2011-2014 F150 Service Manual PDF

2014 F-150 Workshop Manual Page 1 sur 10
SECTION 100-01: Identification Codes 2014 F-150 Workshop Manual

DESCRIPTION AND OPERATION Procedure revision date: 10/25/2013
Identification Codes
Vehicle Identification Number (VIN)
Vehicle Identification Number (VIN) Tag Locator
The Vehicle Identification Number (VIN) is a 17-digit combination of letters and numbers. The VIN is
stamped on a metal tab riveted on the instrument panel, top upper left of the dash. The VIN is also found on
the Vehicle Certification (VC) label.
If the VIN plate requires replacement, authorized dealers must contact their respective regional office.
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Item Description
1 World Manufacturer Identifier (WMI)
2 Brake type and Gross Vehicle Weight Rating (GVWR)
3 Vehicle line and body type
4 Engine type
5 Check digit
6 Model year
7 Assembly plant
8 Production sequence number
World Manufacturer Identifier (WMI)
The first 3 VIN positions are the World Manufacturer Identifier (WMI).
z 1FT - Ford Motor Company, USA, truck (completed vehicle)

z 5LT - Lincoln, USA, truck (Mexico only)
Brake Type and Gross Vehicle Weight Rating (GVWR)
The fourth VIN position is the vehicle brake type and Gross Vehicle Weight Rating (GVWR) code, all
vehicles use hydraulic brakes. This code may also identify the vehicle safety restraint system.
z E - 6,001-7,000 pound GVWR , active safety belts (all positions), driver and front passenger air bags,
side inflatable restraint (first and second row)
z F - 7,001-8,000 pound GVWR , active safety belt (all positions), driver and front passenger air bags,
z M - 6,001-7,000 pound GVWR , active safety belts (all positions), driver and front passenger air bags,
side inflatable restraint (first row)
z N - 7,001-8,000 pound GVWR , active safety belts (all positions), driver and front passenger air bags,
z P - 8,001-8,500 pound GVWR , active safety belts (all positions), driver and front passenger air bags,
z V - 8,001-8,500 pound GVWR , active safety belts (all positions), driver and front passenger air bags,
Line and Body Type
VIN positions 5 through 7 indicate the vehicle line and body type.
z F1C - Ford F-150, Rear Wheel Drive (RWD), regular cab, 5.5 ft, 6.5 ft or 8 ft styleside
z F1E - Ford F-150, Four-Wheel Drive (4WD), regular cab, 5.5 ft, 6.5 ft or 8 ft styleside
z J1G - Lincoln Mark LT, RWD , Crew Cab, styleside (Mexico only)
z J1J - Lincoln Mark LT, 4WD , Crew Cab, styleside (Mexico only)
z W1C - Ford F-150, RWD , Crew Cab, 5.5 ft or 6.5 ft styleside
z W1E - Ford F-150, 4WD , Crew Cab, 5.5 ft or 6.5 ft styleside
z W1R - Ford F-150, 4WD , Crew Cab, styleside, SVT
z X1C - Ford F-150, RWD , SuperCab, 5.5 ft, 6.5 ft or 8 ft styleside
z X1E - Ford F-150, 4WD , SuperCab, 5.5 ft, 6.5 ft or 8 ft styleside
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z X1R - Ford F-150, 4WD , SuperCab, styleside, SVT
Engine Type
The eighth VIN position is the engine type (displacement and number of cylinders).
z F - 5.0L, 4-valve, Dual Overhead Camshaft (DOHC), V8, electronic fuel injection, Flex-fuel
z M - 3.7L, 4-valve, V6, port fuel injection, Flex-fuel
z T - 3.5L, DOHC , V6, gas
z 6 - 6.2L, 2-valve, V8, electronic fuel injection
Additional engine information can be obtained from the engine tag. Refer to Section 303-01A , Section 303-
01B , Section 303-01C or Section 303-01D .
Check Digit
The ninth VIN position is a government-assigned, computer-generated check digit.
Model Year
The tenth VIN position is the model year code.
z E - 2014
Assembly Plant
The eleventh VIN position is the assembly plant code.
z F - Dearborn (Dearborn, Michigan, USA)

