Ford F-Series Vehicle Technical Service Bulletins and OASIS Report

21126: MAF Sensor Service Tip

Applies to: 1997-2010MY Gas Engine Equipped Vehicles

Issue: Diagnostic Trouble Codes (DTCs) P0171-P0175, lack of power, hesitation, rough running, or surging due to contaminated Mass Airflow (MAF) sensors.

Recommendation: Inspect MAF sensor hotwire for contamination. Clean with CRC Mass Air Flow Sensor Cleaner #05110. Do not use shop air or harsh chemicals. Monitor long-term fuel trims (LTFT1 and LTFT2) after cleaning.

Effective Date: 12/03/2009

20680: Coil on Plug (COP) Diagnostic Testing

Applies to: Gas Engines

Issue: Diagnosing COP ignition primary circuit malfunction DTCs P035X-P0360.

Recommendation: Verify harness integrity using PCED Pinpoint Test JF. If DTCs persist, use IDS Toolbox Oscilloscope "Escape PCM Driver" test to confirm PCM driver function. Check for missing coil driver pulses using IDS Power Balance. Do not replace PCM if all coil pulses are present.

Effective Date: 02/25/2009

20677: Multiple Coil Primary Circuit Diagnostics

Issue: DTCs P0350/P035X-P0360 indicate a primary circuit malfunction. Secondary ignition failures do not set these codes.

Details: If a primary circuit malfunction occurs, the PCM may invoke Failure Mode Effects Management (FMEM), shutting down the injector for the affected cylinder to protect the catalyst. Do not condemn the injector when these DTCs are present. A primary circuit malfunction will set P0350/P035X-P0360 before a P030X (misfire) code. If the cause is a short to ground, the ignition coil may be damaged, but the PCM will not be damaged. Verify coil driver functionality before replacing the PCM.

Effective Date: 02/24/2009

19950: Vehicle Equipped with Vapor Management Valve (VMV) with a Service Port

Issue: VMVs may have an integrated or remote service port covered by a green cap.

Recommendation: After servicing for EVAP concerns, ensure the inside of the cap is clean, the seal is in place, and the cap is securely re-fastened to the port (finger tight only) to maintain the service port Schrader valve seal.

Effective Date: 09/07/2007

17930: Erratic Fuel Gauge

Applies to: 1995-2005 Multiple Vehicles with Gasoline Engines

Issue: Erratic fuel gauge readings and Malfunction Indicator Lamp (MIL) illumination with DTCs P0460, P0462, P0463, P2065, P2067, and/or P2068.

Cause: Potential sulfur contamination in local fuels affecting the fuel sender card.

Recommendation: Clear DTCs, drain fuel tank if possible, and advise the customer to use an alternate fuel brand. The condition may self-correct after 2-3 tanks of uncontaminated fuel. Advise customers to reset their trip odometer and monitor mileage. Component replacement may not resolve the issue if caused by contaminated fuel.

Effective Date: 07/22/2004

17339: OBDII Equipped Vehicles - DTC P0171 and/or P0174

Applies to: 1995-2004 OBDII Equipped Vehicles

Issue: MIL illumination with DTC P0171 (System Too Lean - Bank 1) and/or P0174 (System Too Lean - Bank 2) due to a PCV system vacuum leak.

Recommendation: Inspect the PCV system, including rubber components, elbow connectors, and the PCV valve, for deterioration or chafing. Replace affected PCV components. Replacing PCM, MAF sensor, or HEGOs will not fix lean codes caused by leaking PCV components.

Effective Date: 11/12/2003

17063: DTC P0171 or P0174

Applies to: 1999-2003 F-150 Lightning / 2002-2003 F-150 Harley Davidson SuperCrew

Issue: MIL illumination with DTC P0171 or P0174 due to the clean air tube being improperly seated in the air cleaner, causing unmetered air entry.

Recommendation: Verify the clean air tube is properly seated and the PCV valve is fully seated with the hose routed correctly to prevent pull-out. Clear DTCs and retest.

