RADIOS ON THESE VEHICLES ARE STILL EQUIPPED WITH THE 'SHUFFLING WITHIN A SINGLE DISC' FEATURE.

SOME VEHICLES EQUIPPED WITH THE E4OD/4R100 TRANSMISSION MAY EXHIBIT THE TORQUE CONVERTER EXTERNAL ACCESS DUST PLUG DISLODGING AND FALLING OUT DURING SEVERE DUTY USE.  THIS MAY BE CAUSED BY A COMBINATION OF STACK UP TOLERANCE, MATERIAL SHRINKAGE OVER TIME, AND LOADING BEING APPLIES TO THE PLUG DURING USAGE OR CLEANING OF THE UNDERSIDE OF THE VEHICLE.  SEE TSB 02-21-01 ON OASIS AND QCDEALER.COM FOR DETAILS.

SOME 1994-2002 SUPER DUTY F-SERIES, 2000-2002 EXCURSION, AND 1995-2003 ECONOLINE EQUIPPED WITH A 7.3L (ENG S/N 896812 AND LATER) MAY EXHIBIT OIL LEAKS AT THE TURBOCHARGER PEDESTAL AROUND THE EXHAUST BACKPRESSURE ACTUATOR.  THESE VEHICLES MAY BE SERVICED WITHOUT REPLACING THE PEDESTAL.  AN IMPROVED SEAL IS AVAILABLE FOR THE ACTUATOR SHAFT.  SERVICE ONLY LEAKS THAT DRIP OIL.  SEEPAGE THAT COLLECTS DUST BUT DOES NOT DRIP SHOULD NOT HAVE A SERVICE ATTEMPT MADE.  THE PEDESTAL MUST BE REMOVED TO REPLACE THE SEAL.  THE IMPROVED SEAL PART NUMBER FOR 1994.5-1997 MODEL YEARS IS 2C3Z-9P466-BA AND FOR 1998-2003 MODEL YEARS IS 2C3Z-9P466-AA.  ENGINES BUILT IN INDIANAPOLIS AFTER S/N 1953507 (JUNE 11, 2002) AND CANOAS, BRAZIL BUILT AFTER S/N 5070583 (SEPT. 3, 2002) ARE EQUIPPED WITH THE NEW SEAL.

SOME 2002 F-250 THROUGH 750 AND EXCURSION VEHICLES EQUIPPED WITH A 7.3L ENGINE MAY EXHIBIT A LOUD SQUEALING NOISE FROM THE ENGINE AREA WHEN THE ENGINE FAN CLUTCH IS UNDER LOAD WHILE OPERATED IN HOT DUSTY CLIMATES.  THIS MAY BE DUE TO AN ACCUMULATION OF DUST ON THE BACKSIDE OF THE ACCESSORY DRIVE BELT CAUSING THE BELT TO SLIP.  THIS CONDITION HAS BEEN MISINTERPRETED AS A TURBO CHARGER OR FAN CLUTCH ASSEMBLY DUE TO THE NOISE AND/OR FAST FAN CLUTCH CYCLING.  A SERVICE KIT AND PROCEDURE IS SCHEDULED TO BE RELEASED IN 2003.  TO SERVICE IN THE INTERIM, REPLACE THE ACCESSORY DRIVE BELT USING THE 1C2Z-8620-NA BELT FOR VEHICLES EQUIPPED WITH A SINGLE ALTERNATOR SYSTEM AND THE 1C2Z-8620-PA BELT FOR VEHICLES WITH A DUAL ALTERNATOR SYSTEM.