z K - Kansas City (Claycomo, Missouri, USA)
Build Sequence
VIN positions 12 through 17 are an alphanumeric code for the vehicle build sequence. This is also the
vehicle serial and warranty number. The serial number can also be found on the engine block, transmission
and frame.
z A00001-F99999 - Ford
z J00001-L99999 - Lincoln
Vehicle Certification (VC) Codes
Vehicle Certification (VC) Label Locator
Item Description
1 Exterior paint code
2 Region code
3 District Special Order (DSO)
4 Wheelbase code
5 Interior trim code

6 Tape/paint stripe code
7 Radio code
8 Axle code
9 Transmission code
10 Spring code
11 Powertrain calibration information
The Vehicle Certification (VC) label contains information on the manufacturer name, the month and year of
manufacture, the certification statement and the Vehicle Identification Number (VIN). This label also includes
Gross Vehicle Weight Rating (GVWR) information.
If a vehicle requires replacement of the VC label and is 4 years old or less, an authorized dealer must submit
the VIN to their respective regional office. The regional office will submit a web form to the assembly plant
for the replacement label. Once the label has been printed, a representative from the regional office will
deliver the label to the dealer and witness installation on the vehicle. If a vehicle is more than 4 years old
and requires a replacement label, the dealer must submit a request to the Department of Motor Vehicles.
Exterior Paint
Exterior paint codes may be listed as a 2-part code. The first set of characters identify the primary body
color. The second set of characters (if applicable) identify the vehicle accent or 2-tone body color. All colors
are base coat/clear coat.
Primary Exterior Color Codes

z Blank - No paint
z D7 - Sunset
z E4 - Vermilion Red
z J1 - Kodiak Brown #2
z LQ - Pale Adobe Metallic
z N1 - Blue Jeans Metallic
z PQ - Race Red
z RR - Ruby Red (tri-coat)
z UG - White Platinum (tri-coat)
z UH - Tuxedo Black Metallic
z UJ - Sterling Gray Metallic
z UX - Ingot Silver Metallic
z VA - Terrain
z W6 - Green Gem #2
z YZ - Oxford White
Exterior Accent Color Codes

z LQ - Pale Adobe Metallic
z UX - Ingot Silver Metallic
Wheelbase
z 126 - 3,200 mm (126 in)
z 133 - 3,378 mm (133 in)
z 145 - 3,683 mm (145 in)
z 157 - 3,988 mm (157 in)
z 163 - 4,140 mm (163 in)
Interior Trim
Interior trim codes are listed as a 2-part code. The first character identifies the interior trim type. The second
character identifies the interior trim color.
Interior Trim Type

z 3 - Brick Red accent SVT mini-perforated leather, F-150 SVT
z 4 - Blue accent SVT mini-perforated leather, F-150 SVT
z 5 - Milled pebble leather, captains chairs, F-150 FX
z 6 - Sport leather, F-150 FX
z 7 - Mini perforated leather, 40/console/40 split bench seat, F-150 SVT
z 9 - Leather, 40/console/40 split bench seat, F-150 Platinum
z A - Structure vinyl, 40/20/40 split bench seat, F-150
z C - Lucas cloth, 40/20/40 split bench seat, F-150
z D - Speck cloth, 40/20/40 split bench seat, F-150
z E - Milled pebble leather, 40/20/40 split bench seat, F-150
z G - Luxury leather, 40/console/40 split bench seat, F-150
z H - Milled pebble perforated leather, captains chairs, F-150
z K - Leather, captains chairs, F-150 King Ranch
z M - Premium Lucas cloth, 40/20/40 individual seats, F-150
z P - Micro perforated leather #1 captains chairs, F-150 Platinum
z R - Carbonite cloth, sport bucket seats, F-150
z S - STX Sport cloth bucket seats, F-150
z T - Micro perforated leather #2, captains chairs, F-150 Limited
z U - Lucas cloth, captains chairs, F-150
z V - Leather, 40/20/40 bucket seats, Mark LT
Interior Trim Color

