6.0 PowerStroke and TorqShift Bulletins

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Updated: 6-4-08

Customer Satisfaction Programs 08B02 and 48B01; Deductible Reimbursment:
Ford has released two customer satisfaction recalls for the 7.3 and 6.0 PowerStrokes. Owners of some 2002-2005 trucks and vans that had fuel injectors replaced between January 2003 and September 2007 in California and other "green states" were mistakenly charge the $100.00 deductible for the PowerStroke warranty when their truck was still under that state's emissions warranty (state coverage varies, but is typically 50,000 miles).
If your truck is registered in a state requiring additional emissions coverage, and you had a qualifying repair performed within the above dates, and you or the servicing dealer has the original repair invoice, you may be eligible for a refund of the deductible. If your truck qualifies, the VIN will be flagged on Ford's database as needing FSA 08B02 or 48B01.
You only qualify for a refund if you paid the deductible. Deductibles paid by the dealership or an extended warranty are not eligible.
This program is in effect until November 30, 2008.

2003-07 trucks grabbing brakes, pedal kickback:
This may be caused by power steering fluid contamination in the hydroboost system. There is a procedure for installing a temporary filter between the power steering pump and cooler to clean the system. After the cleaning procedure is complete and no brake grabbing or excessive steering effort is felt, remove and discard the filter. If brake grabbing continues, replace the hydroboost unit. Filter P/N XC3Z-7B155-BA; TSB# 99-25-8, 7-11-10

Factory fuel filter marks:
Starting in May 2006 the primary fuel filter in the frame mounted fuel pump is now marked with an "FF". This mark is present on filters installed at the factory on either the truck or a replacement fuel pump. This will identify filters that have not been replaced at the recommended intervals. Broadcast Message 6953.

Soft/low clutch pedal; Clutch pedal falls and/or stays on floor:
Some 2005-2008 F-SuperDuty trucks with manual transmission may exhibit a variety of clutch pedal concerns. Varify the slave cylinder heat shield at the transmission is in place. The heat shield should be fully installed onto the slave cylinder, with the front edge touching the bellhousing. Broadcast Message 0065.

Belt Noise/Chirp/Squeal on Cold Start-up:
This concern is currently under investigation. Verify that the belt is not frayed and is tracking true, and there are no obvious pulley concerns. If no problems are found, do not attempt a repair at this time. Broadcast Message 7055, SSM 19707.

Intermittent Clunk from TorqShift Transmission:
Trucks equiped with the TorqShift may exhibit a clunk when shifting from drive or reverse to park, from reverse to drive, and/or at the 2-3 upshift. If these conditions are intermittent, it is normal play/backlash in the drivetrain. Broadcast Message 7028, 0215.

2005-07 Bucking/Jerking when Towing:
Trucks that exhibit a bucking/jerking sensation at steady speeds in tow/haul when towing large/heavy gooseneck trailers that typically goes away when the accelerator is completely released or depressed fully, and does not occur when using the cruise control, may be caused by movement of the driver's foot after hitting a bump in the road or triansmission upshift in combination with the particular trailer load. There is a revised computer program to make the computer less sensitive to minute accelerator pedal inputs. If reprogramming does not resolve the issue, the problem may be due to the hitch, the trialer or the loading of the trailer. TSB #07-6-9.

Vibration/Hop at 40-48 MPH, Truucks with Trailer Hitch:
Some 2005-07 F-Super Duty trucks with long wheel base (over 156") may exhibit what is described as a hop on smooth or coarse road surfaces. Although Ford conciders this to be characteristic of trucks with a GVW of over 8500 pouns, some drivers may be more sensitive to the condition. There is a damper kit (P/N 5C3Z-5D008-A) available to correct the hop under the described conditions. It will not correct shimmy, harsh ride or vibration after hitting bumps. TSB #07-5-11.

Lack of Power, Trucks with Steel Tanks:
Some trucks may have a lack of power due to low fuel pressure from a plugged fuel filter or in-tank pickup tube, or restricted fuel lines. This could be caused by the steel tank lining becoming de-laminated/flaking off. If this occurs, the tank will need to be replaced, along with the plugged components. Be aware that using biodiesel with more than 5% concentration (B5) may cause this to happen. The replacement tanks do have a more resistant coating to help prevent this occurance, however Ford still recommends using no higher than B5 biodiesel. Broadcast Message 6865, 7103.

Intercooler Hose Blow-Off; Oil Leaks at Intercooler Hoses:
Some trucks may exhibit oil leakage from the hot side intercooler hoses. If one of the hot side intercooler hoses blow off it will cause the truck to exhibit a low power/low boost condition. Hot side intercooler tubes are no longer available as an assembly. Replacement hoses have a revised inner liner that has adhesive properties. Use the following parts as needed to service the condition:
Short upper hose, equal length elbow: 6C3Z-6C640-C; metal tube: single alternator 6C3Z-6K769-B or dual alternator 6C3Z-6K769-A.
Long upper hose, unequal length elbow: 6C3Z-6C640-A; metal tube: single alternator 5C3Z-6K769-AA or dual alternator 5C3Z-6K769-BA.
Use this hose and tube combination if the hose blows off
Clamps: upper hose 6C2Z-6K786-AA; lower hose to tube 6C3Z-6K786-CA; lower hose to intercooler 6C3Z-6K786-EA.
Lower hose, all: 6C3Z-6C640-B.
Clean the hose mating surfaces to ensure the hoses will stay in place. Seat the hoses completely onto their mounting surfaces before tightening the clamps to 9 ft/lbs. Undamaged hoses may be reused, but they must be cleaned and inspected. If the inside of the hose is blue, it is recommended to apply a thin uniform coating of Motorcraft TA-31 RTV silicone to the mounting surface after cleaning. After reeassembling, allow the silicone to cure for three hours before driving the truck. Test drive the truck while monitoring the boost pressures, which should be 22-25 PSI. An overboost condition will cause the hose to blow off.
TSB 07-5-15.
On 2004/05 trucks that exhibit the cold side hose/pipe blowing off at the intake manifold, replace the plastic tube with part #6C3Z-6C640-AA as in recall 05B29 (trucks built from 12-15-03 to 4-1-04), or repair as in TSB # 05-22-3 (trucks built from 4-1-05). Clean the intercooler and intake flange with brake parts cleaner. Seat the hose/pipe onto the intake manifold and torque the clamp to 9 ft/lbs (12 NM). Broadcast Message 1329, TSB 04-20-9, TSB 05-22-3.

White Smoke, Lack of Power, Exhaust Odor, Surge, Runs Rough, or No Start:
The above symptoms on trucks equiped with the 6.0 when the engine is cold may indicate a sticking injector spool valve. To reduce the likelyhood of this condition, there is a revised program available for the Fuel Injection Control Module. This new program uses the injector spool valve solenoids to preheat the oil at the injectors. The diagnostic computer has to be at version 47.8 or higher, or 48.2 or higher to upload this new program. The new program supercedes TSB #06-2-13, which caused the injectors to actuate (buzz) for 30 seconds after the engine is shut off. With this program the injectors will no longer buzz on shut-down.
TSB #07-5-4
This supercedes TSB 06-2-13, which advises the above conditions may be related to poor oil maintenance practices. However, the programming mentioned in the current bulletin does not obviate the need to perform oil changes at the recommended intervals.

2005-07 4X2 Front Wheel Bearing Noise:
Trucks built before 7-21-06 may exhibit front wheel bearing noise, resulting from debris entering the bearings. Replace the front wheel bearings and assciated parts as needed. Install revised dust shields to reduce contamination: 7C3Z-2B159-A (LH) and -B (RH). TSB #06-16-2.

Clunk or Pop from TorqShift at 2-3 MPH, 2003-07:
A clunk or pop may be heard or felt on drive away after starting the engine, backing up and shifting to drive, usually around 2-3 MPH. This condition may be intermittent. It is the result of normal backlash (movement) between the splines on the low/reverse one-way clutch. Broadcast Message 5904

Check Engine Light on with P0460 Fuel Level Sensor Code:
This may be caused by a miscommunication of fuel level ststus between the instrument cluster and engine computer. This code is set when the engine computer does not see the fuel level dropping it expects. It may be caused by customer-installed items, such as a remote start system that does not power the dash when activated, an over-sized fuel tank or in-bed fuel tank. If these conditions do not exsist, the engine computer should be reprogrammed using WDS/IDS version 43.4 or higher. This condition can also be caused by fueling with the engine running, parking on an angle, or driving up a long grade. In some cases the fuel level sender may be faulty, or have a sulfur build up on the sender and have code P463(use Chevron Techron Plus Concentrate to correct). TSB 06-13-11

Check Engine Light on with Accelerator Pedal Codes: 2005-06 Econolines and 2006-2007 F-Series built through 6-12-06 may exhibit the check engine light on with codes P2138, 2139, and 2140. The engine computer should be reprogrammed with WDS/IDS versions 43.4 or higher to correct false setting of these codes. TSB 06-13-10, 06-22-9

Shudder on Turns, F450/550:
Trucks built with the S-110, 130, 135, or 150 DANA axle and TrueTrac limited slip may have a shudder when making tight turns. This is a typical condition that may be due to tire circumfrance difference side to side, vehicle load and distribution of weight, higher gear ratio, or high lubricant temperature. Adding friction modifier will not correct this condition, as the TrueTrac uses parallel worm gears and not friction clutches. Broadcast Message 5751.

Mercon V Use in Mercon Transmissions:
Effective 6-29-4, Ford is discontinuing Mercon ATF licensing and manufacturing. Mercon V is now approved for use in all transmissions specifying Mercon. This includes both the E4OD and 4R100 automatics (but not the 5R110 TorqShift), and the ZF six-speed manual, as well as the transfer cases. Once exsisting stocks of Mercon is depleted it will no longer be available. Transmissions that specify Mercon V should still use only that fluid. The ZF five-speed will still use synthetic Mercon, and the TorqShift still uses Mercon SP. TSB 06-14-4

2003/04 Computer Programming Recall 06E17:
Truck built before 9-29-03 are being recalled to have the computer reprogrammed. The reason for this recall is to correct fuel injection timing during cold operation, EGR valve control, lack of power, check engine light illumination (P02263 or P0299), hard starting and rough running concerns related to Exhaust BackPressure sensor corrosion. Other symptoms not listed in this recall, but which could occur, would be excessive smoke, turbo control and surging at idle or cruise. The new update eliminates the EBP sensor input to the computer. The exhaust backpressure will now be inferred/calculated using other sensor signals. Trucks should be reprogrammed using versions 41.8 or 42.1 or higher.
After this reprogramming, the truck should be test driven, the computer checked for a codes and the codes cleared (even if none are present), the key cycled on for five seconds, then turned off twice, then the engine started and allowed to idle for 5 minutes at operating temperature to allow the computer to relearn the EGR valve closed position value. This is to prevent erronious codes or driveability sysmptoms related to the EGR valve an turbo performance. Broadcast Messages 5452, 5529.
You should notice an increase in turbo cycling closed/whistling at idle and at stops. This is normal, and is to help keep the variable vanes from sticking.

2005-07 F-SuperDuty/Excursion No-Start, High Pressure Oil System Leak:
Some trucks may develop an oil leak at the high pressure oil pump outlet fitting. This will cause a no-start condition as the computer needs to see at least 500 PSI before it will activate the injectors. In some cases the no-start will be intermittent and/or an intermittent stall with no codes will occur. If high pressure oil leak diagnosis indicates a leak at the pump, the pump outlet fitting (W301727) and the discharge tube block should be replaced with fitting and bracket kit 4C3Z-9B246-A. Do not torque the outlet fitting beyond 38 ft/lbs. If the leak is traced to the branch tube running through the engine block, replace with P/N 5C3Z9J332-B (requires removal of the transmission, flywheel and rear engine cover; new flywheel bolts required). TSB 06-14-6.
The following bulletin may be related:
Metal Tapping Noise from Rear of Engine:
Excursions built after 1-10-05 and 2005/06 F-SuperDuty may have a metal tapping noise from the rear of the engine on decel or light acceleration, or under loads when the high oil pressure is at higher levels. This may be due to a damaged/improperly fitting HP oil pump output quick connect fitting. To diagnose, you will need a scan tool with active command capability. Command the IRP duty cycle to 45% and listen at the high pressure oil pump cover with a stethescope as the engine speed is increased to 2800 RPM. If the noise is louder on the pump cover than on other parts of the engine, the pump cover will need to come off to inspect and replace the fitting. Broadcast Message 5511.

2003-06 EGR Code P0404:
Some vehicles may store EGR control performance code P0404. This occurs when the difference between commanded and actual EGR valve position is more than 10% for 10-15 seconds. This can be caused by voltage drop on the EGR control circuits, a sticking EGR valve, or excessive exhaust backpressure. Diagnose by checking for and addressing other codes. Perform the EGR valve active command test. If the valve passes the test, check for excessive exhaust backpressure from plugged exhaust system or sticking VGT vanes. Broadcast Message 5468.

Cylinder Contribution Codes, 2003-06 F-SuperDuty and Excursion:
For trucks with codes P0263, 266, 269, 272, 275, 278, 281 or 284 for cylinder contribution (misfire), there are new diagnsotic steps available in the on-line PC/ED manual. Broadcast Message 5528.