SOME 2003 SUPERDUTY F-SERIES & EXCURSIONS EQUIPPED WITH A 7.3L ENGINE MAY EXHIBIT A LONG CRANK ON HOT ENGINE OR MIL LAMP ON WITH DTC P1211 (ICP NOT CONTROLLABLE  PRESSURE ABOVE/BELOW DESIRED) DURING HARD ACCEL.  THIS MAY BE CAUSED BY THE HIGH-PRESSURE PUMP.  TO DIAGNOSE, WARM THE ENGINE TO EOT ABOVE 170 F.  DRIVE THE VEHICLE USING THE SAME PROCEDURE FOR A BOOST TEST (EX. HARD ACCEL UP A LONG HILL).  IPR% SHOULD NOT EXCEED 50%.  TEST ICP LEAKAGE USING THE HARD START DIAGNOSTIC SHEET IN THE PC/ED.  A LOWER ICP READING OR A HIGHER IPR% IMBALANCE INDICATES A LEAK IN THE HEAD.  NEXT PLUG BOTH ICP HOSES.  LOOK FOR ICP ABOVE 500 PSI.  DO NOT CRANK ENGINE LONGER THAT 20 SECONDS.  IF IPR% EXCEEDS 55% UNDER LOAD, AND ICP IS BALANCED BANK TO BANK, AND THE SYSTEM GENERATES PRESSURE SLOWLY DURING CRANK, REPLACE THE HP PUMP (F81Z-9A543-CRM).

SOME 2003 F-53 MOTORHOME CHASSIS EQUIPPED WITH A 3 CHANNEL ANTI-LOCK BRAKE SYSTEM (ABS) SYSTEM MAY EXHIBIT A FLUCTUATING SPEEDOMETER NEEDLE/ABS LAMP ILLUMINATED AND/OR INOPERATIVE SPEED CONTROL.  THIS MAY BE DUE TO THE VEHICLE SPEED SENSE SIGNAL BEING FED TO THE CLUSTER AND SPEED CONTROL SERVO FROM THE POWERTRAIN CONTROL MODULE (PCM) AND THE ABS MODULE.  TO SERVICE, ACCESS C155A AT THE ABS MODULE.  CUT CIRCUIT 679 (GY/BK) NEAR THE ABS MODULE CONNECTOR ABOUT 20CM (8 INCHES) FROM THE CONNECTOR AND PLACE A HEAT SHRINK END CAP ON BOTH OPEN ENDS.

SOME VEHICLES EQUIPPED WITH THE 7.3L DIESEL ENGINE MAY EXHIBIT ENGINE OIL PAN CORROSION WHEN OPERATED IN HIGH SALT CONTENT/CORROSIVE ENVIRONMENTS.  SEE TSB 02-20-05 ON OASIS AND QCDEALER.COM FOR DETAILS.

THE VALLEY IN THE TOP OF THE CRANKCASE HAS A DRAIN HOLE MACHINED SLIGHTLY TO THE RIGHT OF CENTER AT THE REAR.  ANY LEAK IN THE "VEE" OF THE ENGINE COULD RESULT IN A DRIPPAGE DOWN THE BACK OF THE ENGINE.  THIS LEAK COULD BE PERCEIVED AS AN OIL LEAK IN THE REAR OF THE ENGINE INCLUDING, BUT NOT LIMITED TO, THE REAR MAIN CRANKSHAFT SEAL AND OIL PAN GASKET.  SEE TSB 02-20-04 ON OASIS AND QCDEALER.COM FOR DETAILS.

ROTUNDA TOOL HAS JUST RELEASED A NEW TOOL (FLUID TRANSPORTER 307-D465) THAT CAN BE USED FOR FILLING OR REMOVING FLUID FROM AUTOMATIC OR MANUAL TRANSMISSIONS, AXLES, AND POWER STEERING, QUICKLY WITH NO MESS.  THIS IS A FLUID TRANSPORTER, WHICH IS USED TO EVACUATE OR INJECT FLUID WITH THE USE OF PRESSURIZED AIR AND VACUUM.  THE FLUID TRANSPORTER IS DESIGNED TO FIT INTO HARD TO REACH OPENINGS SAVING TIME AND ELIMINATES MESSY DRIPS AND SPILLS.  THIS IS AN EXCELLENT TOOL FOR FILLING AND CHECKING FLUID LEVELS IN THE 5R55N, 5R55S & 5R55W TRANSMISSION THAT HAVE A FLUID LEVEL & FILL PLUG ASSEMBLY IN THE BOTTOM PAN, AND DO NOT HAVE A DIPSTICK AND FILLER TUBE.  SEE TSB 02-20-03 ON OASIS AND QCDEALER.COM FOR DETAILS.