z A - Adobe
z B - Charcoal Black
z S - Steel Gray
Tape/Paint Stripe
Tape and paint stripe codes do not apply.
Radio Type
z A - Amplitude Modulation/Frequency Modulation (AM/FM) stereo with clock – less human machine
interface
z B - AM/FM stereo, Compact Disc (CD) player with clock – human machine interface 1
z C - AM/FM stereo, CD player, SYNC® - human machine interface 2
z D - AM/FM stereo, CD player, Liquid Crystal Display (LCD), SYNC® - human machine interface 3
z E - AM/FM stereo, CD player, LCD and SYNC®
z F - AM/FM stereo, CD player, LCD , SYNC®, dual-zone Electronic Automatic Temperature Control
(EATC) – human machine interface 5
z G - Sony AM/FM stereo, CD player, SYNC®, human machine interface 6
Axle Type
The following lists the available axle ratios:
z 15 - 3.15 non-limited slip

z B6 - 3.73 limited slip
z H9 - 3.55 limited slip
z L3 - 3.31 electronic locking differential
Transmission Type
z 6 - 6-speed automatic, 6R80
Additional transmission information is available on the transmission tag. Refer to Section 307-01 .
Spring Code
Spring codes are listed as a 2-part code. The first 2 characters listed identify the front springs. The second 2
characters listed identify the rear springs.
z Front spring base part number - 5310

z Rear spring base part number - 5560
Powertrain Calibration Information
NOTE: Powertrain calibration information is limited to a maximum of 5 characters per line on the VC label.
Because of this, calibration identification consisting of more than 5 characters will wrap to the second line on
the VC label.
Powertrain calibration information is printed in the lower right corner of the VC label. Only base calibration
information is printed. Revision levels will not appear, however, they can be obtained through a scan tool
using the most current software revision.
Item Description
1 Model year (model year in which calibration strategy was first introduced)
2 Vehicle code
3 Transmission code
4 Unique calibration (designates different hardware to similar vehicles), example: tires or drive ratios
5 Fleet code (describes fleet to which the vehicle belongs), example: 6 - Evaporative Emission (EVAP)
6 Certification region (lead region where multiple regions are included in one calibration), example: A -
U.S. federal
7 Revision level (will advance as revisions occur), not printed on label
Model Year
z 1 - 2001
z 2 - 2002
z 3 - 2003
z 4 - 2004
z 5 - 2005
z 6 - 2006
z 7 - 2007
z 8 - 2008
z 9 - 2009
z A - 2010
z B - 2011
z C - 2012
z D - 2013
z E - 2014
Vehicle Line
z F6 - F-150
z F6 - Mark LT (Mexico only)
Transmission
z 1 - Automatic transmission
Unique Calibration
The Emissions/Corporate Average Fuel Economy/CO2 Compliance Department is responsible for assigning
these calibration numbers. Unique calibration identifications are assigned to cover similar vehicles to
differentiate tires, drive configurations, final drive ratios and other calibration-significant factors.
These 2 characters are chosen by the analyst to provide identifiable information unique to each calibration.
For example, using the number 2 to denote a 2-valve engine versus using the number 4 to denote a 4-valve
engine, offers an easily identifiable difference.
Fleet Code
z 1 - Heavy duty gas engine/Dyno
z 2 - Fast - Automobile Manufacturers' Association, US
z 3 - Alternative durability protocol, US
z 4 - Not assigned
z 5 - Not assigned
z 6 - Evaporative Emission (EVAP)
z 7 - Mileage accumulation, aging endurance durability
z 8 - On-Board Diagnostic (OBD)
z 9 - Not assigned
Certification Region
z 5 - US 50 states
z A - US federal, including altitude, may include Canada and/or Mexico
z B - US California, includes US green states
z C - Canada
z D - China
z E - European Community (Austria, Belgium, Denmark, Finland, France, Germany, Greece, Ireland,
Italy, Luxembourg, Netherlands, Portugal, Spain, Sweden, United Kingdom)
z F - Extended European Community (E plus Croatia, Czech Republic, Estonia, Hungary, Norway,
Poland, Romania, Russian Federation, Slovakia, Slovenia, Switzerland, Yugoslavia)
z G - Gulf Cooperative Council (Bahrain, Kuwait, Oman, Qatar, Saudi Arabia, United Arab Emirates)
z H - Hong Kong
z J - Japan
z K - Korea
z L - Malaysia
z M - Mexico
z N - New Zealand
z P - Australia
z Q - South America (Brazil)
z S - Singapore
z T - Taiwan
z V - Vietnam
z X - Rest Of World (ROW)
z Y - Military
z Z - Israel
Revision Level (not printed on label)