Effective Date: 08/19/2003

16922: P0420 and/or P0430 Catalyst Efficiency DTC's

Applies to: 1996-2003 Ford, Lincoln, and Mercury Vehicles

Issue: DTC P0420 (Catalyst Efficiency Below Threshold Bank 1) and/or P0430 (Catalyst Efficiency Below Threshold Bank 2).

Recommendation: If diagnostics indicate catalyst replacement, only replace the catalyst located between the monitored oxygen sensors for the referenced bank. Do not replace unmonitored catalysts unless they are part of the same assembly.

Effective Date: 06/26/2003

16899: Rolling Idle

Applies to: 2002-2003 F-150 5.4L

Issue: Rolling idle after shifting to Park or Neutral when engine temperature is between 100-140°F (55.6-77.8°C).

Recommendation: Check for DTCs and service as per the appropriate PC/ED or Workshop Manual. If no DTCs are present, use WDS Release B24.10 or later to reprogram the PCM.

Effective Date: 06/13/2003

16819: No Crank, No Start

Applies to: 1999-2003 Various Vehicles

Issue: No crank, no start condition possibly due to inadequate torque of the starter solenoid terminal nuts.

Recommendation: Check the integrity and torque of the B+ terminal (12 +/- 1.8 NM) and S terminal (5.4 +/- 0.9 NM) nuts. If the concern persists, continue with appropriate PC/ED diagnostics.

Effective Date: 05/06/2003

16701: Deletion of Cold Start Heater

Applies to: 1998-2003 F-150, 2000-2001 F-Series Super Duty, 1998-1999 Econoline (all with 5.4L & 6.8L Bi-Fuel Engines)

Issue: New design LPG vaporizers no longer require the cold start heater electrical harness.

Recommendation: When replacing vaporizers on vehicles equipped with this harness, remove the harness. Follow instructions provided with replacement vaporizer service parts and the appropriate Workshop Manual.

Effective Date: 03/17/2003

16244: Bi-Fuel CNG/LPG New Heated Oxygen Sensor (HEGO) Diagnostic Codes

Applies to: 2000-2002 F-Series Bi-Fuel CNG and LPG Trucks

Issue: Undefined service codes may appear in the Alternate Fuel Control Module (AFCM) due to upgraded diagnostics. Codes P2195, P2196, P2197, or P2198 may occur.

Recommendation: Refer to diagnostic procedures in the 2003 F-Series PC/ED. Code definitions include: P2195 - HO2S Signal Stuck Lean (Bank 1, Sensor 1), P2196 - HO2S Signal Stuck Rich (Bank 1, Sensor 1), P2197 - HO2S Signal Stuck Lean (Bank 2, Sensor 1), P2198 - HO2S Signal Stuck Rich (Bank 2, Sensor 1).

Effective Date: 09/19/2002

16170: 4R100-Equipped Vehicles Built Between 01/01/2001 and 05/01/2002 - TCC DTCs P0740, P0741, P0743, P1744 / Replace Solenoid Body

Applies to: 2001-2002 Excursion, Expedition, Blackwood, F-150, F-150 SuperCrew, Harley Davidson SuperCrew, Super Duty F-Series, E-Series, and 2001-2003 Navigator equipped with a 4R100 transmission.

Issue: Flashing Transmission Control Indicator Lamp (TCIL) and/or TCC-related DTCs (P0740, P0741, P0743, P1744). This may be due to a weld issue in the TCC solenoid causing increased resistance and lower torque converter lock pressures.

Recommendation: Replace the solenoid body with part F81Z-7G391-CB.

Effective Date: 08/23/2002

16063: Camshaft Position (CMP) Sensor Alignment Tool Chart

Applies to: 1994-2003 Cars & Trucks

Issue: Service manuals may list incorrect CMP sensor alignment tools.

Recommendation: Refer to the following alignment tool numbers and their applications: T89P-12200-A (303-358), T93P-12200-A (303-453), T95T-12200-A (303-529), T96T-12200-A (303-562), 303-589, 303-630, 303-638.