ALUMINUM CYLINDER HEADS AND BLOCKS REQUIRE FLATNESS CHECKS PRIOR TO GASKET INSTALLATION TO ENDURE THE COMPONENT PART IS NOT OUT OF FACTORY SPECIFICATION.  THE SURFACE QUALITY (FINISH) OF THE CYLINDER HEAD GASKET SURFACE IS MACHINED TO CLOSE TOLERANCES WHICH ENABLE AN EFFECTIVE SEALING JOINT FOR THE MLS (MULTI-LAYERED STEEL) GASKET.  SEE TSB 02-20-02 ON OASIS AND QCDEALER.COM FOR DETAILS.

SOME 1995-2003 E-SERIES, 1994-2003 SUPER DUTY F-SERIES OR 2000-2003 EXCURSION MAY EXHIBIT AN ENGINE OIL LEAK CAUSED BY A SWELLED, CRACKED, CUT OR OTHERWISE LEAKING CAMSHAFT POSITION SENSOR (CMP) O-RING.  A NEW SERVICE O-RING (F81Z-12B615-BA) IS NOW AVAILABLE FOR SERVICE.  IT IS NOT NECESSARY TO REPLACE THE CMP SENSOR FOR A LEAKING O-RING.

ANY WDS AT SOFTWARE RELEASE CD(B21.1) OR LATER MAY EXHIBIT FREQUENT 'TESTMAN' ERRORS WHEN USING THE MODULE PROGRAMMING FUNCTION.  TO SERVICE, RELOAD THE B21 CD (BLUE DISK) AND THEN UPDATE THE WDS TO THE LATEST CALIBRATION DATA (SELECT 'SYSTEM UTILITIES', 'NETWORK OPTIONS', THEN 'UPDATE CALIBRATION').  ANY DEALER WITH A WDS AT SOFTWARE RELEASE CD(B21) IS STRONGLY ENCOURAGED TO RUN UPDATE CALIBRATION TO OBTAIN THE LATEST PCM CALIBRATION DATA.
FOR ASSISTANCE, CONTACT TECHNICAL INFORMATION SUPPORT AT 800-826-4694 OPTION #1.

SOME 1998-2003 ECONOLINE, SUPER DUTY, F650/7550 & EXCURSION WITH 7.3L (ENG SER #0661894) MAY RUN ROUGH OR MISS DURING HARD ACCELERATION DUE TO A POOR CONNECTION AT THE JUNCTION OF THE INJECTOR/GLOW PLUG HARNESS & THE VALVE COVER GASKET. IF ANY CYLINDER IS IDENTIFIED BY A CYLINDER CONTRIBUTION TEST OR IS SUSPECTED DUE TO INJECTOR PERFORMANCE ANALYZER, REMOVE VALVE COVER GASKET & INSPECT THE CONNECTION BETWEEN THE UVC HARNESS & THE VALVE COVER GASKET. THE LOCKING DEVICE FOR THE UVC MAY BECOME RELAXED & ALLOW THE CONNECTION TO FAIL. A RETAINER 2C3Z-14A163-AB IS AVAILABLE TO INSTALL IN THE LOCKING MECHANISM, SECURING THE CONNECTION. IF THE CONNECTION IS NOT SECURE, INSTALL THE CLIP & RE-EVALUATE THE ENGINE'S PERFORMANCE. DO NOT REPLACE THE INJECTOR(S) IF THE CLIP REPAIRS THE CONDITION.

THE 2003 EXCURSION ROOF RACK SLATS ARE DELETED. EARLY 2003 EXCURSION WERE BUILT WITH 1 ROOF RACK SLAT, UNITS BUILT AFTER 09/06/2002 HAVE NO SLATS.

SOME 1999-2003 SUPERDUTY AND EXCURSION VEHICLES MAY EXHIBIT THE CONDITION OF STARTER STAYING ENGAGED AFTER RELEASING KEY FROM START POSITION, REPEAT STARTER FAILURE OR A STICKING/BINDING IGNITION LOCK CYLINDER. THIS MAY BE DUE TO:
-AN IGNITION LOCK CYLINDER BINDING NOT FULLY RETURNING FROM START TO RUN
-SHORT CONDITION ON STARTER RELAY CIRCUIT 113 (YE/LB) OR 1093 (TN/RD)
-STICKING STARTER RELAY
-AN INTERNAL SHORT IN THE POWER DISTRIBUTION JUNCTION BOX (PDJB).
IF ONE OF THESE CONDITIONS OCCUR, INSPECT THE STARTER AND FLYWHEEL FOR DAMAGE & REPLACE AS NECESSARY. INSPECT THE STARTER CIRCUIT FOR SHORTS INCLUDING THE POWER DISTRIBUTION JUNCTION BOX (PDJB) AND VERIFY PROPER CYLINDER LOCK FUNCTION.