z 91-99 - Hardware calibration levels
z 01-04 - Preliminary levels

z 00 - Job 1 production (initial calibration)
z 05-09 - Pre-job 1 revisions to calibrations
z 10-89 - Post-job 1 revisions to calibrations
z 0B - Durability test level
z BD - OBD intermediate level (pre-05)
SECTION 100-02: Jacking and Lifting 2014 F-150 Workshop Manual

Jacking and Lifting
unintentionally lower. Always support vehicle with floor stands. Failure to follow these instructions
may result in serious personal injury.
placing any object under the vehicle. Never place your hand between the power running board and
the vehicle. Extended power running boards will retract when doors are closed. Failure to follow
these instructions may result in serious personal injury.
the vehicle on an uneven or soft surface may result in vehicle slipping or falling from the jack or
jackstand. Failure to follow this instruction may result in serious personal injury.
unless all drive wheels are elevated off the ground. Drive wheels in contact with ground could cause
unexpected vehicle movement. Failure to follow this instruction may result in serious personal
injury.
the parking brake if the rear wheels will remain on the ground. These actions help prevent
unintended vehicle movement. Failure to follow these instructions may result in serious personal
injury.
result in vehicle slipping or falling from the hoist. Failure to follow this instruction may result in
serious personal injury.
Jacking Points — Front
NOTICE: Do not use the control arm as a jacking point. Damage to the vehicle may occur.
The jacking point is a flat portion on the frame, located behind the front tire and wheel and right below the
arrow marked on the frame.
Jacking Points — Rear
NOTICE: Do not use the differential housing as a lift point. Leaks or damage to the rear axle cover
and adjoining differential housing surface may occur if a floor jack or any lifting device is allowed to
contact the cover at any point where the cover joins the housing.
The rear jacking points are located on the rear axle.
Frame Lifting Points
SECTION 100-04: Noise, Vibration and Harshness 2014 F-150 Workshop Manual
Noise, Vibration and Harshness (NVH)
Noise is any undesirable sound, usually unpleasant in nature. Vibration is any motion, shaking or trembling,
that can be felt or seen when an object moves back and forth or up and down. Harshness is a ride quality
issue where the vehicle's response to the road transmits sharply to the customer. Harshness normally
describes a firmer than usual response from the suspension system. NVH is a term used to describe these
conditions, which result in varying degrees of dissatisfaction. Although a certain level of NVH caused by
road and environmental conditions is normal, this section is designed to aid in the diagnosis, testing and
repair of NVH symptoms.
Acceptable NVH
All internal combustion engines and drivelines produce some noise and vibration; operating in a real world
environment adds noise that is not subject to control. Vibration isolators, mufflers and dampers reduce these
to acceptable levels. A driver who is unfamiliar with a vehicle can think that some sounds are abnormal
when actually the sounds are normal for the vehicle type. As a technician, it is very important to be familiar
with vehicle features and know how they relate to NVH symptoms and their diagnosis. For example, if the
vehicle has automatic overdrive, it is important to test drive the vehicle both in and out of overdrive mode.
Glossary of Terms
Amplitude
The quantity or amount of energy produced by a vibrating component (G-force). An extreme vibration has a
high amplitude. A mild vibration has a low amplitude. See Intensity.
Boom
Low frequency or low pitched noise often accompanied by a vibration. Also refer to Drumming.
Buffet/Buffeting
Strong noise fluctuations caused by gusting winds. An example would be wind gusts against the side glass.
Buzz
A low-pitched sound like that from a bee. Often a metallic or hard plastic humming sound. Also describes a
high-frequency vibration. Vibration feels similar to an electric razor.
Chatter
A pronounced series of rapidly repeating rattling or clicking sounds.
Chirp
A short-duration, high-pitched noise associated with a slipping drive belt.
Chuckle
A repetitious, low-pitched sound. A loud chuckle is usually described as a knock.
Click
A sharp, brief, non-resonant sound, similar to actuating a ball point pen.
Clonk
A hydraulic knocking sound. Sound occurs with air pockets in a hydraulic system. Also described as
hammering.
Clunk/Driveline Clunk
A heavy or dull, short-duration, low-frequency sound. Occurs mostly on a vehicle that is accelerating or