2005/06 F-Series Front Suspension Bottoms Out:
Some trucks may bottom out on the rubber jounce bumpers and/or make a banging/clunking noise. This condition is typically worse cold and more noticable on bumps or rough roads. There are new jounce bumpers (5C3Z-3020-DA)and larger metal cups (5C3Z-3A089-BA) to correct this problem. Install new self tapping screws (N802455-S426) to retain the metal cups.
TSB 06-6-6

Coolant Expelling From Degas Bottle:
Trucks built with the 6.0 PowerStroke engine may exhibit coolant loss, low coolant, or coolant blowing out of the degas bottle. First, ensure the coolant level is not too high and the expulsion is not due to normal expansion. The coolant level in the bottle at normal operating temperature should be at the MIN mark. 2005 trucks should be checked to see if recall 05B32 applies to them.
The coolant bottle cap should be checked to see if it is capable of holding 16 PSI, and it is sealing properly on the coolant bottle. Pressure test the cooling system to verify there are no leaks. Note: It is advised to either disconnect the right exhaust manifold from the right side turbo Y-pipe, or to raise the rear of the vehicle and remove the EGR valve to check for an EGR cooler leak. Failure to do so may result in a hydralically-locked cylinder. Repair any leaks as necessary.
Inspect the coolant for oil, which would indicate a leaking oil cooler. Check the engine oil sensor reading against the coolant temp sensor. An EOT that is 25 degrees higher may indicate a failed oil cooler. On Econolines, if the engine oil cooler is replaced, the heater core inlet hose should be replaced with part 5C2Z-18472-AA, which includes an internal restrictor. If oil is present in the cooling system, the system will have to be cleaned using a solution of 1/2 cup low-sudsing liquid dishasher detergent to six gallons of water, possibly up to three times. Flush the system afterwards with clean water.
If the coolant expulsion occurs under high load conditions, suspect head gaskets that are leaking compression into the cooling system. It may be necessary to test drive the truck with a pressure gauge TEE'd into a hose and the cooling system sealed so it will not vent to verify over-pressure. When replacing the head gaskets, it is necessary to install new head bolts--they are not reusable. There is a revised torque sequence and specification for the head bolts. The head gasket kits have been revised to include parts needed in the service, but the gaskets themselves are not updated. Recommend using kit 5C3Z-6079-B, which includes all parts for both sides of the engine and covers 2003-2005. You will have to purchase the two intake manifold to head gaskets, oil filter, oil filter base o-ring, oil vent tube o-ring and heater pipe to timing cover o-ring seperately. Note: The turbo should be checked for sticking/overboost to prevent reoccurance of the head gaskets blowing.
TSB 06-3-8.

2003-2005 6.0 Water In Fuel Lamp Illuminated:
Some trucks may exhibit a water in fuel lamp that continues to illuminate after draining the water separator, or a flickering water in fuel lamp. This may be due to sedimate build up in the water reservoir or a computer calibration issue. Check the electrical connections at the fuel pump assembly for damage or corrosion. If the harness is damaged, repair or replace it as needed. There is a jumper harness available, part number 6C3Z-9F759-A*. Remove and fuel manifold from the fuel pump and inspect for debirs inside, and clean as needed. If the sensors inside the manifold ot the sensor pins are corroded, replace the WIF sensro (fuel manifold) with kit 6C3Z-9C264-A*.
*The fuel filter heater has been deleted from the fuel manifold. When installing the updated harness or manifold, also remove the fuel heater fuse (2003/04, 30 amp fuse #105 under the dash; 2005, 30 amp fuse #7 under the hood). If the light is on intermittently or flickers, or will only go out if the computer stored codes are cleared, the computer may need to reprogrammed.
TSB# 06-6-5, 06-22-5; Broadcast Message 4968.

Emergency Use of Off Road Fuel:
The EPA has issued a temporary waiver for the use of high-sulfur off road diesel fuel in vehicles being driven on the road in some areas of the US. This is in response to shortages resulting from hurricanes Katrina and Rita. Using high sulfur fuels (over 500 ppm sulfur) can cause engine damage. It is recommended that oil change intervals be shortened by 50 percent (mileage or operating hours)when high sulfur fuel is being used to help prevent damage. Broadcast Message 4952/53.

99-06 F-SuperDuty Lack of Power/Low Fuel Pressure:
Some vehicles with steel fuel tanks may exhibit the above conditions due to the lining/sealer inside the fuel tank coming delaminated and plugging the pickup screen or fuel filter, or damaging the fuel pump. It is suspected that using gasolines or additives containing ethanol, methanol, ketones, or biodiesels higher than 5% is causing this to occur. Broadcast Message 5076.
I have seen this occur in an Econoline that filled from various fuel stations, so in this case fuel should not have been a cause.

Coking (carbon) Deposits in Turbo and/or EGR Valve:
Coking deposits are usually a build up of unburned fuel or oil in the exhaust system and related components (valves, turbo, EGR valve). This can be caused by poor fuel quality, overfueling/leaking injectors, idling for excessive periods of time (especially in cold ambient temperatures), low engine operating temperatures, injection timing (calibration) or oil consumption. Unburned fuel usually appears as white smoke, but over time the coking condition can result in excessive black smoke. Coking depositis can plug the EBP sensor tube, foul the EBP sensor, cause the EGR valve to stick open, block the EGR cooler, plug the MAP (boost) sensor hose, or cause the variable turbo vanes to stick open (no power/boost) or closed (excessive backpressure, black smoke, popping noise, bucking). The cause of the coking issue should be identified before replacing parts to prevent reoccurance. If poor fuel is suspected, use Stanadyne Performance or Motorcraft PM-17-A Cetane Boost. TSB 06-4-12, 06-23-16.

Exhaust Smoke/Smell, Harsh Transmission Shifts, 2005/06:
2005/06 F-SuperDuty and Econolines built before 12-5-05, and 05 Excursions built before 1-10-05, may exhibit excessive exhaust smoke with complaints of increased odors while operating in high idle (PTO, charge protection or cold idle mode), as well as harsh tow/haul 3-2 downshifts while slowing down grade under load, or tow/haul 5-2 downshifts, shift hunting in normal or tow/haul mode, or late 5-6 shift in tow/haul. The computer should be reprogrammed with calibrations included in release B39.15 or higher, or B40.2 or higher.
TSB #06-2-4.

RECALL 05E15 REVISED 1-10-06
Now included are certain 2004 and 2005 trucks built after 6-1-04. All trucks effected by this recall will now be reprogrammed using WDS version 40.7 or higher, or 41.1 or higher.
2004/05 Emissions and EBP Sensor Recall 05E15:
Certain 2004 and 2005 trucks are being recalled for computer reprogramming and replacment of the Exhaust BackPressure sensor and, in some cases, the EBP sensor connector. Econolines built between 12-9-03 through 5-28-04, and SuperDuties and Excursions built between 12-1-03 through 5-31-04 will have the EBP sensor connector replaced. SuperDuties and Excursions built between 9-29-03 through 11-30-03, or between 6-1-04 through 1-18-05, and Econolines built from 6-1-04 through 3-3-05 do not have the connector replaced. All of the above trucks will be reprogrammed to the latest calibration level. Since many trucks ahave already had the EBP sensor replaced with the current level part, the sensor part number should be inspected. If the part number on the sensor is 1850353 over a number starting with "C1", the sensor does not need to be replaced. Any other numbers, or unreadable numbers, will be replaced.

2004-2006 Vehicle Computer Reprogramming Recalls 05E16 and 05B35:
Under 05E16, certain 2005/06 E350's built from 3-4-05 through 8-7-05, 2005 Excursions built from 1-19-05 through 9-30-05, and 2005/06 F250/350's built from 1-19-05 through 7-31-05, as well as trucks reprogrammed under 05E15 with WDS version B36.10 through 38.8 between 7-5-05 and 7-18-05(prior to suspension of the recall in July, 2005), will have their computer's reprogrammed due to the programming information being incomplete. Additionally, certain E350/450's built between 3-4-05 and 8-7-05, and F250/350/450/550's built between 1-19-05 and 7-31-05 will be recalled for reprogramming under 05B35. There is no time limit on 05E16, however, 05B35 is only in affect until 1-7-07.

2005 F-SuperDuty and Excursion Coolant Bottle Recall 05B32:
All 2005 model/year trucks built at the Kentucky truck plant have coolant bottles on which the fill marks are positioned incorrectly, potentially resulting in the bottles being over filled, which may result in coolant being expelled from the bottle cap under normal expansion or aeration. Under this recall, labels will be afixed to the bottles showing the correct cold fill range. This recall will be in affect until 12-31-08.

Cold Temperature Lack of Power, Poor Economy, Hard Start, Excessive White Smoke, or Coking (carboning) of Turbo, EGR System or EBP:
This could be due to gelling of the fuel, formation of ice in the fuel tanks or lines or poor fuel quality. If diagnosis finds no cause for the above symptoms, try using a fuel conditioner, such as Stanadyne Performance Formula or equivalent, such as Motorcraft PM-22-A or -B (cetane boost), or PM-23-A or -B (anti-gell/cetane boost), that will improve the cetane level and lower the gell point of the fuel. Do not use any product containing alcohol. If the conditions improve with the additive, then find another fuel source or continue to treat the fuel. Broadcast Message 1309, 1464, 5113, 6875; SSM #17406.

Oil Leak from Rear of Engine Area: Stuck/bouncing Speedo and/or Tach, 2006 Trucks Built Before 1-26-06:
Before diagnosing the instrument cluster for this issue, first check for codes stored in the ABS module or engine computer. If there are no relivent codes, check the vehicle speed input to the cluster while stopped. If the input and the displayed speed do not match, drive the vehicle and monitor the speedometer at 0, 20, 40 and 60 MPH as indicated on the scan tool. If the speedometer is off by more than 5 MPH, replace the cluster. If the speedometer display matches the sensor input, diagnose the ABS rear axle speed sensor and wiring, and the ABS module wiring. For tachomater concerns, check the RPM signal in the engine computer against the tach reading at 1000 and 2000 RPM. If the display is more than 250 RPM off, replace the cluster. Broadcast Message 5165, TSB 06-7-4.

Recall 05B27--2005 TorqShift Transmissions, Trucks with Snow Plow Package:
On trucks built prior to 1-12-05, the snap ring on the low/reverse planetary may become dislodged due to the frequent forward/reverse shifting common when plowing snow. If this occurs, damage to the low/reverse planetary or transmission case may occur. Ford will disassemble the transmission, inspect for damage, and replace the snap ring with a revised part, if no other damage is found. This recall has been extended to 9-30-06, regardless of mileage.

04-06 Econoline Poor A/C Cooling/Compressor Failure:
Failure of the A/C compressor may be due to high side system pressures resulting from insufficient air flow across the condenser at idle and low speeds. A revised cooling fan clutch is available to improve air flow and prevent compressor failure. P/N 4C3Z-8A616-SA.
TSB #05-19-3. Vans built through 1-17-06 should have the engine computer reprogrammed using WDS/IDS version 39.15 or higher, or 40.2 or higher. TSB # 05-23-16

Long Cranking Times at Factory Delivery or After HP Oil System Repair:
If a 6.0 cranks for longer than 2.5 seconds in temperatures above 32 degrees it may be due to air trapped in the HP oil system. To purge the air, drive the truck through 12 hard accelerations from 25-50 MPH. Turn off the engine and allow the truck to sit for 5 minutes. Restart the engine to see if crank time has improved. Crank times of 3-5 seconds in cold temperatures should be considered normal.
TSB #05-19-14.

6.0 Oil Pan Corrosion:
Some engines may exhibit oil pan corrosion if operatted in high salt enviroments. If corrosion is found, the pan should be cleaned of oil and dirt, sanded and cleaned. Apply Motorcraft PM-13-A High Temp Anti-corrosion Coating to the pan. TSB #05-20-3

2002-2006 Battery Terminal Bolt Broken or Corroded:
Trucks with the stamped metal battery terminals no longer require replacement of the cable if only the terminal bolt fails. The bolt (P/N 5C3Z-10756-A) and nut (5C3Z-18865-A) are now available to service this condition.
TSB #05-20-1

Broken EGR Valve Connector:
If the connector at the EGR valve breaks, it is no longer necessary to replace the entire engine harness to repair. The connector (P/N 5C3Z-14A411-A) is now available. Braodcast Message 4819.

6.0 Moan/Droan Between 1500-2000 RPM:
Engineering has investigated this condition and found the cause to be engine firing pulses causing the turbo mounts to vibrate/resonate. For trucks built through 9-29-03 install a revised turbo pedestal, P/N 3C3Z-6N639-BA. Trucks built after 9-29-03, install a turbo bracket A-brace, P/N 5C3Z-6N639-BA. If the draon is still present after installing the brace on trucks built from 9-30-03 through 1-17-05, replace the turbo pedestal with 5C3Z-6N639-AA. Ensure the droan is not caused by a bound exhaust system. Inspect for any damaged or broken exhaust hangers. Check the turbo downpipe by loosening the pipe at the top and bottom, checking its alignment and retightening. If the droan is still present, check the part number embossed on the turbo pedestal just below the turbo compressor outlet to the intercooler. If the number IS NOT 1846207C1, replace the pedestal with the above part. After replacement, or if the number IS 1846207C1, loosen the turbo inlet pipes and EGR cooler flange and neutralize by installing the components in this order: snug the flange between the LH and RH inlet pipes; torque the EGR cooler clamp to 53 in/lbs; torque the pedestal bolts to 23 ft/lbs; torque the turbo inlet clamp to 9 ft/lbs: snug the inlet pipes to manifolds. Ensure all components are properly aligned. Torque the flange between the LH and RH inlet pipes to 20 ft/lbs and the inlet pipes to the manifolds to 20 ft/lbs. Broadcast Message 0992, SSM 17530, TSB #04-9-4 & 05-19-12.

