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Get Free 2002 FORD F150 V8, 5.4L; SOHC; TSBs

Technical Service Bulletins

Released 12/11/2018
Multiple Vehicle Lines - Revised Engine Oil Leak Diagnostic Procedure Using New White Fluorescent Dye

Released 4/14/2006
MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID.

TSB Description

Released 1/26/2006
MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS

Released 5/23/2003
BODY—BED EXTENDER—COMPONENT REPLACEMENT—SERVICE TIP

Released 9/1/2002
ENGINE—ENGINE OIL—RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS—GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY

Released 7/23/2002
COOLING SYSTEM—MOTORCRAFT PREMIUM GOLD ENGINE COOLANT—SERVICE TIPS

Released 4/11/2002
ENGINE—NEW GASKET REMOVER/CLEANER AND SERVICE TIPS FOR ALUMINUM HEADS AND BLOCKS

Released 3/16/2002
PAINT—NEW POLISHING PRODUCTS—SERVICE PROCEDURES

Released 12/23/2001
• ENGINE COOLANT—PROPYLENE GLYCOL—FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL • ENGINE COOLANT—PROPYLENE GLYCOL-BASED—FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS

Released 4/23/2018
2001-2015 - Vehicles With Modular 4.6L, 5.4L Or 6.8L Engines - Determining Root Cause Of Engine Damage Due To Oil Pressure Loss.

Released 4/23/2018
1997-2003 F-150/2004 F-150 Heritage/1997-1999 F-250/2002-2003 Blackwood - Safety Recall 11S21 - Fuel Tank Strap Fracture - Requests For Recall Service Action

TSB Description

Released 10/19/2017
Remanufactured Powertrain Core Returns

Released 12/15/2015
Multiple Vehicles - Transmission Cooler Flush General Service Bulletin (GSB)

Released 12/8/2015
Multiple Vehicles - Engine Failure Analysis General Service Bulletin (GSB)

Released 3/7/2007
SPARK KNOCK UNDER LIGHT LOAD AND ACCELERATION—3.8L, 3.9L, AND 4.2L—SPLIT PORT INTAKE MANIFOLD RUNNER CONTROL (IMRC)

Released 11/16/2005
SAFETY BELT RETRACTION SPEED

Released 10/3/2005
SAFETY BELT WEB STOP BUTTON SERVICE

Released 9/11/2005
REMOVAL AND INSTALLATION OF REAR BOLT-IN GLASS—SERVICE TIP

Released 7/5/2004
BODY—FRONT WINDOW(S)—POP/THUMP NOISE END OF WINDOW TRAVEL AND/OR DRIVER’S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION

Released 6/20/2004
TICKING OR KNOCKING NOISE COMING FROM THE CATALYTIC CONVERTERS

Released 2/2/2004
BODY—BACK GLASS—SLIDING BACK GLASS WINDNOISE/WATER LEAK—SEAL REPLACEMENT

Released 1/11/2004
DRIVEABILITY—STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401—ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY

Released 12/15/2003
STEERING—TIE ROD END INSPECTION PROCEDURE

Released 10/11/2003
BODY—WATER LEAK FROM ROOF OPENING PANEL—ROOF OPENING PANEL BINDS OR WILL NOT OPEN PROPERLY * NOISE—RATTLE FROM ROOF OPENING PANEL AREA