SOME VEHICLES MAY EXHIBIT A WHINING/BUZZING NOISE IN THE SPEAKERS ON AN AFTERMARKET ENTERTAINMENT RADIO OR AFTERMARKET TWO-WAY RADIO. THE NOISE WILL GO FROM LOW FREQUENCY TO HIGHER FREQUENCY WITH ACCELERATION. THIS CAN BE MISDIAGNOSED AS A DEFECTIVE ALTERNATOR. IT IS NOT. THIS CONDITION IS CAUSED BY AN ABSENCE OF, OR LOW QUALITY FILTERING IN THE AFTERMARKET COMPONENT. REPLACEMENT OF THE ALTERNATOR DOES NOT SERVICE THIS CONDITION. AFTERMARKET ENTERTAINMENT RADIOS AND TWO-WAY RADIOS MUST BE ABLE TO ACCEPT OUTSIDE INTERFERENCE (RFI). THE AFFECTED AFTERMARKET COMPONENTS SHOULD BE REFERRED BACK TO THEIR RESPECTIVE MANUFACTURERS FOR PROPER NOISE FILTERING.

SOME 2002 SUPER DUTY F-SERIES AND EXCURSION VEHICLES MAY EXHIBIT MULTIPLE GAUGES (2 OR MORE) BEING INOPERATIVE OR FLUCTUATING RAPIDLY. THIS MAY BE CAUSED BY AN INTERNAL FAILURE OF THE HYBRID ELECTRONIC CLUSTER (HEC) MODULE. TO SERVICE, VERIFY POWERS AND GROUNDS TO THE HYBRID ELECTRONIC CLUSTER (HEC) MODULE. IF ALL INPUTS CHECK OK, INSTALL A NEW HYBRID ELECTRONIC CLUSTER (HEC) MODULE.

SOME VEHICLES EQUIPPED WITH A 5.4L ENGINE/4R100 TRANSMISSION, FEDERAL EMISSIONS, BUILT BEFORE 8/26/02, MAY EXHIBIT A ROUGH IDLE AND/OR HESITATION WHEN ACCELERATING. THIS MAY OCCUR INTERMITTENTLY WITHIN THE FIRST 2-3 MINUTES AFTER START WHEN THE ENGINE IS NOT WARMED UP (IE. CONDITIONS OTHER THAN HOT RESTART). THE CONDITION MAY BE AGGRAVATED BY AN UNMETERED AIR LEAK OR EXHAUST LEAK. THIS MAY BE CAUSED BY THE POWERTRAIN CONTROL MODULE (PCM) CALIBRATION. SEE TSB 02-18-07 ON OASIS AND QCDEALER.COM FOR DETAILS.

SOME 2001-2002 EXCURSION, EXPEDITION, BLACKWOOD, F-150, F-150 SUPERCREW AND HARLEY DAVIDSON SUPERCREW, SUPER DUTY F-SERIES, E-SERIES, AND 1001-2003 NAVIGATOR EQUIPPED WITH A 4R100 TRANS & BUILT BETWEEN JANUARY 1, 2001 & MAY 1, 2002 MAY EXHIBIT FLASHING TRANSMISSION CONTROL INDICATOR LAMP (TCIL) & ANY OR ALL OF THE FOLLOWING TORQUE CONVERTER CLUTCH (TCC) RELATED DTC'S: P0740, P0743, P1744.  CUSTOMER MAY NOT REPORT ANY DRIVEABILITY CONDITIONS - ASIDE FROM POSSIBLE SLIGHTLY FIRMER SHIFTS EMPLOYED BY THE CONTROLLER WHEN DTCS ARE SET - AND MAY HAVE THE VEHICLE SERVICED BECAUSE OF THE FLASHING TCIL.  THIS MAY BE DUE TO A WELD ISSUE W/THE TCC SOLENOID THAT CAUSES AN INCREASE IN RESISTANCE AND SUBSEQUENT LOWER TORQUE CONVERTER LOCK PRESSURES.  TO SERVICE, REPLACE THE SOLENOID BODY WITH F81Z-7G391-CB.