decelerating abruptly. Also described as a thunk.
Conductor
The components that carry (transmit) a vibration frequency from the originator to the reactor.
Cycles Per Second
Cycles per second. Same as hertz (Hz).
Cracks
A mid-frequency sound, related to squeak. Sound varies with temperature conditions.
Creak
A metallic squeak.
Cycle
The process of a vibrating component going through a complete range of motion and returning to the
starting point.
Decibel (dB)
A unit of measurement, referring to sound pressure level, abbreviated dB.
Drone
A low-frequency, steady sound, like a freezer compressor. Also described as a moan.
Drumming
A cycling, low-frequency, rhythmic noise often accompanied by a sensation of pressure on the ear drums.
Also described as a low rumble, boom or rolling thunder.
Flutter
Mid to high intermittent sound due to air flow. Similar to a flag flapping in the wind.
Frequency
The rate at which a cycle occurs within a given time.
G-force
The additional load or weight produced in an object during acceleration. When measuring the level or
amplitude of a vibration without sound, the unit G is added to associate the force of the vibration to gravity.
This is similar to measuring the weight of an object, which is also a function of gravity.
Gravelly Feel
A grinding or growl in a component, similar to the feel experienced when driving on gravel.
Grind
An abrasive sound, similar to using a grinding wheel, or rubbing sand paper against wood.
Hertz (Hz)
A unit of measure used to describe noise and vibration concerns expressed in cycles per second.
Hiss
Steady, high-frequency noise. Vacuum leak sound.
Hoot
A steady, low-frequency tone, sounds like blowing over a long neck bottle.
Howl
A mid-range frequency noise between drumming and whine. Also described as a hum.
Hum
Mid-frequency steady sound, like a small fan motor. Also described as a howl.
Intensity
The physical quality of sound that relates to the strength of the vibration (measured in decibels). The higher
the sound's amplitude, the higher the intensity and vice versa. See Amplitude.
Knock
A heavy, loud, repetitious sound, like a knock on the door.
Moan
A constant, low-frequency tone. Also described as a hum.
Ping
A short-duration, high-frequency sound, which has a slight echo.
Pitch
The physical quality of sound that relates to its frequency. Pitch increases as frequency increases and vice
versa.
Pumping Feel
A slow, pulsing movement.
Rattle
A random and momentary or short-duration noise.
Reactor
The component, or part, that receives a vibration from an originator and conductor and reacts to the
vibration by moving.
Roughness
A medium-frequency vibration. A slightly higher frequency than a shake. This type of vibration is usually
related to drivetrain components.
Rustling
Intermittent sound of varying frequency, sounds similar to shuffling through leaves.
Shake
A low-frequency vibration, usually with visible component movement. Usually relates to tires, wheels, brake
drums or brake discs if it is vehicle speed sensitive, or engine if it is engine speed sensitive. Also referred to
as a shimmy or wobble.
Shimmy
An abnormal vibration or wobbling, felt as a side-to-side motion of the steering wheel in the driveshaft
rotation. Also described as waddle.
Shudder
A low-frequency vibration that is felt through the steering wheel or seat during light brake application.
Slap
A resonance from flat surfaces, such as safety belt webbing or door trim panels.
Squeak
A high-pitched transient sound, similar to rubbing fingers against a clean window.
Squeal
A long-duration, high-pitched noise.
Tap
A light, rhythmic or intermittent hammering sound, similar to tapping a pencil on a table edge.
Thump
A dull beat caused by 2 items striking together.
Tick
A rhythmic tap, similar to a clock noise.
Tip-In Moan
A light moaning noise heard during light vehicle acceleration, usually between 40-100 km/h (25-65 mph).
Transient
A noise or vibration that is momentary, a short duration.
Vibration
Any motion, shaking or trembling, that can be felt or seen when an object moves back and forth or up and
down.
Whine
A constant, high-pitched noise. Also described as a screech.
Whistle
High-pitched noise with a very narrow frequency band. Examples of whistle noises are a turbocharger or air
flow around an antenna.
Wind Noise
Any noise caused by air movement in, out or around the vehicle.
SECTION 100-04: Noise, Vibration and Harshness 2014 F-150 Workshop Manual
DIAGNOSIS AND TESTING Procedure revision date: 10/25/2013
Noise, Vibration and Harshness (NVH)
Special Tool(s)
Electronic Vibration Analyzer
(EVA)
100-F027 (014-00344) or
equivalent
EngineEAR
107-R2100 or equivalent
EngineEAR/ChassisEAR
Mastertech® Series MTS 4000