Flutter Noise on Deceleration:
Some 03-06 trucks may exhibit a fluttering noise from the air filter assambly on deceleration. This is a characteristic of the engine and posses no problems with the engine or turbo. No repair should be attempted. Broadcast Messages 1046, 4818
This condition should be intermittent and typically occurs when the accelerator is quickly released after a hard acceleration. If the flutter occurs at every deceleration, under load or at upshift on acceleration, suspect a sticking VGTurbo actuator or turbo vane ring.

2004/05 Trucks with False EGR codes and/or Harsh Shifts/Gear Engagements:
Pickups built after 9-29-03 and Excursions built between 9-29-03 through 1-10-05 may exhibit EGR codes P0488 or P1334 with no driveability symptoms, harsh 3-2 downshifts in Tow/Haul, harsh 3-5 or 5-6 upshifts, or smoking during elevated idle operation. Additionally, 04 Econolines may also exhibit EGR surging (change in engine noise level), idle surge and low power, smoking, and rough idle following a cold start that corrects at operating temperature. To correct these conditions, the computer should be reprogrammed with WDS version 38.9 or 39.1 or higher (not version 39).
F-Series/Excursions: TSB 05-17-16.
Econolines: TSB 05-18-5.

6.0 Oil Recommendations:
Some trucks with the 6.0 may exhibit hard starting, rough running and lack of power in cold temperatures, particularly on a cold start. This may be due to the oil being to thick for the operating conditions. Ford is recommending to use the following oils for the listed operating temperature.

  • SAE 15W-40 is the preferred oil above 30 degrees, but it is acceptable for use down to 10 degrees, and is recommended for towing down to this temperature.
  • SAE 10W-30 is the preferred weight between -10 to 30 degrees.
  • SAE 5W-30 and 5W-40 is acceptable for use below 30 degrees, and 0W-30 is acceptable below zero.
    (All temperatures are in Fahrenheit.)
    The oil used should meet Ford's specification of WSS-M2C171-D or API CI-4 PLUS, CI-4/SL or DHD-1. CH-4 is acceptable for use if CI-4 PLUS is not available. TSB #05-16-6.
    Keep in mind that CI-4 oil is designed for the increased soot contamination and higher coolant temperatures of cooled EGR systems on a diesel; CH-4 is not.
    Nowhere does the TSB mention synthetic versus conventional oil recomendations or ranges.
    Ford has not released anything recommending NOT to use a specific brand of oil.

    05 6.0 PowerStroke HP Oil Leak at Injectors:
    Some vehicles may exhibit a hard or no start with low ICP pressure readings. Remove the valve covers and inspect for oil leakage where the oil rail installs onto the injectors. If leakage is found the affected injector should be replaced. Inspect for a missing oil inlet o-ring or spring clip. If these parts are missing, they will need to be located or engine dmage will result. Look inside the rocker carrier on top of the heads, in the oil pan and on the oil pick up screen. If the missing parts are not in these locations, remove the lube oil pump and regulator and inspect. Broadcast Message 3862, 4582, 5019.

    2005/06 A/C or Ventilation Control Problems:
    Trucks built between 9-15-04 to 6-8-05 may blow air out of the defrost vents with the mode selector in other positions. The vacuum pump may also run excessivly. Lower the glove box and inspect the vacuum lines to see if they are wraped around the panel/floor door actuator rod. If the hoses are wraped around the rod, inspect for damage to the hoses. If the hoses cannot be repaired, replace them with part number 5C3Z-19D699-AA for automatic temp control or 5C3Z-19D699-BA for manual climate control.
    TSB 05-14-9.

    Discontinued Dual Mass Flywheel:
    2003-2004 trucks built before 12-1-03 with the 6.0 engine and 6 speed transmission and equipped with a dual mass flywheel, the flywheel is no longer available. If the flywheel needs replacement, use the single mass flywheel and clutch assembly for latewr models. Broadcast Message 4476.

    Serpentine Belt Fraying/Shredding/Broken:
    Trucks built prior to 1-1-2005 that exhibit this problem should have the water pump pulley and serpentine belt replaced. On trucks with dual alternators, this is for the inner main belt--the outer secondary belt is not replaced. TSB 05-13-16.
    Water pump pulley: 5C3Z-8509-A
    SuperDuty single alternator belt: 3C3Z-8620-DB
    SuperDuty dual alternator belt: 3C3Z-8620-BC
    Econoline single alternator belt: 3C3Z-8620-AB
    Econoline dual alternator belt: 3C3Z-8620-BB
    Excursion belt: 3C7Z-8620-AC

    Light Surge after Turbo Replacement:
    2004-2006 engines that exhibit a light surge on light acceleration up to 50 MPH, typically after a cold start, at steady speeds between 1800-2800, or when climbing a grade (towing or not), may have a sticking Variable Geometry Turbo actuator. If diagnosis leads to replacement of the VGT actuator, the turbo lube oil line--P/N 3C3Z-9T516-BA; should be replace as well. Broadcast Message 4459, TSB 05-21-5.

    Lack of Power After Turbo Replacement:
    When replacing a turbo for a lack of power and/or excessive smoke/oil consumption, inspect the turbine housing for the presence of the turbine wheel. If the turbine wheel shears off it will drop into the downpipe and cause a lack of power, possibly along with trouble codes P2263 (03/early 04) or P0299 (04.25-up). Broadcast Message 4449.

    Exhaust Smell in Cab:
    If an exhaust smell is present in the cab, inspect for leaks at the exhaust manifolds. Ford's procedure calls for warming up the truck to operating temperature, then shutting off the engine, remove the EBP sensor and use a smoke machine to feed smoke into the exhaust system. Inspect each exhaust port, manifold flange and Y-pipe joint for smoke leakage. I find using a length of hose as a stethyscope while the engine is running works well to pinpoint exhaust leaks. If a leak is found at the exhaust manifold, replace only the manifold gasket that is leaking(I think this should read INSTALL a gasket, since originally there are no gaskets at the manifolds). Gasket P/N 5C4Z-9448-A.
    TSB 05-13-9.

    Cylinder Head Revision:
    Engines built after 3-30-05, and current service replacement heads, will no longer have threaded holes for the rocker carrier bolts. The 8 MM bolts were only utilized for factory assembly. The rocker carriers are retained to the heads by the head bolts. The original carriers may be reused with the new style heads. SSM 18676.

    Engine Block and Upper Oil Pan Revision:
    Engines built after 9-29-03 no longer have the six center mounting bolts for the aluminum upper oil pan/windage tray. The upper oil pan casting has been redesigned to eliminate the need for these bolts. Upper oil pans with these bolt holes should have bolts installed to prevent nooise from vibrations. New style upper oil pans can be used on older blocks, but older upper pans cannot be used on newer blocks. Broadcast Message 4357.

    Installing Upfitter Switches on 05/06 F-Series:
    To install upfitter switches on trucks not originally equiped with them, purchase wiring harness part number 5C3Z-14A303-AA, switch assembly 5C3Z-13D730-AAA, and, if the truck does not have the TowCommand trailer brake controller, utility box 5C3Z-2513546-CAA. Installtion instructions can be found HERE.
    Broadcast Message 4400, 4977

    Safety Recall 05S34, 2004 F-SuperDuty, Excursion and Econoline:
    Affected vehicles are 2004 F-SuperDuty/Excursions built between 9-29-03 and 5-31-04, and Econolines built between 12-9-03 and 5-28-04. On all F-SuperDuties/Excusrsion the FICM harness will be inspected for chafing/damage. If damage is found, the harness will need to be replaced (estimated less than 2% of vehicles will require this action). If no damage is found a harness protection kit will be installed. On these trucks built between 12-1-03 to 5-31-04 the ICP sensor connector will be replaced due to the possibility of a poor crimp on the factory connector terminals. The Econolines covered under this recall only get a replacement ICP sensor connector.
    Revised 7-6-05: The F-Seires and Excursions will have the FICM harness part number inspected. If the harness has a tag with "C97" on it, no FICM harness repair is necessary.

    Customer Satisfaction Program 05B29, 2004 F-SuperDuty and Excursion:
    Trucks built between 12-15-03 and 3-31-04 with the plastic cold side intercooler tube with worm gear clamps (tubes marked "9 NM") are being recalled for replacement of the cold side tube. The replacement is an aluminized steel tube with silicone hose ends and T-bolt clamps, part number 6C3Z-6C640-AA. This recall will be in effect until 7-31-06, regardless of mileage.
    2004/05 Trucks:
    The recall does not apply to trucks built after 3-31-04 with the plastic tube and T-bolt clamps (marked "12 NM"). These trucks are covered by TSB #05-22-3. If the plastic duct on these trucks blows off, and the tube is undamaged, first reinstall the plastic along with a reinforcing ring. Position the ring over the duct and under the clamp, with the gap opposite the bolt on the clamp. If the clamp is broken or missing, replace it with p/n 1C3Z-6K786-BA. Clean all parts before reassmbly. If the duct continues to blow off or was damaged, replace it with hose and tube assembly 6C3Z-6C640-AA.

    2005 High Pressure Oil System Leak:
    Some 2005 SuperDuties and Excursions built after 1-10-05 may experience symptoms related to high pressure oil system leakage, most commonly a hard/no start when the engine is warm. If diagnosis indicates a leak at the HP oil pump, inspect the pump quick connect fitting. If the leak is at the fitting o-ring, replace the fitting with P/N W301727. Broadcast Message 4320, 4932.

    2000-2005 E-450 Rear Caliper Kits:
    There is now a rear caliper kit available for the 2000-2005 E-450. The calipers may now be overhauled instead of replaced. Kit # 4C3Z-2120-A contains two dust boots, two caliper seals and an instruction sheet. Broadcast Message 4316.

    Water in After Axle Fuel Tank, 99-06 Cab and Chassis:
    Water present in the 40 gallon rear fuel tank on trucks with 7.3 or 6.0 PowerStroke engines may be due to snow and ice accumulating on top of the tank. As the snow and ice melts, the water may be drawn into the "mushroom" fuel tank vent cap. The original vent cap should be replaced with a vent line kit, P/N 5C3Z-9S327-A. The kit comes with a hose, which should be routed to the crossmember forward of the fuel tank, and a new vent cap. The vent cap should be positioned horizontally to prevnt moisture from collecting in it.
    TSB 05-13-7

    2005 Clutch System:
    If any component in the hydraulic clutch system--master cylinder, line or slave cylinder; needs to be replaced, the entire system should be replaced as an assembly. Broadcast Message 4247.

    2005 High Pressure Oil System Test Adapter:
    Pickups and vans built after 11-4-04 and Excursions built after 1-10-05 have a revised standpipe and retaining plug. Trucks built after 9-29-03 that have had the heads removed may also have the revised standpipe as it is included in the head gasket kit. Pressure test adapter 303-1163 is now available to test the high pressure system on these engines. Broadcast Message 4246.

    2004 SuperDuty and Excursions built after 9-29-03, EGR Throttle Valve Concerns:
    Some trucks may exhibit an intermittent crank/no start concern. EGR throttle valve position codes P0488 or P1334 may also be present. Visually inspect the EGR throttle valve under the intake elbow to verify it is not stuck closed. Normal operation is for the valve to cycled closed, then open when the key is turned on. Broadcast Message 4235.
    Trucks reprogrammed with WDS version B36.10 and higher may set P0488 and/or P1334 for the EGR throttle valve position sensor. Engineering is investigating this problem. If normal diagnosis does not show a faulty component, do not attempt a repair at this time. Broadcast Message 4245, 4544.

    2005 Front Crankshaft Seal Leak:
    Some trucks built between 12-15-04 and 1-25-05 may develop a leak at the front crank seal. This leak may appear to be coming from the oil regulator plug at the bottom of the timing cover. Florescent dye should be added to the engine oil. Trace the leak with a black light with the crank pulley removed to verify to source of the leak. Braodcast message 4217. This should be applied to all 6.0's with oil leaks that appear to come from the pressure regulator.

    2005 F-450/550 Rear Axle Hub Seal Leak, Dana S-110:
    Rear axles built in Brazil (check housing tag) between 5-1-04 and 2-28-05 (serial numbers HN01297868-HN01775113, on carrier tag) may leak gear lube from the axle hub seal. To correct, remove the axle hubs and replace the seals. On the axle housing, clean grease and dirt from the seal journal. Apply a bead of Loctite 680 to the full circumfrance of the seal journal and install a seal sleeve onto the journal. The kit(5C3Z-1S175-BA) includes sleeves for both sides of the axle housing and a tool to install the sleeves.
    TSB 05-12-4

    2005 Trucks, Crank/No Start, Hard Start, Runs Runs Rough at Idle:
    Pickups and vans built before 4-15-05 and Excursions built between 1-10 and 4-15-05 may exhibit hard or no start conditions with a low ICP signal, or a rough idle with a high ICP signal. This may be due to a damaged high pressure oil pump and/or IPR valve. The IPR valve should be removed (mounted on HPP cover under the turbo) and inspected for a damaged inlet screen or debris on over half the screen. If either condition is present, the IPR (5C3Z-9C968-CA) and the high pressure oil pump (5C3Z-9A543-AA) should be replaced, along with the oil and oil filter. If neither condition is present, continue with normal diagnosis. If a rough idle is present after replacing the above parts, injector damage may have occured.
    TSB 50-12-3.