Released 6/9/2003
TRIM—REPLACEMENT CENTER CONSOLE EMBLEM FOR HARLEY DAVIDSON TRUCKS

Released 5/23/2003
BODY—BED EXTENDER—COMPONENT REPLACEMENT—SERVICE TIP

Released 4/2/2003
BODY—DRIVER SIDE WINDOW BINDS WHEN OPERATED * ELECTRICAL—DRIVER SIDE WINDOW BINDS WHEN OPERATED

Released 2/23/2003
BODY—MIRROR—EXTERIOR MIRROR GLASS AND MOTOR REPLACEMENT—SERVICE TIPS

Released 1/7/2003
BODY—WATER LEAK FROM ROOF OPENING PANEL AREA

Released 11/25/2002
TRIM—SEAT HEADREST COVER LOOSE- SUPERCREW MODELS ONLY

Released 11/21/2002
RIDE—HARSH RIDE—CAB/BODY OSCILLATION/BOUNCE—HIGHWAY SPEEDS—4X2 MODELS ONLY

Released 6/5/2002
SHEET METAL—PRIMED SERVICE PARTS—PREP PROCEDURE AND MSDS INFORMATION

Released 5/3/2002
BODY—“SQUEAK” OR BIND FROM TAILGATE * NOISE—“SQUEAK” OR BIND FROM TAILGATE

Released 4/23/2002
DIAGNOSTIC TROUBLE CODE (DTC)—P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT—GASOLINE ENGINE VEHICLES ONLY *

Released 4/21/2002
STEERING—ROOF DITCH MATERIAL CRACKING—SERVICE TIPS

Released 3/16/2002
PAINT—NEW POLISHING PRODUCTS—SERVICE PROCEDURES

Released 2/25/2002
ELECTRICAL—CDX6 RADIO DAMAGED DURING SERVICE SHIPPING—CORRECT SHIPMENT PROCEDURES FOR CDX6 RADIO—SERVICE TIPS

Released 1/4/2002
STEERING—IDLER ARM REPLACEMENT SPECIFICATIONS

Released 11/1/1996
LOCKS—INTRODUCTION OF NEW LOCK DESIGN—SERVICE TIP

Released 12/4/1994
PAINT—PRIMED SHEET METAL—PREP PROCEDURE AND MSDS INFORMATION

Released 6/2/1991
PAINT—CODES—REVISED 1991 FLEET COLOR PAINT CODE NUMBERS

Released 12/21/2006
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)

Released 8/14/2003
TRANSMISSION—NEW TRANSMISSION COOLER FLUSHER SERVICE TIPS

TSB Description

Released 7/23/2002
COOLING SYSTEM—MOTORCRAFT PREMIUM GOLD ENGINE COOLANT—SERVICE TIPS

Released 12/23/2001
• ENGINE COOLANT—PROPYLENE GLYCOL—FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL • ENGINE COOLANT—PROPYLENE GLYCOL-BASED—FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS

Released 2/27/2008
BATTERY SERVICE—OPERATION OF BATTERY EYE—CHARGING SERVICE TIPS

Released 8/15/2006
KEYPAD DIAGNOSTICS—DEALER INSTALLED ACCESSORY

TSB Description

Released 5/8/2006
SPEED CONTROL DIAGNOSTICS—W/O SCP

Released 10/26/2005
CLUNK OR BUMP WHEN STARTING FROM A STOP

Released 7/18/2005
WIRING—SOLDERING AND CRIMPING REPAIRS— SOLDERING TIPS

Released 7/5/2004
BODY—FRONT WINDOW(S)—POP/THUMP NOISE END OF WINDOW TRAVEL AND/OR DRIVER’S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION

Released 3/8/2004
ELECTRICAL—SPLICING NEW WIRE(S) INTO EXISTING ELECTRICAL HARNESS—SERVICE PROCEDURE

Released 2/2/2004
BODY—BACK GLASS—SLIDING BACK GLASS WINDNOISE/WATER LEAK—SEAL REPLACEMENT

Released 11/6/2003
ELECTRICAL—HEAVY STATIC OR SIGNAL LOSS ON TWO WAY RADIO COMMUNICATION—BI-FUEL LPG VEHICLES ONLY

Released 10/11/2003
BODY—WATER LEAK FROM ROOF OPENING PANEL—ROOF OPENING PANEL BINDS OR WILL NOT OPEN PROPERLY * NOISE—RATTLE FROM ROOF OPENING PANEL AREA