THE LATEST CALIBRATION UPDATE FOR 2002 SUPER DUTY AND EXCURSION EQUIPPED WITH A 7.3L DIESEL ENGINE CONTAIN DIAGNOSTIC ENHANCEMENTS TO 1) PREVENT FALSE CODE SETTING OF CLUSTER FAULT CODES U1262 AND U1027 & 2) WAIT-TO-START INDICATOR ON CALIFORNIA CALIBRATIONS.  ALSO INCLUDED ARE IMPROVED WAIT-TO-START INDICATOR FUNCTION ADDRESSING THOSE THAT STAY ON AND THOSE VEHICLES WITH INDICATORS THAT COME ON INTERMITTENTLY WHILE DRIVING.  4R100 TRANSMISSION ENHANCEMENTS INCLUDE INCREASED LOW REVERSE CLUTCH CAPACITY IN M1 ONLY.  THIS RELEASE INCLUDES TEAR TAG NUMBERS; QLJ5, VDH5, KEK5, BXE5, VDU5, NQW5, ZRE4, AEB4, AND GDU4.  CALIBRATIONS WITH CATCHWORDS; QLJ4, VDH4, KEK4, BXE4, VDU4, NQW4, ZRE3, AEB3, AND GDU3 RESPECTIVELY, AS WELL AS ZRE2, AEB2, AND GDU2 MANUAL TRANSMISSION CALIBRATIONS CAN ONLY BE REPROGRAMMED WITH THIS RELEASE.

SOME 2002 SUPER DUTY F250-550 AND EXCURSION EQUIPPED WITH A 7.3L DI, 4R100 TRANSMISSION AND BUILT BEFORE DECEMBER 10, 2001, MAY REMAIN IN 2ND GEAR WITH THE GEAR SHIFT LEVER IN THE FIRST GEAR POSITION.  WHEN CHANGING GEARS FROM MANUAL 2 (M2) TO MANUAL (M1) WHILE THE VEHICLE IS NOT IN MOTION, THE TRANSMISSION WILL CONTINUE TO MAINTAIN THE M2 (SECOND GEAR RATIO) UNTIL RELATIVE VEHICLE MOTION IS DETECTED.  WHEN RELATIVE VEHICLE MOTION IS DETECTED, THE TRANSMISSION WILL THEN CHANGE GEARS, (DOWN SHIFT) TO ACHIEVE THE M1 (FIRST GEAR) RATIO.  THIS IS A NORMAL DESIGN CHARACTERISTIC AND WILL NOT AFFECT 4R100 TRANSMISSION HARDWARE.

SOME 2002 F-SERIES SUPER DUTY AND EXCURSION VEHICLES EQUIPPED WITH THE 7.3L DI ENGINE MAY EXHIBIT ERRATIC COOLANT TEMPERATURE GAUGE READINGS.  TO SERVICE, VERIFY THAT THE ENGINE TEMPERATURE SENDER HAS A GREY (NOT BLACK) PLASTIC HARDSHELL CONNECTOR, AND THAT THE CORRESPONDING WIRE HARNESS CONNECTOR IS ALSO GRAY.  IF THE SENDER HAS A BLACK HARDSHELL CONNECTOR, REPLACE THE BLACK SENDER WITH THE GREY (F5AZ-12A648-A) SENDER.  NOTE: IT MAY BE NECESSARY TO BREAK OFF THE POLARITY TAB FROM THE BLACK WIRE HARNESS CONNECTOR TO ENABLE IT TO FIT ONTO THE GREY SENDER.