    2005 Stall When Engaging Drive or Reverse, or at Stops, TorqShift Only:
    Trucks built between 10-1 and 11-30-04 may exhibit a stall under the above conditions, along with various shift solenoid codes. This may be due to a sticking torque converter control solenoid. The transmission pan should be cleaned out, the TCC solenoid (3C3Z-7J136-BA) and external fluid filter replaced, and the cooler flushed and flow checked. TSB 05-12-1.
    NOTE: These conditions may occur on vehicles outside of the build dates above. However, the same repair applies, although the solenoid part number may be different.

    Various Electronic and Driveability Symptoms and Codes:
    2005 F-Super Duty trucks built before 5-11-05 may exhibit various electronic-related symptoms due to loose/miss-installed fuses in the engine compartment fuse box. These symptoms may be intermittent. The fuses should be inspected to verify they are installed into the terminals in the fuse box and not along side the terminals.
    Fuses--Symptoms
    #9, 20 amp: Trailer turn signals inoperative
    #10, 10 amp: Check Engine Light; Codes P1633, P0446
    #11, 10 amp: Speedo bounce, ABS light, Cruise control inop; Codes U1900, U2023, P0500-P0503
    #12, 2 amp: Cruise control inop, TBC Fault displayed, chime; Code C2803
    #13, 15 amp: Day time running lamps inop
    #15, 15 amp: Crank/no start, bucking, stall; Codes P2614, P2617, P1378
    #17, 10 amp: A/C inop or not cooling
    #18, 10 amp: Crank/no start, bucking, stall; P2614, P2617, P1378, P0611
    #20, 10 amp: Trailer back up lamp inop
    TSB 05-11-14

    2005 ABS Light On:
    The PCM and ABS moudule need to be checked for codes to determine where to look for the problem:
    For PCM codes P0500-503 with ABS codes, check fuse #11 in the engine compartment fuse box and the ground in front of and below the driver side battery.
    ABS code C1175: Check for wiring damage between the ABS module to the rear axle speed sensor.
    ABS code C1236: Inspect for water or corrosion in the rear axle speed sensor connector. If corrosion is found, replace the connector with part #5C3Z-14S411-AA. If the light comes on when towing or under acceleration, or if no wiring concerns are found, inspect the rear differential for loose bolts or a damaged sensor ring, or excessive air gap between the tone ring and ring gear (greater than 0.010").
    ABS codes C1175 and C1236: Perform the checks listed for C1175 first, then for C1236 if no wiring problems are found.
    TSB 05-11-12

    2003-05 F-Series and Excursion, Various Driveability Concerns:
    Trucks that exhibit surge at idle, changes in engine sound at idle (EGR cycling), low power/smoke/rough idle on cold start that corrects when engine warms up, surge when selecting resume on the cruise control, flutter noise from engine just before transmission kickdown, buck/surge on manual transmission, should be reprogrammed with the latest calibration. This program includes a reduced EGR valve on-time during extended idle.
    2004 Vehicles Built After 9-30-04: Reprogram with WDS with release version B36.10 or higher, or B37.10 or higher, but not version 37.0 to have the correct calibration update. Broadcast Message 4118.
    2003-2004 F-Series and Excursion Built Before 9-30-03: For the above conditions, in addition to diagnostic code P1729, on 03/early 04 trucks, reprogram with WDS version B37.4 or higher. TSB 05-11-05
    2005 F-Series and Excursion: Reprogram with WDS version B37.4 or higher under TSB 05-11-04. Pickups built after 11-4-04 and Excursions built after 1-10-05 may also have white smoke on drive away after being parked for a short period. Additionally, Excursions built before 1-10-05 may also have an illuminated, flickering or intermittent water in fuel light or P0401 diagnostic code.

    Installing TowCommand on 05-07 F-Series:
    There is now a kit available to install TowCommand trailer braking system on trucks that were not originally equiped at the factory. For diesel and all dual rear wheel applications use kit 5C3Z-19H332-BA. For gasoline trucks with single rear wheels use kit 5C3Z-19H332-AA. Broadcast Message 4065, 4643, 4937, 5883.
    If a TowCommand brake controller is dealer installed on an 05 truck, it may not work correctly unless a master cylinder with a brake pressure transducer is installed, and the instrument cluster reconfigured to recognize the TowCommand. Broadcast Message 4642, 4928.

    05 F-Series/Excursion Inaccurate Fuel Level on Low Mileage Trucks:
    Some trucks may have an inaccurate fuel level indicated by the gauge at low miles. This may be due to being transported to the dealership at an angle. It may take driving for up to half a tank of fuel to correct. The gauge may self correct if the batteries are disconnected for a minute, then reconnected, or leaving the key on (engine off) for 15 minutes with the truck parked on a level surface. Broadcast Message 4044.

    05 F450/550 Steering Gear Recall 05S30:
    Certain 2005 F450 and 550 trucks built between 3-9-05 through 3-14-05 are being recalled for a steering gear inspection and, if necessary, replacement. The build date on the steering gear ID tag needs to be inspected for the following date codes: 020305, 030305, 040305 (March 2, 3 or 4, 2005). If any of these date codes are found, the bolt to the right of the steering gear ID tag needs to be checked for a green certification mark. If the above dates are on the tag and there is a green mark on the bolt, or if the above dates are not on the tag, no futher action is required. If the above dates are found with no green mark, the steering gear needs to be replaced with part number 5C3Z-3504-BA. New attaching hardware should be used when installing the replacement steering gear: 3 mounting bolts, W709143-S426; 1 input shaft pinch bolt, N803942-S101; 1 pitman arm nut, W709296-S426; hydraulic line seal N806316-S; cotter pin.

    05 False ABS Activation, ABS Light, Codes:
    Some trucks may exhibit false ABS activation or the ABS light on with codes C1175 or C1236. This may be due to an erratic/missing wheel speed input from the rear axle. The axle cover should be remaove and the speed sensor ring inspected for damage or excessive run-out, loose or damaged differential carrier bearings, sensor connector corrosion, or wiring damage. Broadcast Message 3874.

    05 F450/550 Coil Spring Recall 04B25:
    Some trucks built from 7-27-04 through 11-11-04 with snop plow package may have been built with lighter than specified front coil springs, which could sag over time. Identified vehicles also have an incorrect vehicle certification lable. Ford will replace the affected springs and install a supplimental weight rating lable. This recall is in effect until 3-31-06.

    6.0 PowerStroke Fuel Filter or Oil Filter Housing Leaks:
    The following parts are now available to correct leaks at the fuel filter and oil filter housings:
    Primary (frame) Fuel Filter Housing: 3C3Z-9N180-BA
    Primary Fuel Filter Cap: 3C3Z-9G270-BA
    Primary Fuel Filter O-ring: 3C3Z-9364-BA
    Secondary Fuel/Oil Filter Housing, <9-30-03: 3C3Z-9C166-AA
    Secondary Fuel/Oil Filter Housing, 9-30-03>: 4C3Z-9C166-AA
    Secondary Fuel Filter Cap: 3C3Z-9G270-AA
    Secondary Fuel Filter O-ring: 3C3Z-9364-AA
    Oil Filter Cap, F-Series: 3C3Z-6766-CA
    Oil Filter Cap, Econoline: 4C2Z-6766-BA
    Oil Filter O-ring: 3C3Z-6840-AA
    Broadcast Message 3744, 3743, 4683

    2003-05 Various Running Problems, Check Engine Light; New EBP Sensor:
    Trucks built before 1-17-05 that exhibit buck/jerk, hesitation, lack of power, stalling, stumble, black smoke, surging, rolling idle, changes in engine sound at idle or when driving at a steady speed, or with the trouble codes P2263 or P0299, may have an exhaust backpressure sensor signal that is incorrect or erratic. A revised EBP sensor is available if this is found to be the case. Part number 4C3Z-9J460-A. Broadcast Message 3815.
    Normal EBP signal reading should reflect atmospheric pressure with the key on/ engine off. Typically, this is 14.7 PSI/0.88-0.9 volts at sea level, decreasing one PSI/0.10 volt for every 2000 feet of elevation. It should be within 0.5 PSI of BARO and MAP sensor pressure signals.

    2004 Econoline Heater Core Leak:
    Vans built between 1-20-04 and 5-29-04 with a front heater only may develop a leak at the heater core. Replace the core with part number 4C2Z-18476-AA as well as the inlet hose, P/N 5C2Z-18472-AA, which has an internal flow restrictor.
    TSB 05-2-5.

    E450, Fluid Leak from Transmission-Mounted Parking Brake:
    Vans built from 96-05 that leak ATF from the parking brake assembly may have a leak between the transmission and p.brake that is overfilling the p.brake housing. Drain the excess fluid by removing the p.brake fluid fill plug. Once the fluid level stabilizes, reinstall the plug and check the transmission fluid level, adjusting as needed. Monitor the fluid level in the p.brake housing, and if the level again increases, the p.brake assembly will need to be replaced. Broadcast Message 3684.

    2005 F-Series Speedometer Needle Bounce, Cruise Control Drop Out, DTC P0500, and/or Uncommanded Wiper Activation:
    If any of the above conditions are present, inspect the wiring harness running behind the coolant bottle to the wiper motor for chafing on a brake line clip and shorting to ground. If harness damage is found, repair and insulate the damage, and secure the harness away from the clip. Broadcast Message 3695.

    2004/05 F-Series Manual Transfer Case Jumps Out of 4WD:
    Trucks with automatic transmissions and manual 4X4 may jump out of 4HI to 2WD or 4LO to neutral. Adjust the transfer case shift lever plate--disconnect the shift rod from the transfer case pivot lever; loosen the plate retaining and pivot bolts; move the plate reward and tighten the bolts; place the transfer case into 4HI and move the shift lever to the 4HI position; Hold the shift lever against the shift gate and reconnect the rod to the pivot lever. If the rod and pivot lever pin do not line up, replace the shift bracket assembly (4C3Z-7210-BA) and adjust as above.
    TSB 05-3-6

    Steering Wheel Shimmy After Riding Over Bumps/Ruts:
    Some 05 and 07 F-Series trucks may exhibit an oscillation/shimmy in the steering wheel after hitting bumps or ruts in the road. Typical steering wheel movement is 5 degrees and usually smooths out after about 5 oscillations. This condition is more prevalent on 4X4 trucks with steering wheels that have radio and climate controls. The truck will need to be inspected: tire pressure checked; steering damper inspected (replace with 5C3Z-3E651-D if needed); all suspension and steering fasteners torqued; steering checked for binding; steering gear adjustment checked/adjusted. The caster may need to be reduced by 0.5-0.75 degrees. After this, trucks build prior to 10-8-04 should have the steering wheel replaced.
    King Ranch tan/pebble: 5C7Z-3600-ABA
    Charcoal black: 5C7Z-3600-CBA
    TSB 05 22-1, 06-22-14

    2003/04 Lack of Power, Runs Rough, Check Engine Light on With EGR Codes:
    Some trucks may exhibit exhibit the above symptoms, as well as have excessive white or black smoke, and may have the following EGR valve code(s): P0401, P0402, P0403, P0404, P0405, P0406. Diagnostics for the EGR valve have been updated, as has the EGR valve--P/N 4C3Z-9F452-A. Broadcast Message 3614, SSM 18362.

    03 F-Series/Excursion Rear Pinion Seal Leak:
    When repairing rear pinion seals leaks on single rear wheel trucks built between 1-1-03 and 6-30-03, a new pinion flange (P/N 2C3Z-4851-AA) should also be installed with the seal (E8TZ-4676-B). The original flange may have irregularities which are causing the leak. SSM 17486

    Ratcheting noise from front axle; Hub locks not disengaging--99/03 F-series/Excursion 4X4
    This will usually occur after hitting a bump while driving in 4X2 mode. This may be due to a worn or damaged axle shaft support needle bearing allowing the axle to wobble or vibrate in the within the hub. The entire hub assembly should be removed and the bearing and seals inspected for damage. If the truck is equipped with manual shift transfer case, ensure the vacuum fitting is capped to prevent contamination. The axle needle bearing P/N is C6TZ-3123-A. SSM #13697/8.
    If the axle shaft is damaged, the outboard end of the shaft is available separately (P/N 3C3Z-3B387-AA). SSM #17066

    Temperature Gauge Reads Hot, 05 F-Series:
    Some trucks built before 12-10-04 may have a temp gauge reading at the top of the green normal band or into the red hot band, with normal coolant temperatures. If no overheat condition is present, the instrument cluster should be replaced. If there is a code in the engine computer for ECT over 240 degrees, or if coolant is being expelled from the degas bottle, do not replace the cluster. Diagnose the overheat condition.
    TSB 05-1-2

    04 F-Series/Excursion Power Steering Noise:
    Some trucks may exhibit a moan or grunt noise from the power steering when turning the steering wheel, usually more pronounced on left turns. The noise may sound like it's coming from the steering gear or column. Replace the hydraulic pressure line running from the brake hydroboost to the steering gear, and the return line running from the gear to the cooler. Take care to prevent any debris from entering the hydraulic system.
    Pressure line: 4C3Z-3A719-C
    Return line: 4C3Z-3A713-A
    TSB 04-23-08

    05 F-Series Steering Gear Noise:
    Some trucks built before 11-24-04 may exhibit a noise when turning the steering wheel, especially left turns. The noise may sound like it's coming from the steering gear or column. To repair, replace the steering gear with part number 5C3Z-3504-AA. Broadcast Message 3509.