Effective Date: 07/26/2002

15605: P0455 Suspect VMV

Applies to: 1998-2002 Ranger, 1997-2002 Expedition, 1998-2002 Navigator, 1997-2002 F-Series (under 8500 GVW), 2002 Blackwood, and 2002 Explorer 4DR/Mountaineer.

Issue: Driveability conditions and/or MIL illumination with DTC P0455 (Gross Leak Detected) for the evaporative emission system.

Recommendation: Refer to the Evaporative Emissions section of the Workshop Manual and TSBs 01-07-04 and 99-23-04. If the VMV is sticking or leaking, replace it with P/N F75Z-9C915-AA or P/N F87Z-9C915-BA. Verify service by clearing KAM and test driving until all OBDII monitors pass.

Effective Date: 02/06/2002

15518: No Start, No DTC's Stored, Check CKP Sensor Polarity

Applies to: 1990-2002 vehicles equipped with a Crankshaft Position Sensor (CKP).

Issue: Crank/no start condition after CKP wiring/connector repair.

Recommendation: Verify terminal polarity after repairing CKP sensor connector terminals. The PCM or EDIS software may not process a reversed signal waveform.

Effective Date: 01/07/2002

07-05-08: Battery Service - Operation of Battery Eye - Charging Service Tips

Description: This TSB describes the operation and function of the Battery Eye and correct battery recharging procedures to avoid misdiagnosis and determine the best way to charge a battery.

Effective Date: 03/01/2007

06-19-14: No Crank / Starter Terminal Fatigue

Applies to: 1991-2007 Various Vehicles

Issue: No crank condition due to an open circuit in the starter relay to starter motor circuit at the starter motor connection.

Recommendation: Follow the service procedure steps to correct the condition.

Effective Date: 09/19/2006

05-05-06: Alternative Fuel Vehicle - Compressed Natural Gas Fuel Tank Inspection

Applies to: 1996-2004 Various Vehicles

Issue: Federal law requires guidance for CNG tank inspection every 36 months or 36,000 miles, or after a fire or accident.

Recommendation: It is the customer's responsibility to get their CNG fuel containers inspected by 3 years/36,000 miles to comply with FMVSS requirements and industry standards.

Effective Date: 03/04/2005

05-04-17: Intermittent Rough Idle - Non-Commanded EGR Flow

Applies to: 1997-2005 5.4L 2V Vehicles

Issue: Intermittent rough idle possibly due to non-commanded EGR flow.

Recommendation: Detect EGR flow by comparing stabilized DPFEGR KOER voltage at idle after manually opening and closing the EGR valve through 8 cycles. If DPFEGR voltage increases by 0.03V or more and is associated with rough idle, replace the valve.

Effective Date: 02/22/2005

04-17-04: Malfunction Indicator Lamp (MIL) Illuminated - System Lean Diagnostic Trouble Codes (DTC's) - Service Tips

Applies to: 2000-2004 Various Vehicles

Issue: Diagnosing DTCs P0171, P0174, P1130, P1131, P1150, P1151, P2195, or P2197 (System Lean or Lack of HEGO Switches) when a vacuum leak is present.

Recommendation: Perform TSB inspections/repairs when these codes are found. Use scan tool data to compare total fuel corrections at idle and high RPMs to determine if a vacuum leak is the root cause.

Effective Date: 08/16/2004

03-20-03: Driveability - (MIL) Illuminated with DTC's P0442, P0455, P0456, P0457, P1442 or Check Fuel Cap Lamp Illuminated with DTC P0457

Applies to: 1997-2003 Various Vehicles

Issue: MIL illumination with DTCs P0442, P0455, P0456, P0457, or P1442, or "Check Fuel Cap" lamp with DTC P0457 for the evaporative emission system.

Cause: Loose or leaking hoses, loose or broken fuel cap, or a leak at the top of the fuel filler pipe neck.

Recommendation: Use the Rotunda Leak Detector Smoke Machine (Part 218-00001) or equivalent to locate and repair leaks in the evaporative emission system. Refer to the TSB service procedure for details.