Driveline Balance and NVH
Analyzer (Vetronix)
257-00018 or equivalent
Squeak and Rattle Repair Kit

164-R4900
Ultrasonic Leak Detector

Diagnostic Theory
The shortest route to an accurate diagnosis results from:
z system knowledge, including comparison with a known good system.

z system history, including repair history and usage patterns.
z condition history, especially any relationship to repairs or sudden change.
z knowledge of possible sources.
z using a systematic diagnostic method that divides the system into related areas.
The diagnosis and correction of NVH symptoms requires:
z a road or system test to determine the exact nature of the symptom.

z an analysis of the possible causes.
z testing to verify the cause.
z repairing any symptoms found.
z a road test or system test to make sure the cause has been corrected or brought back to within an
acceptable range.
Diagnostic Procedure Overview
Qualifying the symptom by the particular sensation present can help narrow down the cause. Always use the
"symptom" to "system" to "component" to "cause" diagnosis technique. This diagnostic method divides the
problem into related areas to correct the customer concern.
z Verify the "symptom".

z Determine which "system(s)" can cause the "symptom" using the diagnostic tools described in this
section.
z After determining the possible "system(s)", refer to the appropriate section in this manual to identify
the worn or damaged "components".
z After identifying the "components", identify the "cause" of the failure.
Tools and Techniques
The diagnostic tools allow for a systematic collection of information that is necessary to accurately diagnose
and repair NVH problems. Remember that the vibrating source component (originator) may only generate a
small vibration. This small vibration can in turn cause a larger vibration/noise to emanate from another
receiving component (reactor), due to contact with other components (transfer path). For the best results,
carry out the test as follows:
a. Test drive the vehicle with the vibration sensor inside the vehicle.
b. Place the sensor in the vehicle according to feel.
If the condition is felt through the steering wheel, the source is most likely in the front of the
vehicle.
A vibration that is felt in the seat or floor only will most likely be found in the driveline, drive axle
or rear wheels and tires.
c. Record the readings. Also note when the condition begins, when it reaches maximum intensity and if
it tends to diminish above/below a certain speed.
If a vibration symptom is vehicle speed related, the tire and wheel rpm/frequency and
driveshaft frequency should be calculated.
If a vibration symptom is engine speed related, the engine, engine accessory and engine firing
frequencies should be calculated.
Frequencies with an amplitude reading of 0.06 Gs or less are barely perceptible NVH levels.
No corrective action is necessary.