Released 5/23/2003
BODY—BED EXTENDER—COMPONENT REPLACEMENT—SERVICE TIP

Released 4/2/2003
BODY—DRIVER SIDE WINDOW BINDS WHEN OPERATED * ELECTRICAL—DRIVER SIDE WINDOW BINDS WHEN OPERATED

Released 2/23/2003
BODY—MIRROR—EXTERIOR MIRROR GLASS AND MOTOR REPLACEMENT—SERVICE TIPS

Released 1/18/2003
ELECTRICAL—REMOTE KEYLESS ENTRY (RKE)— SERVICE TIPS

Released 1/7/2003
BODY—WATER LEAK FROM ROOF OPENING PANEL AREA

Released 11/25/2002
TRIM—SEAT HEADREST COVER LOOSE- SUPERCREW MODELS ONLY

Released 11/21/2002
RIDE—HARSH RIDE—CAB/BODY OSCILLATION/BOUNCE—HIGHWAY SPEEDS—4X2 MODELS ONLY

Released 6/17/2002
LAMP—BRAKE—INADVERTENT DISABLING OF BRAKE SHIFT INTERLOCK

Released 4/10/2002
MODE WITH ALT FUEL GREEN LIGHT ON, ROLLING IDLE, SURGING IDLE, AND/OR SURGE AT CRUISE IN LPG MODE WITH ALT FUEL GREEN LIGHT ON

Released 2/25/2002
ELECTRICAL—CDX6 RADIO DAMAGED DURING SERVICE SHIPPING—CORRECT SHIPMENT PROCEDURES FOR CDX6 RADIO—SERVICE TIPS

Released 12/8/2001
• DRIVEABILITY—DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY—STICKING OR BINDING IGNITION LOCK CYLINDER—HIGH EFFORT WHEN TURNING IGNITION SWITCH • ELECTRICAL—STICKING OR BINDING IGNITION LOCK CYLINDER

Released 12/8/2001
• DRIVEABILITY—BI-FUEL WIRING CONNECTOR CROSS-REFERENCE CHART • ELECTRICAL—BI-FUEL WIRING CONNECTOR CROSS-REFERENCE CHART

Released 10/11/2001
WIRING—WIRE HARNESS TERMINAL REPAIR KIT AND WIRE SPLICE PROCEDURE

Released 11/1/1996
LOCKS—INTRODUCTION OF NEW LOCK DESIGN—SERVICE TIP

Released 12/4/2005
INTERMITTENT ROUGH IDLE—NON-COMMANDED INTERMITTENT ROUGH IDLE—NON-COMMANDED

Released 6/22/2005
MIL ON WITH DTC P1131 AND/OR P1151—4.2L ENGINE

TSB Description

Released 4/17/2004
MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED—SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC’S)—SERVICE TIPS

Released 1/11/2004
DRIVEABILITY—STREAMLINED DIAGNOSTIC PROCEDURE FOR VEHICLES WITH MIL ON AND DTCS P0401, P0402, P1400 OR P1401—ADDITIONAL SYMPTOMS MAY INCLUDE RUNS ROUGH, LACKS POWER, SURGE, POOR FUEL ECONOMY

Released 6/6/2003
DRIVEABILITY—BI-FUEL—OXYGEN SENSOR DIAGNOSTICS—HIGH OXYGEN SENSOR VOLTAGE READING

Released 3/20/2003
DRIVEABILITY—MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED WITH DTC’S P0442, P0455, P0456, P0457, P1442 OR CHECK FUEL CAP LAMP ILLUMINATED WITH DTC P0457

Released 8/10/2002
DRIVEABILITY—5.4L 2V—IDLE-AIR BYPASS FLOW INDUCED WHISTLE * ENGINE—5.4L 2V—IDLE-AIR BYPASS FLOW INDUCED WHISTLE * NOISE—IDLE-AIR BYPASS FLOW INDUCED WHISTLE—VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY

Released 4/23/2002
DIAGNOSTIC TROUBLE CODE (DTC)—P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT—GASOLINE ENGINE VEHICLES ONLY *

Released 3/19/2002
DRIVEABILITY—IDLE—HIGH IDLE SPEEDS- THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES—VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE *

Released 3/12/2002
DRIVEABILITY—ENGINE LACKS POWER WHEN OPERATING IN HIGH AMBIENT TEMPERATURES ABOVE 38C (100F)—VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY * ENGINE—5.4L—ENGINE LACKS POWER WHEN OPERATING IN HIGH AMBIENT TEMPERATURES ABOVE 38C (100F)

Released 12/8/2001
• IDLE—HIGH IDLE SPEEDS— THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES—VEHICLES BUILT THROUGH 11/01/01 EQUIPPED WITH 5.4L ENGINE • ENGINE—5.4L—PCV SYSTEM ICING— VEHICLES BUILT THROUGH 11/01/01

Released 10/28/2009
STAINLESS STEEL EXHAUST STUDS - 5.4L AND 6.8L 2V ENGINES

Released 4/5/2005
USE OF STAINLESS STEEL EXHAUST STUDS IN SERVICE FOR 5.4L 2V ENGINE

TSB Description

Released 6/20/2004
TICKING OR KNOCKING NOISE COMING FROM THE CATALYTIC CONVERTERS

Released 7/20/2003
ENGINE—4.2L—VIBRATION AND/OR RATTLE IN GEAR AT IDLE OR WHEN ACCELERATING FROM A SLOW SPEED 32 KM/H (20 MPH)—VEHICLES BUILT BEFORE 2/25/02 EQUIPPED WITH AUTOMATIC TRANSMISSION ONLY *

Released 6/25/2003
ENGINE—ROMEO BUILT 4.6L 2V—TICK NOISE FROM ENGINE—ENGINES BUILT BEFORE 9/17/2003

Released 4/23/2018
1997-2003 F-150/2004 F-150 Heritage/1997-1999 F-250/2002-2003 Blackwood - Safety Recall 11S21 - Fuel Tank Strap Fracture - Requests For Recall Service Action

Released 9/8/2014
1997-2003 F-150/2004 F-150 Heritage/1997-1999 F-250/2002-2003 Blackwood - Safety Recall 11S21 - Fuel Tank Strap Fracture - Requests For Recall Service Action

TSB Description

Released 10/13/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Owner Letter

Released 8/18/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Dealer Bulletin

Released 8/3/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Additional Information - Recall Reimbursement

Released 8/1/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Customer Information Sheet: Passed Inspection

Released 8/1/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Technical Info

Released 8/1/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Dealer Q&A

Released 8/1/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Customer Information Sheet: Did Not Pass Inspection

Released 7/29/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Additional Information - Background Summary

Released 3/7/2007
SPARK KNOCK UNDER LIGHT LOAD AND ACCELERATION—3.8L, 3.9L, AND 4.2L—SPLIT PORT INTAKE MANIFOLD RUNNER CONTROL (IMRC)

Released 8/22/2005
WDS COP KIT DIAGNOSTIC TIPS—COIL ON PLUG (COP) IGNITION SYSTEMS—ENGINE MISFIRE OR ROUGH RUNNING

Released 6/22/2005
MIL ON WITH DTC P1131 AND/OR P1151—4.2L ENGINE

Released 6/5/2005
ALTERNATIVE FUEL VEHICLE—COMPRESSED NATURAL GAS FUEL TANK INSPECTION

Released 6/20/2003
DRIVEABILITY—DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES—4.6L AND 5.4L ENGINE—ROUGH IDLE, HARD START OR NO START WHEN COLD—LOSS OF POWER—LEAN FUEL DTC’S—RESTRICTED CATALYTIC CONVERTER *