Effective Date: 09/25/2003

03-10-02: Driveability - Compressed Natural Gas (CNG) - Rough Idle or No Start When Cold - Vehicles Equipped with CNG Bi-Fuel Engine Only

Applies to: 1996-2002 Various Vehicles equipped with CNG Bi-Fuel Engine

Issue: Rough run in alternate fuel mode, no start when cold in alternate fuel mode (but starts in gasoline mode), or no start in alternate fuel mode at any time.

Cause: Possible regional fuel quality issues causing contamination of low flow injectors in the Compuvalve and associated fuel introduction hardware.

Recommendation: Clean the low flow injectors in the Compuvalve and associated fuel introduction hardware.

Effective Date: 05/14/2003

03-10-03: Driveability - Crank No Start - Bi-Fuel CNG/LPG Vehicles - Low Flow Injector Service Kit Without Coolant Lock-Off

Applies to: 1996-2002 Bi-Fuel CNG F-150, E-250/350; 1996-2000 Contour; 2000-2003 Bi-Fuel LPG F-150; 2000-2001 Super Duty F Series Vehicles (without coolant lock-off).

Issue: No start condition possibly caused by stuck low flow injectors on the Compuvalve due to fuel contamination.

Recommendation: Use the separately released low flow injectors for service to avoid Compuvalve replacement.

Effective Date: 05/14/2003

03-06-06: Driveability - Bi-Fuel - Oxygen Sensor Diagnostics - High Oxygen Sensor Voltage Reading

Applies to: Bi-Fuel Vehicles

Issue: DTCs for high oxygen sensor voltage (P0132 and P0152) may lead to premature Compuvalve replacement.

Recommendation: If an oxygen sensor code is set, and no faults are detected during Pinpoint Test H, follow the modified repair action outlined in the TSB for additional test procedures.

Effective Date: 03/19/2003

02-23-04: (DTC's), Lamp 4x4, Speedometer Inaccurate &/or Inoperative - After (PCM) or Instrument Cluster Replacement - Gas Eng. Only

Applies to: 1999-2002 Various Vehicles (Gasoline Engines)

Issue: Inoperative or inaccurate speedometer, 4x4 lamp illuminated, and/or DTCs P1635 or P1639 after PCM or instrument cluster replacement.

Cause: The Vehicle Identification (VID) block was not programmed correctly during PCM replacement.

Recommendation: Ensure the VID block is programmed correctly during PCM replacement. Failure to do so may generate fault codes P1639 (VID Block Not Programmed or is Corrupt) or P1635 (Tire/Axle Out of Acceptable Range).

Effective Date: 11/18/2002

02-22-01: Driveability - Surge/Rolling Idle - Poor Fuel Economy - Diagnostic Trouble Codes (DTCS) P1336, P1309, P0340 - MIL

Applies to: 1994-2003 Various Vehicles

Issue: Poor fuel economy, DTCs P1336, P1309, P0340 with MIL on, loss of power, surge, hesitation, and rough acceleration due to incorrectly installed gear-driven Camshaft Position (CMP) sensor synchronizer assemblies.

Recommendation: New diagnostics have been developed for WDS to diagnose incorrectly installed gear-driven CMP sensor synchronizer assemblies.

Effective Date: 10/29/2002

01-21-13: Driveability - Electrical - Sticking or Binding Ignition Lock Cylinder - High Effort When Turning Ignition Switch - Diagnostic Trouble Codes (DTC) P0500, P1502 and/or U1039

Applies to: Some Vehicles

Issue: Roughness or excessive effort when turning the ignition key from RUN to START, or the key not fully returning from START to RUN, potentially causing intermittent accessory function. On Continental models, a MIL may illuminate with DTCs P0500, P1502, and U1039 stored in the PCM.

Cause: A sticking or binding ignition lock cylinder, possibly due to the key-in-ignition warning chime switch.

Recommendation: Replace the key-in-ignition warning chime switch located on the ignition switch lock cylinder with revised part XL2Z-11A127-AB. Refer to the TSB for details.

Effective Date: 10/24/2001