    05 F- and E-Series Crank/No Start, Hard Start, Runs Rough at Idle:
    Some trucks built before 11-1-04 may exhibit a crank no start with a low ICP reading, a hard start with slow building ICP, or a rough idle with a high ICP. If these symptoms are confirmed, remove and inspect the IPR valve. If the IPR screen is deformed, sucked into the valve, has a hole in it, or has metal debris covering more than half its surface, replace the HP oil pump (5C4Z-9A543-AA) and IPR valve (5C3Z-9C968-CA). If a rough idle is still present, the metal debris may have contaminated one or more fuel injectors. Perform normal injector diagnosis.
    If the IPR screen is not damaged or contaminated, perform normal diagnosis as per the symptom.
    TSB 04-25-18

    Bump or Clunk when Starting from a Stop, 4X2 Vehicles:
    This may be due the slip yoke on the driveshaft not slipping smoothly. Separate the slip yoke from the driveshaft (index for reassembly) and lube the splines with Motorcraft P/N XG-8 PTFE (Teflon) grease.
    TSB 04-26-6
    (4X4 vehicle can be fixed in the same manner, although not covered by this TSB)

    99-05 F-SuperDuty Rear Suspension Lean:
    This applies to rear suspension lean only. The truck needs to be parked on a level surface with no load (or at least loaded evenly) and all tires inflated evenly. Inspect for spring damage or shackle bushing wear. Measure vertically from the lowest point of the wheel rim (not from the ground) to the wheel lip. If the measurment is within 3/5" from side to side, no action is required. If the measurement is greater than 3/4", measure the gap from the top of the axle to the rebound bumper bracket. If this measurment is within 3/4", inspect the body mounts and have the frame checked. If the measurement is between 3/4-1", install shim 3C3Z-5A300-AA on the low side, between the spring spacer and spring seat. If the measurement is between 1-1.75", install shim 5C3Z-5742-AA on the low side. If the measurement is greater than 2", replace the spring. Install longer U-bolts if necessary.
    TSB 04-23-6

    2005 F-SuperDuty Rancho Shock Boot Change:
    Starting 10-30-04, the red plastic dust boot on the rear Rancho shocks was replaced by a white metal dust shield. The front shocks still have the red boot. Broadcast Message 3414

    Oil Filter Lid Leaks:
    To prevent leaks from the oil filter cover, be sure to replace the sealing o-ring when performing oil changes. Torque the cover to 18 ft/lbs. If leaks continue to occur, check the housing for burrs and the lid for damage. If using an aftermarket filter, try a factory one. Broadcast Message 3403.

    03-05 F-SuperDuty Manual Transfer Case Code P1729:
    This can be due to the transfer case not fully shifting into low range. To ensure full engagement, shifting to low range should be done with the transmission in neutral and the vehicle rolling below 3 MPH. Broadcast Message 3402.

    Recall on 2004 TorqShifts:
    Certain trucks built from 3-8-04 through 6-24-04 may experience a failure of the low/reverse planetary assembly. Specifically one or more of the planet gear pinion shafts may walk out of the carrier. If this occurs metallic contamination of the fluid will occur and will cause harsh or slipping shifts and/or harsh or delayed engagements in forward or reverse. Trucks affected by this recall will have the low reverse planetary replaced if no damage has occured, or will have the transmission overhauled and repaired as needed, along with replacement of the transmission cooler, if damage has occured. This recall has been extended until 3-31-06
    Customer Statisfaction Program 04B24.

    Related to:
    Harsh or Delayed Forward or Reverse Engagement:

    This could be caused by a sticking line pressure control (PC-A) solenoid. Typically the line pressure will be fluctuatiing wildly (up to 500 PSI!). To service, first remove and insdpect the external cooler line filter. If it contains fine gray metalic debris. If metal is found, the source is most likely a defective revese planetary pinion shaft that is coming out of the carrier and contacting the case or adjacent components. The transmission will need to be disassembled and repaired as needed or replaced. Broadcast Message 3250
    If little or no debris is found replace the line pressure control solenoid with P/N 4C3Z-7G383-AA. Broadcast Message 1586/SSM 17874/18051
    This repair will require removing the solenoid harness, so a new harness sealing o-ring (P/N 3C3Z-7Z276-AA) will need to be installed. In some cases the solenoid body will need to be removed from the trans to remove the harness and solenoid. In this case the solenoid body gasket (basic P/N 7C155, trans tag number needed) will be needed as well. Note: Do not loosen the 10mm head bolts on the solenoid body. Only loosen the 8mm head bolts.
    If the solenoid has been replaced and the condition it still pressent, suspect a contamination issue of the solenoid or a sticking pressure relief valve.

    2004 F-Series/Excursion Barometric Pressure Sensor Application:
    Be advised that the barometric pressure (BARO) sensor was changed for the 2004 model year. Trucks built before 9-29-03 use the same BARO sensor as previous models--F8UZ-12A644-AA. Trucks built on or after 9-29-04 (2004.25) use part number 4C2Z-12A644-AA. Using the incorrect part for applicate will cause driveability symptoms. Broadcast Message 3162.

    2005 F-Series/Excursion Cup Hold Not Closing Flush:
    Before replacaing the cup holder for this problem, remove the cpholder and utility hook, and inspect for any wiring that may be interfering with the closing of the cup holder (cigar lighter or trailer brake controller harnesses; radio antenna cable). Relocate any problem wires. If nothing is interfering, replace the cupholder. Broadcast message 3166.

    2004/05 F-Series/Excursion Check Engine Light On, Codes P2614/P2617, Multiple Driveabilty Problems, Wait to Start or Water in Fuel Lights Flicker:
    Trucks built between 9-29-03 and 9-15-04 may exhibit the above conditions as well as misfire, hesitation/stumble, rough idle, and/or lack of power symptoms. These may be caused by the injector harness chafing and shorting to ground under the fuel injection control module, along the intake manifold or on heater hose clamps. If the conditions are intermittent, attempt to duplicate them by wiggling the harness as the engine is running. If a chafed injector wiring harness is confirmed, replace it with a revised harnes, 4C3Z-9C891-AB. Broadcast Message 3285.

    2005 F-Series Super Duty Factory Trailer Brake Controller Tips: Diagnosis procedures for the Towcommand system is in the workshop manual, section 206-10, Auxiliary Brake System. All voltage tests sould be made with the controller at the maximum gain setting of 10.0. Brake controller output voltage increases with vehicle speed. In park with the controller fully applied manualy, the output voltage on trucks built before 3-23-05 should be greater than 1-3 volts; after 3-23-05 greater than 10-12 volts. Controller output with the brake pedal is the same for either build dates. Full voltage is only available above 15 MPH. The Towcommand system works in both forward and reverse. Broadcast Message 3286, 4312, 4940.
    When installing an aftermarket controller on trucks equiped with a factory installed controller, the factory one must be left intact and the aftermarket controller installed separately. The vehicle harness connector for an aftermarket cointroller is now a 4-pin connector, and is mounted to the back of the storage bin to the right of the steering column. The radio may need to be removed to access it. Broadcast Message 3332, 4080, 4926.
    The Towcommand system is ment to only work with electric trailer brakes and not surge or electric over hydraulic brake systems. Broadcast Message 3179, 4924.
    A message center display of "Trailer Fault" is not a problem with the the TowCommand controller. If this message only displays with a trailer attached, the problem is with the trailer wiring. If it displays with no trailer, the fault lies in the vehicle harness between the TowCommand and the trailer connector. Broadcast Message 4927.

    2005 F-Series Super Duty Aftermarket Brake Controller Installation:
    The vehicle harness connector for the brake controller is located on a support brace behind the dash below the radio. If provided, the adapter harness for connecting to the brake controller will be in the glove box. When installing an aftermarket controller on trucks equiped with a factory installed controller, the factory one must be left intact and the aftermarket controller installed separately. Broadcast Message 3332.

    Econoline Front Coil Spring Recall:
    Some 2004 Economline Vans built from 1-21-04 through 5-26-04 at the Lorain Assembly Plant were built with light springs than indicated by the vehicle certification label. Ford will replace the springs on affected vehicles at no charge until 9-30-05. CSP Recall 04B19.

    Econoline EGR Code P0401:
    Some 2004/05 Econolines built before 9-2-04 may have a P0401 trouble code stored in the computer with or without the check engine light being illuminated. The computer should be reprogrammed with the latest calibration to correct this concern. if the P0401 returns after reprogramming, diagnose the EGR valve and EBP sensor. TSB 04-20-4

    Econoline ABS Module Recalls:
    2003 Econoline vans built between 4-23-02 through 9-19-03 and 2004 vans built from 5-6-03 through 11-19-03 may have a defective antilock brake (ABS) module. These modules may short internally, causing the ABS light to illuminate and, in some cases, can overheat and cause a fire. Under safety recall 04S22, Ford will install a heat shield and a lower amperage ABS module fuse to prevent damage from the module overheating. If an ABS module fails, extended coverage programm 04N03 extends the warranty period of the module on these vans to 150,000 miles or ten years from date of purchase, whichever occurs first. If a van has already reached 150,000 miles, the coverage will only extend until 9-30-05.

    TorqShift and PTO Operation--PTO Line Pressure Insufficient/Possible Transmission Damage:
    Some trucks built before 9-22-04 will exhibit insufficient line pressure--less than 150 PSI--during PTO operation. This can result in no torque converter lock-up during PTO operation and can cause PTO or transmission damage. Assuming the PTO was correctly installed (a mission PTO line pressure orifice can cause the same problem), reprogram the powertrain computer to the latest calibration included in WDS release B33.6 or higher. Check for any transmission damage and repair as necessary. TSB 04-20-10

    TorqShift Transmission or PTO failure, and/or Cooling System Contamination:
    Trucks with PTO may exhibit a low or oscillating line pressure condition, or low/no PTO torque due to incomplete PTO wiring. Installers must provide a battery voltage signal wire from PTO circuit 322 (blunt-cut light blue/yellow wire at left side of dash) to the ECM, regardless of type of idle speed controller. This will command the engine speed to 1200 RPM, lock the torque converter and set line pressure to 150 PSI. Installers should referance the information at www.fleet.ford.com/truckbbas. Broadcast Message 1730.

    2005 F/E-Series Stationary Elevated Idle Control (Idle Kicker):
    The stationary eleveated idle control system has changed for the 2005 model year. An APCM "idle kicker" control will not work on 2005 trucks. Information on how to raise the idle available at www.fleet.ford.com/truckbbas. Select "bulletins", then select "Q-108", titled New Stationary Elevated Idle Control for 2005 from the QVMP bulletin index. Broadcast Message 3164; 4987

    2005 F-Series Headlamp Switch Service:
    The headlamp switch no longer pops out of the dash panel on 2005 F-Series trucks. The switch must be serviced by accessing the rear of the dash trim panel. Do not attempt to pry the swiutch out of the panel as damage will occur. Broadcast Message 1513.

    2005 Block Heater Option:
    All 2005 F-Series and Excursions with the 6.0 PowerStroke have a block heater installed on the engine. However, the cord for the block heater must be ordered as an option (code 41H). The cord is installed on vehicles originally sold in the following states: Alaska, Colorado, Iowa, Maine, Minnesota, Missori, North and South Dakota, and Wyoming. Broadcast Message 1512, 3090.

    2005 Optional Auxiliary "Upfitter" Switches:
    2005 F-Series trucks may be ordered with four optional auxiliary switches mounted below the climate control panel. These switches control installed fused relays (two 10 amp and two 30 amp) that can be wired to power accessories. The leads from the relays can be found behind the fuse box under the dash, and are labeled to identify with which switch each is associated. Broadcast Message 3093

    Wire Chafing Issues:
    A variety of driveability issues can arise from chafing/shorting wiring, such as crank/no-start, stall, running rough, misfire, buck/jerk or lack of power. The most common location for this is the valve cover/cover bolts near the FICM or the intake manifold bolts where the harness routes under the air intake hose. The harness should be rerouted and any chafe points insulated with rubber vacuum caps. Other chafe problems can occur where the sensor harnesses route around the valve covers, thermostat housing, idler pulleys, glow plug relay bracket, and near the accelerator pedal assembly (adjustable pedals), and also near the PCM by the battery and near the relay box brackets at the left rear corner of the engine compartment. On Econolines, also inspect at the top edge of the computer, along the oil dipstick tube bracket and auxiliary A/C lines. Broadcast Messages 1407 and 3077.

    Hard or No Start, Glow Plug Module Connector:
    In cases of a hard or no start caused by an inoperative or intermittent glow plug system, inspect the module connectors for damage, loose or displaced terminals, spread terminals or corrosion. There is a harness connector service kit available to repair 2003 and 2004 engines, P/N 4C3Z-12B568-AA. TSB #04-17-13

    2004/05 Econoline Poor Charging Performance, Modified Vehicles with Single Alternator:
    If you are purchasing an Econoline with the intent of installing high-load electrical devices on it, it is recommended to order the vehicle with the dual alternator option. If this is not possible, or your van is equiped with a single alternator and you find you need additional charging capcity, a 140 amp alternator, P/N 4C3Z-10346-BA, is available for purchase. Broacast Message 3055.