d. Place the vibration sensor on or near the suspect area outside the vehicle.
e. Continue the road test, driving the vehicle at the speed the symptom occurs and take another
reading.
f. Compare the readings.
A match in frequency indicates the problem component or area.
An unmatched test could indicate the symptom is caused by the engine, torque converter or
engine accessory. Use the diagnostic tools in the rpm mode and check if symptom is rpm
related.
The following diagnostic tools and techniques can be used separately or in conjunction with each other to
aid in the diagnosis of NVH symptoms. They are listed in order of preference for ease in their use for
locating these symptoms.
NVH Analyzer (Vetronix)
The Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) and the MTS 4100 NVH
analyzers are tools to aid in the identification and isolation of a noise, vibration or harshness symptom in a
vehicle. They measure noise and vibration data and compare it with data obtained from the vehicle's PCM
as well as vehicle variants that were entered by the user such as pulley size, axle ratio and tire size in order
to provide possible sources. The Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer
(Vetronix) and the MTS 4100 have the following characteristics:
z Interface with the vehicle's computer system

z Support and store vibration data input from 1 or 2 accelerometers
z Support and store noise data input from 2 microphones
z Provide a photo-tachometer for operation of the driveshaft balancing function
z Provide a strobe output capable of driving a standard timing light
z Contain a real-time clock circuit that provides time and date information which is used for tagging test
data
z Have the capability to print to an external printer and interface with a PC
z Can be powered from a variety of power sources: cigarette lighter, AC power or the internal battery
pack
The Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) and the MTS 4100 NVH
analyzers have 4 main operating modes. The first is for vibration diagnosis. This mode measures data from
1 or 2 accelerometers simultaneously while obtaining data from the vehicle. Then it carries out a frequency
analysis on the accelerometer information and compares the vibration frequencies with the frequencies
associated with various rotating components within the vehicle. The data can be presented in 4 different
display modes: principle component, bar chart, frequency spectrum or waterfall. All display mode formats
contain the same common elements, such as amplitude.
The second is for noise diagnosis. This mode measures noise from 1 or 2 microphones simultaneously. All
noise measurements are in decibels (dBs). All frequency bands used for noise measurements are the same
as for the vibration measurements, up to 1,000 Hz.
The third is driveshaft balancing. Driveshaft balancing is done using 1 or 2 accelerometers and a photo-
tachometer. The accelerometers measure the vibration at both ends of the driveshaft, while the photo-
tachometer measures the rotation speed and position reference. Refer to Section 205-00 .
The fourth is the strobe. A strobe or standard timing light can be connected to an analyzer, to provide a
means for measuring rotation speed. The strobe function is used for isolating the source of a vibration.
Electronic Vibration Analyzer (EVA)
The Electronic Vibration Analyzer (EVA) is a hand-held electronic scan tool which will assist in locating the
source of unacceptable vibrations. The vibration sensor can be remotely mounted anywhere in the vehicle
for testing purposes. The unit displays the 3 most common vibration frequencies and their corresponding
amplitudes simultaneously. A bar graph provides a visual reference of the relative signal strength
(amplitude) of each vibration being displayed and its relative G-force. The keypad is arranged to make the
EVA simple to program and use. Some of the functions include the ability to average readings as well as
record, play back and freeze readings. The EVA has a strobe balancing function that can be used to detect
imbalance on rotating components such as a driveshaft or engine accessories.
Item Description
1 Electronic Vibration Analyzer (EVA) screen
2 Frequency mode displayed in rpm or Hz
3 Active sensor input (A or B)
4 Current active mode
5 G-force indicators or the strongest frequencies in descending strength of each vibration
6 Strength of each vibration
7 Frequency in rpm/Hz of each vibration
Record the readings taken with the diagnostic tool.
Frequencies should be read in the "average" mode.