THE LATEST CALIBRATION UPDATE (WDS VERSION B16.2) FOR 2002 SUPER DUTY F-SERIES EXCURSION AND E350/450 EQUIPPED WITH 7.3L DIESEL ENGINES CONTAIN SOME ENHANCEMENTS TO DIAGNOSTICS.  F-SUPER DUTY & EXCURSION ALSO RECEIVE 4R100 SHIFT IMPROVEMENTS (E350/450 EXCLUDED).  INCLUDED IN THE LATEST RELEASE ARE PCM TEAR TAG NUMBERS; AEB3, GDU3, ZRE3, VDH3, KEK3, BXE3, VDU3, QLJ3, NQW3, HPI3, VLB3, HJH3, & IQW3.  ENHANCEMENTS TO DIAGNOSTICS INCLUDE 1) IMPROVEMENTS FOR SELF TEST & GENERIC SCAN TOOL FIX, 2) REDUCE THE OCCURRENCE OR P0340 CAMSHAFT POSITION SENSOR FALSE DIAGNOSTIC CODE.  THIS RELEASE ALSO CONTAINS A FIX FOR 4R100 LATE SHIFT PERCEPTION (HANGING IN 3RD GEAR) ON F-SUPER DUTY & EXCURSION ONLY.  SPECIFICALLY, 3-4 SHIFT AT LIGHT THROTTLE DUE TO POTENTIAL LACK OF CONVERTER LOCK-UP OCCURRING AFTER 2-3 (MOST PREVALENT ON 3.73:1 AXLE RATIO VEHICLES).

SOME 2002 SUPER DUTY F-SERIES WITH 7.3L ENGINE, MAY INTERMITTENTLY EXHIBIT AN INVALID APCM DISPLAY READOUT OF 4100 RPM OR ABOVE.  WHEN THIS CONDITION IS PRESENT, THE RPM CONTROL MAY BYPASS PROGRAMMED SET-POINTS AND RAPIDLY INCREASE ENGINE SPEED TO AN UNPROGRAMMED RPM.  THE ACTUAL COMMANDED ENGINE SPEED IS LIMITED BY THE POWERTRAIN CONTROL MODULE (PCM), AND CANNOT INCREASE ABOVE 2500 RPM.  TO AVOID THIS CONDITION, CONNECT POTENTIOMETER OR RESISTOR NETWORK TO APCM AND USE CUSTOM REMOTE RPM CONTROL FEATURE (SEE SECTION 6.1.2 OF APCM OPERATING INSTRUCTION).  THE APCM IS ALSO CAPABLE OF PROVIDING ADDITIONAL PTO OVER-SPEED PROTECTION BY PROGRAMMING AN UPPER RPM LIMIT.  REFER TO THE APCM USERS/OWNERS GUIDE FOR DETAILED PROGRAMMING AND FUNCTIONAL INFORMATION.

SOME 2002 F-SERIES SUPER DUTY AND EXCURSION MAY EXHIBIT A SLIGHT BRAKE PULL TO THE RIGHT ON INITIAL BRAKE APPLICATION AND THEN A SLIGHT BRAKE PULL TO THE LEFT UPON RELEASE OF THE BRAKE PEDAL.  THIS MAY BE DUE TO A DELAYED OR SLOWED LEFT FRONT BRAKE CALIPER RESPONSE TO BRAKE PEDAL APPLICATION AND/OR BRAKE PEDAL RELEASE.  TO SERVICE, PERFORM NORMAL DIAGNOSTICS, INSPECT AND VERIFY THAT ALL BRAKE LINES, HOSES, AND LININGS ARE IN PROPER WORKING ORDER.  IF THE CONDITION IS STILL PRESENT, REPLACE THE LEFT FRONT CALIPER.

ON ALL 2000-2002 REAR WHEEL DRIVE VEHICLES WITH 4R70W, 4R100, 5R55N, AND 5R55W TRANSMISSIONS, THE TORQUE CONVERTER DRAIN PLUG IS BEING ELIMINATED AS A RUNNING CHANGE.  VEHICLES BUILT AFTER 4-20-2001 AND/OR FORD AUTHORIZED REMANUFACTURED CONVERTERS, MAY HAVE A MIX OF CONVERTERS WITH AND WITHOUT THE DRAIN PLUG UNTIL THE SUPPLY IS EXHAUSTED.  NEW PROCEDURES FOR CHANGING THE TRANSMISSION FLUID AND FOR THE USE OF AUTOMATIC TRANSMISSION FLUID EXCHANGE MACHINES ARE LISTED IN THE APPROPRIATE YEAR/MODEL WORKSHOP MANUAL, OR THE LATEST WORKSHOP MANUAL CD-ROM UPDATE.  SPECIAL NOTE: WHEN CHANGING THE AUTOMATIC TRANSMISSION FLUID, DO NOT USE ANY FLUID ADDITIVES.  THE USE OF CLEANING AGENTS OR FLUID ADDITIVES DURING REPAIRS OR FLUID CHANGES MAY CAUSE INTERNAL TRANSMISSION DAMAGE.