Released 6/6/2003
DRIVEABILITY—BI-FUEL—OXYGEN SENSOR DIAGNOSTICS—HIGH OXYGEN SENSOR VOLTAGE READING

Released 3/18/2003
DRIVEABILITY—DEDICATED COMPRESSED NATURAL GAS (CNG)—ROUGH IDLE OR NO START WHEN COLD—VEHICLES EQUIPPED WITH DEDICATED 4.6L OR 5.4L CNG ENGINE ONLY

Released 3/10/2003
DRIVEABILITY—BI-FUEL CNG/LPG LOW FLOW NJECTOR SERVICE KIT WITHOUT COOLANT LOCK-OFF * DRIVEABILITY—CRANK NO START—BI-FUEL CNG/LPG VEHICLES—LOW FLOW INJECTOR SERVICE KIT WITHOUT COOLANT LOCK-OFF

Released 2/10/2003
DRIVEABILITY—COMPRESSED NATURAL GAS (CNG)—ROUGH IDLE OR NO START WHEN COLD— VEHICLES EQUIPPED WITH CNG BI-FUEL ENGINE ONLY

Released 2/4/2003
FUEL—BI-FUEL—CNG FUEL LEAK AT FILL VALVE— E-SERIES AND F-SERIES CNG FILL VALVE— REVISED SERVICE PARTS

Released 8/10/2002
DRIVEABILITY—5.4L 2V—IDLE-AIR BYPASS FLOW INDUCED WHISTLE * ENGINE—5.4L 2V—IDLE-AIR BYPASS FLOW INDUCED WHISTLE * NOISE—IDLE-AIR BYPASS FLOW INDUCED WHISTLE—VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY

Released 4/16/2002
FUEL SYSTEM—FUEL PUMP “WHINING”/“BUZZING” NOISE COMES THROUGH ENTERTAINMENT OR TWO-WAY RADIO SPEAKER *

Released 4/10/2002
MODE WITH ALT FUEL GREEN LIGHT ON, ROLLING IDLE, SURGING IDLE, AND/OR SURGE AT CRUISE IN LPG MODE WITH ALT FUEL GREEN LIGHT ON

Released 3/19/2002
DRIVEABILITY—IDLE—HIGH IDLE SPEEDS- THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES—VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE *

Released 3/10/2002
DRIVEABILITY—BI-FUEL CNG—NO START IN CNG MODE WITH ALT FUEL GREEN LIGHT ON

Released 1/22/2002
DRIVEABILITY—SURGE/ROLLING IDLE—GEAR DRIVEN SYNCHRONIZERS—INCORRECT INSTALLATION—CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION *

Released 12/8/2001
• DRIVEABILITY—DIAGNOSTIC TROUBLE CODES (DTC) P0500, P1502 AND/OR U1039 CONTINENTAL MODELS ONLY—STICKING OR BINDING IGNITION LOCK CYLINDER—HIGH EFFORT WHEN TURNING IGNITION SWITCH • ELECTRICAL—STICKING OR BINDING IGNITION LOCK CYLINDER

Released 12/8/2001
• DRIVEABILITY—BI-FUEL WIRING CONNECTOR CROSS-REFERENCE CHART • ELECTRICAL—BI-FUEL WIRING CONNECTOR CROSS-REFERENCE CHART

Released 9/13/2011
WHITE FLAKES OR POWDER COMING FROM A/C VENTS

Released 10/16/2009
WHITE FLAKES COMING FROM A/C VENTS

TSB Description

Released 6/16/2009
WHITE FLAKES COMING FROM A/C VENTS

Released 12/15/2008
WHITE FLAKES COMING FROM A/C VENTS

Released 12/21/2006
HEATER CORE LEAKAGE AND ELECTROLYSIS (INFORMATION ONLY)

Released 11/10/2005
WHITE FLAKES COMING FROM A/C VENTS

Released 11/6/2003
ELECTRICAL—HEAVY STATIC OR SIGNAL LOSS ON TWO WAY RADIO COMMUNICATION—BI-FUEL LPG VEHICLES ONLY

Released 12/11/2018
Multiple Vehicle Lines - Revised Engine Oil Leak Diagnostic Procedure Using New White Fluorescent Dye

Released 4/23/2018
2001-2015 - Vehicles With Modular 4.6L, 5.4L Or 6.8L Engines - Determining Root Cause Of Engine Damage Due To Oil Pressure Loss.