    Diagnostic Scan Tool Tips: When performing retests or multiple self tests on the 6.0 with any scan tool, false codes can be generated if the ignition is not cycled between tests. The ignition must be cycled to off then on before requesting each KOEO or injector buzz test. Broadcast Message 1816.
    On scan tools capable of performing power balance tests a bad cylinder may cause a low reading in adjacent or companion cylinders. Additionally,the FICM can compensate for a low cylinder and make pinpointing the faulty cylinder difficult. The FICM compensation can be neutralized by using the datalogger injection test active command. Start testing by selecting the power balance function (in park or neutral only). Without closing the power balance screen, switch to datalogger, select an injector to monitor and highlight it without actually turning it off. The FICM will revert to base fuel control and will not compensate for the low cylinder for one minute. Switch back to the power balance screen andlook for the low cylinder. An injector should not be replaced based on the results of the power balance test. Back up the results with relative compression, code retrieval and buzz testing, and crankcase and compression testing. TSB #04-15-13

    F350 DANA 80 Dually Rear Axle Chatter on Turns:
    Ford now recommends using 75W-90 gear lubricant along with 8 ounces of friction modifier to correct and prevent a chatter condition on turns. If chatter is slight, this can be a normal operating condition. If chatter is still severe after replacing the fluid, disassemble the differential assembly and replace the clutch pack, P/N 3C3Z-4880-AA. Prelube the clutch friction plates with friction modifier before assembly.
    TSB #04-16-04

    Intermittent Unsuccessful Remote Start and/or Stall After Remote Start:
    Some trucks may exhibit a no start condition when using a remote start system. Or, the the engine may start and run for up to five seconds then stall. The start/stall condition may repeat itself up to four times without operator input. The technician should contact the Ford Remote Start Technical Hotline for diagnostic assistance. A tach signal booster, P/N 102818-2, may be needed. Broadcast Message 1722.

    Safety Recall 04S15: Loose Grounding Stud at Engine Block.
    Some trucks built between 12-1-02 and 3-31-03 may have a loose grounding stud at the lower right front corner of the engine block. The grounding stud should be replaced and any dirt cleaned from the block and/or battery cable end. If the stud is found to be loose, the radio noise supression strap at the right rear of the engine and any components adjacent to it should be inspected for damage and replaced or repaired as necessary.
    Grounding Stud: W704983-S309A
    Radio Suppression Strap: F81Z-19A095-AA.

    Overhead Trip Computer Distance to Empty Reading Incorrect:
    Trucks built after 11-18-02 may have an incorrect DTE reading displayed on the OTC. The OTC will need to be reprogrammed using As-Built data matching the specific tank sizes listed in TSB #04-15-10.

    No Temperature Control on MAX A/C Setting, Vehicles with Manual Climate Control:
    When MAX A/C is selected, there is no coolant flow through the heater core. This is a normal function of the heater control valve when operating in the MAX setting. Switching from MAX will allow coolant to flow to the heater core and the air temperature from the registers can then be adjusted for comfort. Broadcast Message 1781.

    Serpentine Belt Noise:
    Trucks built before 6-1-04 may exhibit belt squeaks or squealing. To correct, use the following belts per application:
    F-Series, Single Alternator: 3C3Z-8620-DB
    F-Series, Dual Alternator: 3C3Z-8620-BC and -HB (both required)
    Excursion: 3C3Z-8620-AC.
    TSB #04-14-12

    Low RPM, Buck/Jerk, Miss, Stumble:
    Some trucks built between 9-29-03 to 4-28-04 may exhibit these symptoms after decelerating down a long grade with the cruise control engaged. To service, the computer will need to be reprogrammed with the latest level calibration release, available with WDS release B31.11.
    TSB 04-13-8

    No Start or Constant Engine Misfire:
    There are several things that can cause this symptom, including a failed FICM (fuel injector control module). In cases where the FICM is at fault the condition should be present at all engine temperatures, and codes P0611 or U0105 may be set. If codes P2614 or P2617 are stored the cause is more likely to be a wiring chaffing issue. The harness will need to be pushed and pulled to determine if the harness is shorting out. WDS should be used to verify the injectors can be commanded on (injector buzz test) and that the FICM is powering up (datalogger PIDS FICM_VPWR: ignition power; FICM_LPWR: FICM logic power from relay; FICM_MPWR: FICM output power to injectors--47-50 volts). If an injector does not click during the buzz test, a test light can be installed between the injector connector terminals 1 and 2 and checked for illumination when re-running the test.
    TSB 04-18-6

    Exhaust Leak/Hiss Noise:
    Some trucks may exhibit an exhaust leak at the driver side turbo inlet Y pipe. This usually occurs at the flex bellows portion of the pipe, and may be due to misalignent of the pipes. Replace the inlet Y pipe, following the new service procedure (also found in droan noise above). Broadcast Message 1419.
    Failed factory Y pipes should be returned to International for inspection. Failed replacement Y pipes, or replacement pipes that will not line up properly should be returned to Ford's North American Diesel Team (contact HOTLINE for details) for inspection.

    Shorted Fuel Injection Control Module: Some trucks may continue to run at idle after the ignition is shut off, and the instrument cluster may stay on. This may be caused by an internally shorted FICM. To shut off the cluster and engine remove the FICM relay in small auxiliary relay box near the brake master cylinder. To prevent battery drain disconnect the batteries. Replace the FICM to correct this condition. SSM #16749.

    Radio Interference with Head- or Parking Lights On:
    To diagnose this condition, try operating the power mirrors. Disconnect whichever mirror causes interference and try actuating the switch again to confirm the noise is gone. Replace the mirro cover to correct the condition (base part number 17D742 or 17D743). Broadcast Message 1304

    Manual Transmission Fluid Leak:
    This may be mistaken for a rear main seal leak. To diagnose, add florescent dye to the transmission and test drive the truck. Inspect the transmission for leaks with a UV lamp. Broadcast Message 1490.

    High Pressure Oil Standpipe Service:
    On engine built before 9-29-03, if the standpipe running up through the head(s) to the high pressure oil tube is remove, it will need to be replaced. On engines built on or after 9-29-03 the o-ring on the standpipe xcan be replaced and the pipe reused. Broadcast Message 1426.

    Oil Level Check Tip:
    When checking the oil level on the 6.0, the vehicle must be on a level surface and the dipstick must be fully seated into the tube to ensure an accuarte reading. Do not add oil if the level is above the "MIN" line on the dipstick. Broadcast Message 1512, 1574.

    ESOF Transfer Case Concerns:
    On some trucks with the electronic shift-on-fly transfer case there may be engagement/shift concernes. Check the ESOF motor relays on the driver side fender. If the relays or relay box have become dislodged, corrosion may form on the relay terminals or inside the relays. Broadcast Message 1511

    Lack of A/C Cooling at Highway Speeds/Rapid Compressor Clutch Cycling:
    This may be due to low suction pressures causing the A/C compressor clutch to cycle too rapidly. On vehicles built before 7-18-04, recover the refrigerant from the system and recharge with 45 OZ on single A/C and 68 OZ on dual A/C vehicles. These capacities are different than shown on the A/C specification lable. Trucks built after 7-18-04 are factory filled with the above capacities even though the label has not been updated. Broadcast Message 3233; 4399.

    Dual Mass Flywheel Applications:
    F250/350 trucks with the 6 speed manual transmission built before 12-1-03 are equipped with a dual mass flywheel. All F-Series trucks built after that date with the 6 speed have single mass flywheels. Some F-450/550's built before the above date may have dual mass flywheels, too. When replacing, use only the same type parts that were originally installed on the truck. Broadcast Message 1472.

    TorqShift Harsh/Slipping Engagements, Upshifts, and/or Downshifts:
    If these symptoms are experienced after the batteries have been disconnected, then it is due to the transmission adaptive strategy being cleared from the computer. This may occur when the vehicle is delivered new from the factory as well. Warm the engine and transmission to operating temperature. Perform three series of upshifts at light, medium and heavy throttle. Perform three sets of gear engagements (N-R, N-D, D-R, R-D) with the brake pedal firmly depressed and waiting three seconds between each engagement. Peform these steps once in normal mode and once in tow/haul. Broadcast Message 1196

    6.0/6.4 Fuel Economy:
    Ford vehicles equiped with the 6.0 PowerStroke diesel are not rated for fuel economy by the EPA. If economy is in question, a boost test should be performed. If boost reaches 22-25 PSI in third gear, wide open throttle under load, then th engine s operating normally and no economy related repairs need to be performed. If not in specs, then the engine will need to be diagnosed--check sensor reading, VGT and EGR operation, fuel pressure and quality, crankcase pressure, intake or exhaust restriction, exhaust or CAC leaks.
    Fuel economy will be affected by many factors, including: excessive idle time (one hour equals approxmately 33 miles of driving), fuel quality and blend, ambient temperature, driving habits, vehicle use, towing, loads, add-on accessories. Broadcast Message 1271, 4450, 6989

    Oil Leaks from Lower Engine Area:
    Some 6.0 engine may exhibit an oil leak that appears to be coming from the lower crankcase (bedplate), upper or lower oil pan, rear main seal, or front or rear covers. First inspect the cam and crank position sensors to ensure the leak is not the o-ring on one of these sensors. If the sensor(s) is wet, remove it and replace the o-rings. Cam sensor (driver side): 3C3Z-9N693-HA and -JA; crank sensor (passenger side): 3C3Z-9C064-DA.
    An oil leak may occur at front or rear covers if they were removed without cutting the sealing joints behind them. Broadcast Message 1268

    Vacuum Pump Inop or Ventilation System Deverts to, or Only Blows Through, Defrost Vents:
    If the vents devert to the defrost mode, this is usually due to a leak in the vacuum system. Typically if the problem is in the automatic hub system, this will only occur when 4X4 is selected. If it occurs on in a specifc ventilation mode, the vacuum servos associated with that selection would be suspect. If the ventilation system stays on defrost at all times, a leak in the system at the vacuum pump, or the vacuum pump itself may be at fault. For vacuum pumps that are inoperative or continuously running, replace with P/N 4C3Z-2A451-AB. Broadcast Message 1244, 1575, 3278; TSB #04-16-08

    Oil Leaks from Front and/or Rear Crank Seals:
    If an oil leak has been verified as coming from either the front or rear crankshaft seals, the crankshaft end play must be checked to ensure it is 0.020" or less. If within specs, replace the seal using the correct tools and procedures. Broadcast Message 1240

    2004 F-Series/Excursion Lack of A/C Cooling:
    Trucks built between 12-1-03 to 1-26-04 may have strands of insulation trapped between the compressor and refrigerant line manifold. The system will need to be recovered and the the insulation removed from the joint. The tube and manifold assembly (4C3Z-19D850-CA) may be reused if it is undamaged, but the o-rings (1F1Z-19E889-AB) should be replaced. Broadcast Message 1118.

    2004 Econoline Cut-Away Cab Driveability Concerns:
    Some vehicles built before 2-27-04 may experience low engine RPM and/or other driveability concerns after a long deceleration in manual second or third gear. To correct, reprogram the computer to the lastest availabe calibration. Broadcast Message 1124.

    03/04 F-Series/Excursion Cam and Crank Sensor codes:
    Some trucks may exhibit a variety of driveability concerns with camshaft (CMP) and crankshaft (CKP) position codes P2614 and P2617 stored in the computer. If both of these codes are stored along with other codes, those other codes should be diagnosed first. f these two codes are stored with no other codes they should be disregarded and the concern should be diagnosed by symptom. For example, a chaffed FICM harness or no fuel pressure can cause both of these codes to be set together. Broadcast Message 1150, 1301.

    03/04 TorqShift Solenoid Body/Solenoid Harness Application:
    If the TorqShift solenoid body needs to be replaced, the new body may come with a missing pressure sensor. If the harness needs to be replaced it may come missing a connector for a pressure sensor. The input from the sensor in question was deleted from the TorqShift programming and is no longer used. The replacement parts an not incorrect and may be used. Broadcast Message 1151.

    03-05 F-Series Overheating with Snow Plow Installed:
    If a snow plow is installed on a truck with the 6.0, it may disrupt the air flow through the front of the truck causing the cooling fan to stop or turn in reverse. For trucks with snow plows there is a revised fan clutch available (P/N 4C3Z-8A616-SA). Some trucks have been modified with a jumper on the fan connector to keep the fan continuously engaged. This jumper must be removed before connecting the new fan. Broadcast Message 1137.
    2005 trucks with snow plow package already have this fan installed at the factory. Trucks without snow plow package that have a plow installed will need the above fan.
    TSB 05-4-4, 06-24-12, 07-8-4

    ICP/EBP Sensor Repair Kit:
    Both PowerStroke engines may exhibit codes related to the ICP(7.3: P1280; 6.0: P2285) and/or EBP sensors (P0472). If these codes are present, clear them. Start the engine and wiggle the sensor connector that matches the stored code. If the code returns, replace the sensr connector--P/N 3C3Z-12224-BA for 94-96; 3C3Z-12224-AA for 97-2004. Broadcast Message 1078/SSM #17573.

    Trouble Codes P0603 and/or P0605:
    Some PowerStroke trucks may exhibit codes related to keep alive memory--KAM (P0603); or read only memory--ROM (P0605). P0603 may be set if the batteries or computer are disconnected. On the 6.0 the computer should be reprogrammed with the latest available calibration. Broadcast Message 1076.