WHEN PERFORMING TSB 01-13-05 (4R100 - DELAYED OR NO 2ND GEAR - DIAGNOSTIC TROUBLE CODES P0781, P0755 AND/OR P0756 - VEHICLES EQUIPPED WITH 4R100 TRANSMISSION WITH TRANSMISSION BUILD DATES BETWEEN 7/27/2000 AND 3/23/2001 ONLY) THE SERVICE PROCEDURE PARAGRAPH ADVISES TO FOLLOW ALL THE NORMAL SERVICE PROCEDURES AS INDICATED IN THE APPROPRIATE WORKSHOP MANUAL.  THE PAPER 2001 WORKSHOP MANUAL (VOLUME 2, PAGE 307-01-262) FOR EXCURSION, SUPER DUTY F-SERIES INCORRECTLY STATES INTERMEDIATE ONE-WAY ROTATION IS "CLOCKWISE".  THIS SHOULD STATE "WHEN INSTALLED CORRECTLY THE OUTER RACE MUST ROTATE COUNTERCLOCKWISE".  NOTE: THE ONLINE PUBLICATIONS HAVE BEEN UPDATED AND ARE NOW CORRECT.

SOME 1999-2002 SUPER DUTY F-SERIES (F-250-550) AND EXCURSION EQUIPPED WITH A 4R100 AUTOMATIC TRANSMISSION MAY EXHIBIT A COLD WEATHER REVERSE ENGAGEMENT STALL.  THIS CONDITION MAY OCCUR AT EXTREME COLD AMBIENT TEMPERATURES CAUSING INCREASED FLUID VISCOSITY WHICH ALLOWS THE TORQUE CONVERTER CLUTCH TO ENGAGE DUE TO INADEQUATE INTERNAL OIL PRESSURE AT ENGINE IDLE WHILE THE VEHICLE IS STATIONARY.  TO SERVICE, REPLACE THE EXISTING TRANSMISSION FLUID WITH MERCON SYNTHETIC MULTI-PURPOSE TRANSMISSION FLUID - XT-2-QSM TRANSMISSION FLUID.

SOME 2000-2001 F-650/750 EQUIPPED WITH A CAT ENGINE MAY EXHIBIT A ROUGH ENGINE IDLE CONDITION.  THIS MAY BE DUE TO A LOW IDLE RPM SETTING.  BEGINNING 2/19/2001, ALL F-650/750 EQUIPPED WITH A CAT ENGINE, BUILT AFTER VIN NUMBER 1MA50189 ARE FACTORY SET WITH AN IDLE SPEED OF 760 RPM TO REDUCE THE POSSIBILITY OF EXCESSIVE VIBRATION DURING IDLE ENGINE SPEED CONDITIONS.  NOTE: SUPERCREWZER SPEC TRUCKS ARE NOT AFFECTED BY THIS MESSAGE.

SOME 1999-2000 SUPER DUTY F-SERIES 250/350 SRW/DRW & 2000 EXCURSION MAY EXHIBIT A BRAKE SQUEAL/SQUEAK FROM THE REAR BRAKES.  THIS MAY BE CAUSED BY THE REAR BRAKE PADS.  A NEW BRAKE PAD IS NOW AVAILABLE (YC3Z-2200-AA) WHICH WILL ELIMINATE THIS CONDITION.  FOR ANY CONTINUING REAR BRAKE NOISE, PLEASE SUBMIT AND EDSR.

SOME 1999-2000 SUPER DUTY F-SERIES MAY EXHIBIT A LACK OF A/C COOLING AT HIGHWAY SPEEDS.  THIS MAY BE CAUSED BY RAPID CYCLING OF THE A/C COMPRESSOR CLUTCH DUE TO LOW SUCTION PRESSURES.  TO SERVICE RAPID A/C CLUTCH CYCLING ONLY, EVACUATE AND RECHARGE THE A/C SYSTEM WITH 56 OZ. OF R134A.  THIS ACTION SHOULD PREVENT THE RAPID CYCLING DUE TO LOW PRESSURES.