TSB Description

Released 4/23/2018
1997-2003 F-150/2004 F-150 Heritage/1997-1999 F-250/2002-2003 Blackwood - Safety Recall 11S21 - Fuel Tank Strap Fracture - Requests For Recall Service Action

Released 10/19/2017
Remanufactured Powertrain Core Returns

Released 12/15/2015
Multiple Vehicles - Transmission Cooler Flush General Service Bulletin (GSB)

Released 12/8/2015
Multiple Vehicles - Engine Failure Analysis General Service Bulletin (GSB)

Released 10/17/2007
4.6L 2V, 5.4L 2V, OR 6.8L 2V—SPARK PLUG THREAD REPAIR PROCEDURE—NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY

Released 2/15/2007
SOME 1997-2007 VEHICLES WITH 5.4L 2V AND 6.8L 2V MODULAR ENGINE SPARK PLUG THREAD OUT OF WARRANTY REPAIR PROCEDURE FOR ALUMINUM HEADS

Released 1/9/2007
MERCONâ ATF REPLACED BY MERCON (R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS

Released 12/18/2006
IDENTIFYING THE CORRECT REPLACEMENT HEAD GASKET FOR CERTAIN REMANUFACTURED ENGINES—SERVICE TIP

Released 4/14/2006
MERCON ATF IS BEING REPLACED BY MERCON V ATF AS A SERVICE FLUID.

Released 1/26/2006
MERCON ATF IS BEING REPLACED BY MERCON V AS A SERVICE FLUID FOR SOME MANUAL TRANSMISSIONS

Released 12/4/2005
INTERMITTENT ROUGH IDLE—NON-COMMANDED INTERMITTENT ROUGH IDLE—NON-COMMANDED

Released 10/26/2005
CLUNK OR BUMP WHEN STARTING FROM A STOP

Released 8/22/2005
WDS COP KIT DIAGNOSTIC TIPS—COIL ON PLUG (COP) IGNITION SYSTEMS—ENGINE MISFIRE OR ROUGH RUNNING

Released 6/22/2005
MIL ON WITH DTC P1131 AND/OR P1151—4.2L ENGINE

Released 6/5/2005
ALTERNATIVE FUEL VEHICLE—COMPRESSED NATURAL GAS FUEL TANK INSPECTION

Released 4/5/2005
USE OF STAINLESS STEEL EXHAUST STUDS IN SERVICE FOR 5.4L 2V ENGINE

Released 3/23/2005
REAR AXLE NOISE REPAIR

Released 6/1/2004
NOISE—DRIVELINE CLUNKING/GRUNTING NOISE OR SHUDDER SENSATION DURING LIGHT TO MODERATE ACCELERATION AND/OR BRAKING *

Released 8/14/2003
TRANSMISSION—NEW TRANSMISSION COOLER FLUSHER SERVICE TIPS

Released 7/20/2003
ENGINE—4.2L—VIBRATION AND/OR RATTLE IN GEAR AT IDLE OR WHEN ACCELERATING FROM A SLOW SPEED 32 KM/H (20 MPH)—VEHICLES BUILT BEFORE 2/25/02 EQUIPPED WITH AUTOMATIC TRANSMISSION ONLY *