    TorqShift Gear Trouble Codes:
    When diagnosing a TorqShift transmission, trouble code P0700 may be stored. Diagnose using any additional stored codes. P0730 may be found stored with codes P2700-2704. Use the additional code(s) to determine which clutch or clutch control is causing the gear ratio P0730 code to be set. Broadcast Message 1158, 1525.

    FICM Replacement:
    When replacing the fuel injection control module (FICM), the new FICM will need to be programmed after installation. Replacement FICM's are shipped unprogrammed and have to be programmed to match the exisisting computer. Broadcast Message 1171.

    Shudder on Acceleration:
    On trucks with single driveshafts, check the rear axle spacers. If the spacers are installed with the thin side (1 7/8") facing forward, they should be reversed (swapped left to right) so the wide side (2 1/4") faces forward. If the truck now only shudders with a load, swap out the spacers with 2" flat ones from an F250 long wheel base (two-piece driveshaft), P/N 2C3Z-5598-PA.

    6.0 Reprogramming Errors:
    If you encounter any errors wihile attempting to reprogram the PCM, FICM or TCM, exit the session on WDS in completed status, not delete. Ensure the vehicle battery is fully charged and the WDS sofeware is up to date. If there is a no communication/no start condition, reboot the WDS. When WDS restarts, go to previous sesions and select the vehicle you had saved and perform the programmable module installation function for the PCM only. If unresolved, contact HOTLINE. Broadcast Message 1064.

    Low Power/No Boost and/or Code P0299 or P2263:
    If the turbocharger is suspected to be the cause of low boost, it should be tested by manually activating the variable geometry turbo control valve. The engine should be at operating temperature. Using the WDS active commands in datalogger, monitor , VGT%, RPM abd MGP. Set the RPM to 1200 and the VGT% to 0 and record the EBP and MGP readings. Increase VGT to 85% and watch for an increase in EBP and MGP, and listen for a whistle from the turbo. If there is no pressure increase or whistle, check the control wiring for the VGT by installing a est light in the VGT harness and commanding the VGT from 0-85%--the light should be off and then slowly brighten. If the wiring checks out, replace the VGT control valve (P/N 3C3Z-6F089-AA) and retest. If the condition is unchanged, then replace the turbocharger. Broadcast Message 0887.
    Engineering is currently investigating false P2263 codes. Broadcast Message 1290, 3005

    Normal EGR Valve Operation--Open at Idle:
    Trucks built after 9-30-03 and those truck reprogrammed with WDS version 27.9 or higher will now have the EGR valve open at idle. This is to reduce engine noise at idle that has occured from removing the pilot injection. When diagnosing the EGR valve it is normal for the valve position value (EGRVP) to not change until the EGR duty cycle is greater than 30%. Broadcast Message 1067.

    False Codes Set During Active Command Testing:
    When performing active commands on the EGR, IPR, and VGT, trouble codes associated with those components may be generated. Disregard codes for these components that result from active caommand testing and be sure to clear all continuous memory codes after testing is complete. Broadcast Message 0962.

    Various Driveability Concerns, Harsh 3-2 Downshift/Clunk, Trucks Built after 9-30-03:
    Trucks built from 9-30-03 to 2-8-04 may exhibit excessive smoke, rough running or misfire after extended idle or poor performance after a cold start, typically at altitudes above 5,000 feet, rough or rolling idle or white smoke on hot restart, rough or rolling idle immeadiately following a cold start, DTC P0500 (no vehicle speed input) on manual trans, or DTC P0299 A harsh 3-2 downshift or a buck/jerk on accelerator tip-in/tip-out in tow/haul mode or a harsh reverse engagement at low mileage may also be present. To correct, reprogram the PCM, FICM and TCM with WDS version B29.4 or higher. Broadcast Message 1019/1167.

    Related to:

    White/gray Smoke, Cold Start Performance Issues, Harsh 3-2 Downshift:
    Trucks built before 9-30-03 may exhibit excessive smoke, rough running or misfire after extended idle or poor performance after a cold start, typically at altitudes above 5,000 feet. A harsh 3-2 downshift or a buck/jerk on accelerator tip-in/tip-out in tow/haul mode may also be present. To correct, reprogram the truck's computers with Running Change 7. Broadcast Message 1364; SSM #17437

    Low Charging System Voltage Under High Load Conditions--Single Alternator Trucks:
    Some trucks with single alterantors may exhibit low changing syatem and battery voltage during high load conditions, such as plowing snow, spreading salt, or running lighting. If the condition occurs only when running these added accessories, there is a 140 amp replacement alternator available--P/N 4C3Z-10346-BA; that may be purchased. Keep in mind the effectiveness of the larger alternator will vary due to component age design and use. Broadcast Message 1036.

    2003-2004 Oil Leak from Head Gasket:
    Some engine may exhibit what appears to be an oil leak from the head gasket. Since there is no pressurised oil at the head gasket, a leak at this location is unlikely. Inspect the following area instead: turbo oil feed and return, oil cooler, HP oil pump cover, ICP sensor, IPR valve, valve cover gasket, rocket carrier gasket, Injector and glow plug ports and crankcase breather port. Use florescent dye and an UV lamp to pinpoint the source of the leak. If the leak is from the head gasket, the head should be removed and it and the block checked for flatness. Broadcast Message 0873.

    Ford's Position on Biodiesel:
    Ford is advising that any of their vehicles powered by a diesel engine, regardless of manufacturer, may exhibit engine or fuel system problems when using fuels with greater than 5% Biodiesel. Any problems when using fuels containing more than 5% Biodiesel should be referred to the fuel manufacturer. Ford only recomends using fuels containing no more than 5% Biodiesel (B5) in their diesel powered vehicles. In addition, as per World Wide Fuel Charter (WWFC) catagory 1-3, fatty acid methyl esters (FAME) must meet EN14214 and ASTM D 6751 specifications. Broadcast Message 0884, 3626, 4942.
    It is also recommended to change the oil using the severe duty schedule (3000 mile; no later than 5000 miles) and replace the fuel filter every other oil change (no later than 10,000 miles)

    Emissions Recall 03E03:
    The federal government requires that all vehciles built from 1996 have the ability to be diagnosed by aftermarket scan tools. This is to ensure that all vehicles meet emission standards without the owners being locked into going to the dealership for repairs. This was addressed by the programming update described under Running Change 5 back in August, but now it is a manditory update.
    Since RC5 has been superceded by RC7, this means all vehciles subject to this recall will have increased engine noise at idle due to the deactivation of the pilot injection in the split shot strategy.

    TorqShift Harsh Disengagement Shifting from Reverse to Park:
    Some trucks built before 11-14-03 may exhibit a harsh disengagement when shifting the TorqShift transmission from reverse to park. A cluck may also be heard. To correct, remove the control body and replace the manual valve with P/N 4C3Z-7D376-AA. Insert the new valve into the body plugged end firts. Install a new valve body gasket, P/N 3C3Z-7C155-DA. Broadcast Message 1219.

    A/C Compressor Cut-Out above 1500 RPM after Battery Disconnect:
    Part of the computer's strategy it to disable the A/C above 1500 RPM after power has been interupted to the computer. If the batteries are disconnected for any reason, the engine should be started and shut off to reset the A/C strategy. The A/C will work normally on the second engine start. Broadcast Message 1316.

    Water Injestion/Snow Packing/Ice Build-Up in the Air Induction System:
    Some trucks equipped with a 6.0 engine may exhibit a trouble code P0103 for the Mass Air Flow sensor circuit. This may be due to water or snow getting into the air cleaner assembly or ice building up in the air cleaner. The check engine lght will only illuminate on Califronia emissions vehicles. To service, check the air cleaner for restrictions, inspect the filterminder and MAF sensor for damage and/or loose wires or damaged/corroded terminals. The MAF sensor should be diagnosed before replacement. Broadcast Messages 1000, 1103.

    Fuel Pump Trouble Code P0232:
    Some trucks may store a trouble code for the fuel pump secondary circuit being high. Diagnosis may lead to replacing the PCM (computer). Before replacing the PCM, check the ground at the driver side upper firewall area for loose connection or corrosion. Remove the grounding screw and check for rusted threads. Correct any problems, if found. If no problems are found, continue with normal diagnosis. Broadcast Message 1110.

    Rear Main Seal Leak:
    Some trucks with the 6.0 may exhibit what looks like an oil leak from the bellhousing, presumably for the rear main seal. This actually may be excessive grease from the torque converter pilot melting and runing out of the bellhousing. It is recommended that 3 ounces of florescent dye be added to the oil, the truck driven, then the leak inspected with an UV lamp. If dye is detected, the engine should be inspected for leaks on top that may be running down the back of the engine. If no upper leaks are detected, replace the rear main seal. Broadcast Message 1017

    Low Lube Oil Pressure:
    Some 6.0 engines may exhiit low lube oil pressure caused by leakage in the high pressure oil system. To determine if this is the case, remove the oil filter and hold down the oil drain valve on the left side of the filter housing with a screwdriver. Watch for oil flow with the engine cranking. If flow is present, diagnose the HP oil system for leaks. If no flow is present, diagnose the lube oil system. Broadcast Message 1044

    6.0 Injector Removal/Installation:
    It should be noted that injector serve on the 6.0 is different than on the 7.3. No air tools should be used in removal or installation of the injectors to prevent damage to the injector. A T-40 Torx bit with a minimum shaft lenght of 2" is require to ensure proper torque of the injector (24 ft/lbs) and to prevent the drive tool from contacting the injector and damaging it. New o-rings and combustion seals should be used any time an injector is removed. Care should be taken when installing the high oil pressure rail to prevent damage to the upper injector o-rings.
    TSB# 03-20-10

    6.0 Programming Update:
    Another update has been issued for the 6.0 as of 10-3. This update is to correct the loping idle on hot start, poor acceleration on cold start, and to correct false codes related to PCM-FICM compatibility and slow oil warm up, and enhanced turbo performance code diagnosis. TSB 03-20-12.

    Wiring Harness Chafing:
    Some 03/04 trucks with the 6.0 may exhibit a crank/no start, rough running, misfire, buck/jerk or lack of power. This may be due to the FICM harness chafing on a valve cover stud near the FICM. Other potential locations for chafing are where the harness routes past the EBP sensor, the belt idler on the driver side of the engine, the glow plug control module bracket on the passenger side of the engine, and the accelerator pedal sensor wires at the steering column (adjustable pedals only). Reroute and repair the harness as necessary. Broadcast Message 0918/1374, SSM #17522.

    Emissions Recall on 2003 F-Series 6.0:
    Certain 2003 F-Series trucks built at the Kentucky Truck Plant between 6-6-02 through 6-8-03 require replacement of the engine emissions lable on the right valve cover. Ford will send new lables to owners who have trucks to which this recall applies. You can bring the turck into any Ford dealership to have the label affixed, or do it yourself. This recall does not apply to California emissions vehicles below 14,000 GVW. SFA 03L12.

    Programming update for 2003/04 6.0 PowerStroke: As of 8-8-03 there has been a new calibration for the 6.0 PowerStroke. This calibration was not installed in trucks built before 8-18-03. This update is supposed to address rough idle/surge/smoke at light throttle application, improved A/C performance at idle, minor manual transmission lauch performance, smoother downshift in tow/haul at 20 MPH, improved performance at low altitude/high barometric pressures and diagnostic updates. It also includes all previous calibration updates/fixes. Broadcast Message 0763/SSM 17048
    The scan tool update implemented on 8-22-03 will cause a fatal exception error in the scan tool if model year 2004 is selected. Until a fix is released, select 2003 for 2004 models. Currently the calibrations are identical. Broadcast message 0798.

    TorqShift Transmission Firm Tip-In and Tip-Out While in Tow/Haul:
    Some customers may complain of bucking or jerking when firmly depressing the accelerator while in Tow/Haul mode. These torque ocsillations should only occur in Tow/Haul because the torque converter is programmed to stay locked to provide engine braking in that mode. Engineering is investigating ways to improve this symptom. If this problem occurs out of Tow/Haul, normal diagnosis should be followed to find the cause. Broadcast Message 0695.

    6.0 Turbo Lag Following Cold Soak:
    In some cases after the 6.0 is allowed to fully cool in temperatures between 30-60 degrees, it may exhibit increased turbo lag for the first 3-5 accelerations or until the engine warms up. Engineering is investigating this concern. Broadcast Message 0600

    6.0 Excursion No Crank After PCM Reprogram:
    If this occurs, enter Body/Security/PATS and perform a PATS parameter reset. Do not perform a key code erase. If errors were encountered and no PCM communication results, the original PCM programming an be reloaded using Programmable Module Installation/PCM, providing the session was saved or the WDS was not removed for the vehicle. Broadcast Message 0509/0834.

    2003 6.0 PCM/FICM/TCM Reprogramming Errors:
    If this occurs, place the session in "complete" status, do not "delete". Connect a battery charger to the vehicle and the A204 cable to WDS. If WDS locks up/does not communicate, reboot WDS by pressing the white and red buttons simultaniously, the the green to restart WDS. Go to previous session and open the original session. Under Toolbox, select Module Programming/Programable Module Intstallation for the PCM only to reload the calibration. Always ensure the WDS has the latest version (check Power Stroke Central on PTS) and both the vehicle battery and WDS are fully charged. Broadcast Message 0525.