SOME 2000 SUPER DUTY F-SERIES 250/350 PRODUCED AT THE CUAUTITLAN ASSEMBLY PLANT FROM 12/15/1999 TO 04/19/2000 EQUIPPED WITH THE CAMPER PACKAGE OPTION, MAY EXHIBIT A NOISE FROM THE FRONT SUSPENSION WHEN 'U' TURNING OR DRIVING OVER BUMPS.  THIS CONDITION MAY BE CAUSED BY AN INCORRECT FRONT STABILIZER BAR INSULATOR(S) (F81A-5484-HA - 34MM DIAMETER) INSTEAD OF (F81A-5484-GA - 30MM DIAMETER).  IF THE INCORRECT INSULATOR HAS BEEN INSTALLED THE STABILIZER BAR WILL MOVE THEN FORCE IS APPLIED.  TO CORRECT THIS CONDITION INSTALL INSULATOR(S) F81Z-5484-GA (30MM DIAMETER).  FOR REMOVAL AND INSTALLATION REFER TO THE 2000 WORKSHOP MANUAL, GROUP 2 CHASSIS, SECTION 204-01A.

SOME 1999/2000 SUPER DUTY F-SERIES 250-550 BUILT BEFORE 2/5/2000 EQUIPPED WITH A 7.3L DIT ENGINE MAY EXHIBIT A NOISE LEVEL EMITTING FROM THE POWER STEERING SYSTEM WHICH SOME CUSTOMERS MAY FIND OBJECTIONABLE.  A REVISED POWER STEERING LINE (YC3Z-3A717-AA) WHICH RUNS FROM THE STEERING PUMP TO THE HYDROBOOST IS NOW AVAILABLE.  THIS NEW POWER STEERING LINE INCORPORATES A TUNING CABLE WHICH WILL REDUCE THE NOISE LEVEL OF THE POWER STEERING SYSTEM.

THE ACCURACY OF THE AVERAGE FUEL ECONOMY AND FUEL RANGE DISPLAYED BY THE OVERHEAD TRIP COMPUTER ON 1999-2000 SUPER DUTY F-SERIES & 2000 EXCURSIONS FOR BOTH GAS AND DIESEL ENGINES CAN BE AFFECTED BY MANY FACTORS, INCLUDING THE FOLLOWING:
* AFE HAS NEVER BEEN RESET.
* VEHICLE REFUELED/STARTED WHEN PARKED ON AN INCLINE.
* VARIATIONS IN SHUT-OFF POINTS AT FUEL STOPS.
* VARIATIONS IN TOP-OFF PROCEDURES AT EACH FILL-UP.
* REFUELING WITH LESS THAN 8 GALLONS OF FUEL
SEE PAGES 18-19 OF THE 1999 F-250/350/450/550 OWNER'S GUIDE AND PAGES 21-22 OF THE 2000 F-250/350/450/550 OWNER'S GUIDE AND PAGES 57-58 OF THE 2000 EXCURSION OWNER'S GUIDE FOR MORE INFORMATION.

SOME 1999-2000 SUPER DUTY F-SERIES 250/350 EQUIPPED WITH CREW CAB AND BUILT BEFORE 2/25/2000 MAY EXHIBIT A 'POPPING' NOISE FROM THE REAR OF THE CAB WHEN DRIVING OVER UNEVEN SURFACES.  THIS MAY BE CAUSED BY THE TWO REAR CAB TO FRAME LOWER BODY MOUNTS DEFORMING UNDER STRESS.  THIS CONDITION CAN BE ELIMINATED BY REPLACING THE CURRENT TWO REAR LOWER MOUNTS WITH NEW MOUNTS - YC3Z-1000155-GA.  IN ADDITION, THE REAR CAB TO MOUNT FASTENERS MUST BE REPLACED AS WELL.  NEW FASTENERS MUST BE USED ANYTIME THESE FASTENERS ARE REMOVED OR LOOSENED.  THE LEFT REAR CAB FASTENER IS - W705718-S301 AND THE RIGHT REAR CAB FASTENER IS - W705262-S301.  TORQUE TO 80 NM (60 LB FT).