Released 6/25/2003
ENGINE—ROMEO BUILT 4.6L 2V—TICK NOISE FROM ENGINE—ENGINES BUILT BEFORE 9/17/2003

Released 6/20/2003
DRIVEABILITY—DEDICATED COMPRESSED NATURAL GAS (CNG) VEHICLES—4.6L AND 5.4L ENGINE—ROUGH IDLE, HARD START OR NO START WHEN COLD—LOSS OF POWER—LEAN FUEL DTC’S—RESTRICTED CATALYTIC CONVERTER *

Released 5/23/2003
BODY—BED EXTENDER—COMPONENT REPLACEMENT—SERVICE TIP

Released 3/18/2003
DRIVEABILITY—DEDICATED COMPRESSED NATURAL GAS (CNG)—ROUGH IDLE OR NO START WHEN COLD—VEHICLES EQUIPPED WITH DEDICATED 4.6L OR 5.4L CNG ENGINE ONLY

Released 2/10/2003
DRIVEABILITY—COMPRESSED NATURAL GAS (CNG)—ROUGH IDLE OR NO START WHEN COLD— VEHICLES EQUIPPED WITH CNG BI-FUEL ENGINE ONLY

Released 2/4/2003
FUEL—BI-FUEL—CNG FUEL LEAK AT FILL VALVE— E-SERIES AND F-SERIES CNG FILL VALVE— REVISED SERVICE PARTS

Released 12/21/2002
OSCILLATION/BOUNCE—HIGHWAY SPEEDS—4X2 CHECKING CYLINDER HEAD AND BLOCK FLATNESS

Released 9/1/2002
ENGINE—ENGINE OIL—RECOMMENDED APPLICATIONS FOR SAE 5W-20 AND SAE 5W-30 MOTOR OILS—GASOLINE AND FLEXIBLE FUEL VEHICLES ONLY

Released 8/10/2002
DRIVEABILITY—5.4L 2V—IDLE-AIR BYPASS FLOW INDUCED WHISTLE * ENGINE—5.4L 2V—IDLE-AIR BYPASS FLOW INDUCED WHISTLE * NOISE—IDLE-AIR BYPASS FLOW INDUCED WHISTLE—VEHICLES EQUIPPED WITH 5.4L 2V ENGINE ONLY

Released 7/23/2002
COOLING SYSTEM—MOTORCRAFT PREMIUM GOLD ENGINE COOLANT—SERVICE TIPS

Released 4/23/2002
DIAGNOSTIC TROUBLE CODE (DTC)—P1635 AND/OR P1639 PRESENT AFTER POWERTRAIN CONTROL MODULE (PCM) OR INSTRUMENT CLUSTER REPLACEMENT—GASOLINE ENGINE VEHICLES ONLY *

Released 4/11/2002
ENGINE—NEW GASKET REMOVER/CLEANER AND SERVICE TIPS FOR ALUMINUM HEADS AND BLOCKS

Released 3/19/2002
DRIVEABILITY—IDLE—HIGH IDLE SPEEDS- THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES—VEHICLES BUILT THROUGH 12/31/01 EQUIPPED WITH 4.6L ENGINE *

Released 3/12/2002
DRIVEABILITY—ENGINE LACKS POWER WHEN OPERATING IN HIGH AMBIENT TEMPERATURES ABOVE 38C (100F)—VEHICLES EQUIPPED WITH 5.4L ENGINE ONLY * ENGINE—5.4L—ENGINE LACKS POWER WHEN OPERATING IN HIGH AMBIENT TEMPERATURES ABOVE 38C (100F)

Released 1/22/2002
DRIVEABILITY—SURGE/ROLLING IDLE—GEAR DRIVEN SYNCHRONIZERS—INCORRECT INSTALLATION—CAMSHAFT POSITION SYNCHRONIZER (CMP) INSTALLATION TOOL CORRECT APPLICATION *