    99-07 Super Duty F-Series Two-Piece Driveshaft Shudder:
    Some trucks may exhibit a vibration on moderate to heavy acceleration from a stop. This is usually due to too high of an angle through the center u-joint. The correct angle through the u-joint should be 0.5-3.0 degrees (compare front shaft angle to rear shaft). Check the engineering number of the center bearing bracket to ensure it is the correct application, and replace if necessary. If the bracket is correct, the shudder may be corrected by shimming the bearing down from the bracket using up to three 1/4" shims, part number E0TZ-4A209-A and two grade eight bolts long enough to expose three threads above the nut when tightened to 46 ft/lbs. Loctite is recommended. Broadcast Message 0518, 1475; TSB 04-22-7, 05-17-6, 06-23-4.

    6.0 Rolling/Rough Idle (surge/lope) After Hot Restart:
    Engineering is investigating a concern of an erratic idle after a hot restart. The condition may clear up on throttle tip-in. Currently there is no fix for this condition. If a truck exhibits these symtoms, unplug the engine oil temp sensor to see if the idle stabilizes. If it does, do not attempt a repair. Disconnecting the EOT sensor eliminates the initial injector actuation of the split shot sequence. Engineering has found that the cause of the rough idle is a problem in the programming for the initial injection.
    Broadcast Message 0425

    6.0 Enhanced PCM Calibrations:
    Some 6.0 F-Series and Excursions may exhibit a low power, low boost condition which clears when cycling the key off and restarting. This may occur while driving or after start-up. Other symptoms may include false cooling fan code P0528, and/or no or slow throttle response when engaging the TorqShift automatic transmission in gear. These symptoms may or may not become apparant after having the recall 03B06 performed prior to the end of May. The enhanced calibrations are available only with WDS versions 24.11 or later. Trucks that have had 03B06 done will only have PCM and TCM updates. Those which have not had the recall done will get PCM, FICM and TCM updates.
    Broadcast Message 0356/SSM #16839.

    Fuel Level Less Than Indicated by Fuel Gauge:
    Some F-Series and Excursions built between 12-1-02 and 4-14-03 may exhibit an inaccurate fuel level reading after refueling. In most cases this is caused by refueling with the ignition in the on or accessory position. The fuel gauge should eventually reinitialize on its own, but it can also be reinitialized by disconnecting the batteries. If the gauge does not reinitialize, then the fuel level system should be diagnosed.
    Broadcast Message 0926

    6.0 Air Cleaner Housing Appears Warped/Misaligned:
    The appearance of a misaligned sealing surface between the air cleaner and mass air flow sensor is due to the design of the air induction system and the positioning of the clamps. The air cleaner should be sealed providing the gap is not greater than 16mm (5/8"). If the gap is greater than these measurments, attempt to reseat the air cleaner to the mass air flow sensor. If the gap is still too wide, replace the air filter element only.
    Broadcast Message 0925, 1581, 3388

    Variable Geometry Turbo Solenoid Diagnosis:
    Some trucks with the 6.0 diesel engine may exhibit a lack of power/no boost concern. The variable geometry turbo (VGT) actuator should be checked for operation: The engine should be at operating temperature. With the engine running and the engine in park/neutral, use WDS to control engine speed to 1200 RPM. While watching exhaust backpressure (EBP) and manifold gauge pressure (MGP), control the VGT actuator (VGT_DC) to 0% and 65%. If the MPG and EBP do not increase as VGT_DC is increased, inspect the wiring to the VGT. If there is no problems found in the wiring, replace the VGT actuator (P/N 3C3Z-6F089-AA) and retest. If there is no change, replace the turbo. SSM 0824.
    If the EBP does increase, and you can hear the turbo pitch change, but the MGP reading does not change, this indicates a problem other than the VGT or turbo.

    2003 6.0 Driveability/TorqShift Shift or Engagement Concerns:
    This is now covered by Customer Satisfaction Program 03B06. It applies to trucks build through 2-23-03. The program will be in affect until 12-31-05. Ford is authorizing a free oil and filter change under this program until 12-31-03.
    Some trucks may exhibit a rough surging idle in drive or reverse when cold , poor throttle response when cold, or low power after extended idling cold. Other symptoms may include harsh shift engagements, harsh 2-3 upshift, 5-3 downshifts and cold 3-5 shift flair. There is a revised calibration for the PCM, FICM and TCM--all must be reprogrammed as a set using WDS version 24.6 or higher.

    ICP Sensor Problems:
    This is now covered by Customer Satisfaction Program 03B05. It applies to trucks build through 2-3-03. The program will be in affect until 12-31-05. Ford is authorizing a free oil and filter change under this program until 12-31-03.
    Some 6.0 PowerStroke engines may exhibit rough/rolling idle, poor idle return, lack of power, injector fault codes or excessive smoke. This may be caused by the ICP sensor reading incorrectly. The ICP sensor and connector terminals should be inspected for damage (the ICP is at the rear of the engine, under the turbo), and the sensor circuits checked for opens or shorts. With the engine at operating temperature (engne oil above 180 degrees), the ICP sensor signal should be 0.16-0.28 volts (less than 70 PSI) with the key on and engine off. The engine needs to be off for at least two minutes for this test. If the ICP signal is not within this range, replace the sensor with P/N 3C3Z-9F838-EA.

    Runs Rough, Lack of Power, Oil Level Overfull/Fuel in Oil:
    This may be due to fuel leaking through or around one or more fuel injectors. There is a comprehensive TSB that has step-by-step diagnostic procedures to isolate the problem to determine in which bank the leak is occuring and to identify which injector and whether it is an o-ring or an injector failure. Note: If more than four quarts of fuel is present in the oil, the turbo charger shaft end play must be inspected. If end play is greater than 0.004", or if the compressor fins have come into contact with the housing, the turbo must be replaced. After replacing any leaking injectors, the oil and filter should be replaced and the truck driven 20 miles. These steps need to be done twice more before releasing the vehicle.
    TSB #04-9-3.

    Diagnostic Communication Error:
    A failed PCM message may occur when diagnosing 6.0 PowerStroke engines. Insure the WDS software level is B23.0.7 or higher. Wait at least four seconds after turning on the ignition before initiating any tests. If the message re-occurs when repeating the test, check the ground at the DLC, perform PPT "AE", and check voltage at the DLC pins 6 and 14 with the key on/engine off--it should be 2.5 volts +/- 0.5 volt.

    Rough/Surging Idle, Excessive Smoke, Lacks Power, Poor Throttle Response:
    This may be accompanied by DTC P2263. Inspect all intercooler hoses and pipes and exhaust system before the turbo for leaks. Ensure the oil level is correct there are no oil leaks and all electrical connectors are secure. Check the ICP sensor as in the following bulletin. If no problems are found, make no attemp to repair the condition. Engineering is investigating. Broadcast Message 0225, 0471. SSM 16488.

    Diesel Engine Power Module-Fuel Injector Control Module Monitor Circuit Shorted:
    Some trucks may have DEPM DTC P0148 (fuel error/engine speed higher than expected) and/or P2552 in the event the FICMM is shorted or open. DTC P2614 (cam position sensor failure) and P2617 (crank position sensor) may also be set. If these sensor codes are set with the P0148, do not attempt to diagnose the CMP or CKP sensor circuits. Broadcast Message 0059.

    PCM Update:
    Some 6.0 PowerStroke engines may exhibit a surge or unstable idle after cold start-up. There is a computer update program for this concern, as well as enhancements to the Cold Ambient Protection (cold high idle) strategy. Affected calibrations are HBF7, JEL7, MAT7, BKG7, FFM7, KMA7, NFW7 and PBD7. Broadcast Message 0417.

    TorqShift 3-4 Shift Flair:
    Some trucks built before 12-16-02 may exhibit a shift flair when upshifting from third gear. There is a computer update for this concern. Affected calibrations are BKG6, FFM6, KMA6, NFW6, and PBD6. Broadcast Message 0232.

    Lack of Power, Hard/No-Start, Runs Rough on Delivery:
    Air in the HP oil and fuel systems may cause the above symptoms. The vehicle should be driven 30 miles to purge the air from the passages. If this does not resolve the concern, use WDS to command the variable geometry turbo actuator to cycle. If the concern is still present, continue diagnosis. Broadcast Message 0211.

    TorqShift Transmission--Incorrect Dipstick:
    If the transmission fluid appears to be low on a TorqShift transmission, the dipstick may be wrong. The correct part number is 3C3Z-7A020-BB. If the fluid is in fact low, the correct fluid to use is Mercon SP. Broadcast Message 0397.

    Lacks or Loses Power in Cold Temperatures:
    This may be due to fuel gelling or moisture freezing and reducing fuel flow. It is recommended to use a fuel conditioner, such as Stanadyne Performance Formula, to prevent this condition. Do not use conditioners that contain alcohol. Broadcast Message 0436.

    Fuel Rail Plug Leak:
    Some engines may have a fuel leak at the rear of the cylinder head(s). This may be due to a misaligned fuel passage plug seal. Replace the plug and seal with P/N 3C3Z-9K042-AA. Broadcast Message 0523, SSM #16634.

    No Crank/No Start; Vehicles with TorqShift Transmission:
    If this condition is occurs it may be due to a problem in the cooling fan electric clutch. This may be accompanied by transmission range sensor codes P1705 (TR not indicating neutral on self test), P0706 (TR-P sensor frequency fault) and P0707 (TR-P sensor circuit duty cycle low input). Check the voltage at the TR sensor pin 21, circuit 371, it soould read 12 volts. If the voltage is low (3-4 volts), unplug the cooling fan electrical connector and retest. If the voltage is now 12 volts, try starting the engine. If it starts, clear codes and test drive to see if the TR sensor codes return. If they do not, diagnose the cooling fan electric clutch. Broadcast Messages 0520, 1069.

    Loose Radiator Hose Clamp:
    A coolant leak at the radiator hose may indicate a broken or weak hose clamp. If a leak is present, allow the engine to cool down. Check to make sure the hose is fully seated on the hose fitting. Install service hose clamp 3C3Z-8287-EA up against the exsisting clamp (no need to remove hose) and torque to 31 in/lbs. Warm up the engine and check for leaks. Broadcast Message 0495.
    The hose clamps can also be replaced by using a heat gun to soften the glue retaining the clamp to the hose. Remove the clamp and replace with P/N W710044-S900 for 2" hose ID or W710043-S900 for 1.75" hose ID. Broadcast Message 0529.

    6.0 PowerStroke Calibration Update History

    2003-2004, up to 9-30-03
    Running Change 1, available 12-16-02
    Addresses:
    3-4 Shift flair

    Running Change 2, available 2-4-03
    Addresses:
    Rough idle in park/neutral on cold start/restart
    Cold idle kicker enhancement

    Running Change 3, available 2-24-03
    Addresses:
    Rough idle in drive/reveres on cold starts
    Poor throttle response on cold starts
    Low power on cold start or after extended idling (may clear by cycling key)
    Harsh TorqShift engagement/2-3 upshift
    TorqShift 5-3 coasting downshift
    Cold 3-5 shift flair
    Modified TorqShift shift position sensor values
    Activated cooling fan trouble code P0528

    Running Change 3s, available 4-3-03--FICM only
    Addresses:
    Hessitation on light accel
    PTO enhancement

    Running Change 4, available 5-19-03
    Addresses:
    Low power on cold start/extended idling (may clear by cycling the key)
    False cooling fan code P0528
    No/slow throttle response on TorqShift engagement

    Running Change 5, available 8-18-03
    Addresses:
    Rough idle/surge/smoke on light throttle tip-in
    Improved A/C performance at idle
    Minor manual transmission launch performance enhancements
    Smoother tow/haul downshift at 20 MPH
    Improved low altitude/high barometric pressure performance
    Diagnostic and network communication upgrades

    Running Change 6, available 10-3-03
    Addresses:
    Improved performance on hard accel after cold start
    Loping on hot restarts
    Cold idle kicker enhancements
    False PCM/FICM program incompatibiliy code U0306 after reprogramming
    Turbo system performance code P2263 enhancements
    Engine oil temp sensor performance code P0196 enhancements
    Running Change 8 (orig. RC7), available 12-12-03
    Addresses:
    Improved hard acceleration performance at high altitudes after cold start
    Rough running/misfire at high altitude after extended idle on cold starts
    Check engine light activation for turbo performance code P2263 turned off (49 State emissions only)
    Harsh 3-2 coasting downshifts or clunk/buck/jerk on accelerator tip-in/tip-out in tow/haul

    2004.25, after 9-30-03
    Running Change 1, available 1-30-04
    Addresses:
    Improved cold start and hard accel performance at high altitudes
    Rough running and/or misfire after extended idle on cold starts at high altitudes
    Rough or rolling idle immediately after cold start
    Check engine light activation for turbo performance code P2263 turned off (49 State emissions only)
    Harsh 3-2 coasting downshifts or clunk/buck/jerk on accelerator tip-in/tip-out in tow/haul
    P0299 turbo under boost enhancements
    P0500 vehicles speed input enhancement for manual transmission
    TorqShift harsh reverse engagement on low mileage vehicles
    Econoline RC1, available 2-26-04
    Addresses:
    Engine speed under run on long decel in manual second or third gear
    mroved fuel pump diagnostic code P0231
    No updated calibration information published after April, 2004.

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