Released 1/21/2002
TRANSMISSION—4R100/E4OD—TORQUE CONVERTER ACCESS EXTERNAL DUST PLUG MAY BECOME DISLODGED

Released 12/23/2001
• ENGINE COOLANT—PROPYLENE GLYCOL—FORD MOTOR COMPANY POSITION ON ENGINE COOLANTS MADE FROM PROPYLENE GLYCOL • ENGINE COOLANT—PROPYLENE GLYCOL-BASED—FORD MOTOR COMPANY POSITION ON PROPYLENE GLYCOL-BASED ENGINE COOLANTS

Released 12/8/2001
• IDLE—HIGH IDLE SPEEDS— THROTTLE STICKS AFTER STEADY STATE DRIVING IN EXTREME COLD AMBIENT TEMPERATURES—VEHICLES BUILT THROUGH 11/01/01 EQUIPPED WITH 5.4L ENGINE • ENGINE—5.4L—PCV SYSTEM ICING— VEHICLES BUILT THROUGH 11/01/01

Released 6/4/1991
TRANSMISSION—AUTOMATIC—ELECTRONIC TRANSMISSION DIAGNOSTIC AND REPAIR CHART

Released 4/23/2018
1997-2003 F-150/2004 F-150 Heritage/1997-1999 F-250/2002-2003 Blackwood - Safety Recall 11S21 - Fuel Tank Strap Fracture - Requests For Recall Service Action

Released 9/8/2014
1997-2003 F-150/2004 F-150 Heritage/1997-1999 F-250/2002-2003 Blackwood - Safety Recall 11S21 - Fuel Tank Strap Fracture - Requests For Recall Service Action

TSB Description

Released 10/13/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Owner Letter

Released 8/18/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Dealer Bulletin

Released 8/3/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Additional Information - Recall Reimbursement

Released 8/1/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Customer Information Sheet: Passed Inspection

Released 8/1/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Technical Info

Released 8/1/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Dealer Q&A

Released 8/1/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Customer Information Sheet: Did Not Pass Inspection

Released 7/29/2011
Safety Recall - Certain 1997 through 2003 Model Year F-150, 2004 Model Year F-150 Heritage, 1997 through 1999 Model Year F-250 Light Duty, and 2002 through 2003 Model Year Blackwood Vehicles Operated in Corrosion States - Fuel Tank Strap Inspection and Repair - Additional Information - Background Summary

Released 1/9/2007
MERCONâ ATF REPLACED BY MERCON (R) V AS A SERVICE FLUID FOR SOME POWER STEERING SYSTEMS

Released 12/15/2003
STEERING—TIE ROD END INSPECTION PROCEDURE

TSB Description

Released 4/22/2003
WHEEL—CORRECT LUG NUT TORQUE SPECIFICATIONS—INCREASED WHEEL NUT AND STUD SIZE—SERVICE TIP

Released 1/4/2002
STEERING—IDLER ARM REPLACEMENT SPECIFICATIONS

Released 11/1/1996
LOCKS—INTRODUCTION OF NEW LOCK DESIGN—SERVICE TIP

Released 12/11/2018
Multiple Vehicle Lines - Revised Engine Oil Leak Diagnostic Procedure Using New White Fluorescent Dye

Released 10/17/2007
4.6L 2V, 5.4L 2V, OR 6.8L 2V—SPARK PLUG THREAD REPAIR PROCEDURE—NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY

TSB Description

Released 8/22/2005
WDS COP KIT DIAGNOSTIC TIPS—COIL ON PLUG (COP) IGNITION SYSTEMS—ENGINE MISFIRE OR ROUGH RUNNING

Released 7/18/2005
WIRING—SOLDERING AND CRIMPING REPAIRS— SOLDERING TIPS

Released 10/11/2001
WIRING—WIRE HARNESS TERMINAL REPAIR KIT AND WIRE SPLICE PROCEDURE

Released 12/4/1994
PAINT—PRIMED SHEET METAL—PREP PROCEDURE AND MSDS INFORMATION

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