Frequencies have a range of plus or minus 2 Hz. A reading of 10 Hz can be displayed as an 8 Hz
through 12 Hz.
Vibrate Software®
Vibrate Software® (Rotunda tool number 215-00003) is a diagnostic aid which will assist in pinpointing the
source of unacceptable vibrations. The engine's crankshaft is the point of reference for vibration diagnosis.
Every rotating component will have an angular velocity that is faster, slower or the same as the engine's
crankshaft. Vibrate Software® calculates the angular velocity of each component and graphically represents
these velocities on a computer screen and on a printed vibration worksheet. The following steps outline how
Vibrate Software® helps diagnose a vibration symptom:
z Enter the vehicle information. Vibrate will do all the calculations and display a graph showing tire,
driveshaft and engine vibrations.
z Print a Vibration Worksheet graph. The printed graph is to be used during the road test.
z Road test the vehicle at the speed where the vibration is most noticeable. Record the vibration
frequency rpm and the engine rpm on the worksheet graph. The point on the graph where the
vibration frequency rpm reading and the engine rpm reading intersect indicates the specific
component group causing the symptom.
A frequency measurement tool capable of measuring vibration frequency and engine rpm will
be needed.
z Provides graphics of diagnostic procedures to aid in testing components.
Reed Tachometer
The Reed tachometer is a hand-held vibration sensor which will assist in locating the source of unacceptable
vibrations. The vibration sensor can be placed anywhere in the vehicle for testing purposes. The Reed
tachometer contains several reeds that are tuned to vibrate or resonate at different frequencies ranging from
10 to 80 Hz or 600 to 4,800 rpm. Though the Reed tachometer is able to measure multiple frequencies, it
does not measure amplitude.
Sirometer
The Sirometer measures frequency in hertz and rpm. To use the Sirometer, place it on any vibrating
component and slowly scroll the wire out by turning the knob. As the length of wire changes, so does its
natural frequency. Find the length of wire that vibrates with the highest amplitude. This frequency will match
that of the vibrating component. Read the frequency for that length of wire.
Combination EngineEAR/ChassisEAR
An electronic listening device used to quickly identify noise and the location under the chassis while the
vehicle is being road tested. The ChassisEARs can identify the noise and location of damaged/worn wheel
bearings, CV joints, brakes, springs, axle bearings or driveshaft carrier bearings.
EngineEAR Basic Unit
An electronic listening device used to detect even the faintest noises. The EngineEARs can detect the noise
of damaged/worn bearings in generators, coolant pumps, A/C compressors and power steering pumps.
They are also used to identify noisy lifters, exhaust manifold leaks, chipped gear teeth and for detecting wind
noise. The EngineEAR has a sensing tip, amplifier and headphones. The directional sensing tip is used to
listen to the various components. Point the sensing tip at the suspect component and adjust the volume with
the amplifier. Placing the tip in direct contact with a component will reveal structure-borne noise and
vibrations, generated by or passing through, the component. Various volume levels can reveal different
sounds.
Mechanic's Stethoscope
A mechanic's stethoscope is an inexpensive tool for locating noises in engines and other moving parts. It
can be used to help diagnose piston slap, worn gears, faulty valves, coolant pump failure, damaged gaskets,
defective bearings and body squeaks.
Squeak and Rattle Repair Kit
The Squeak and Rattle Repair Kit (Rotunda tool number 164-R4900) contains lubricants and self-adhesive
materials that can be used to eliminate interior and exterior squeaks and rattles. The kit consists of the
following materials:
z PVC (soft foam) tape

z Urethane (hard foam) tape
z Flocked (black fuzzy) tape
z UHMW (frosted) tape
z Squeak and rattle oil tube
z Squeak and rattle grease tube
Ultrasonic Leak Detector
The Ultrasonic Leak Detector is used to detect wind noises caused by leaks and gaps in areas where there
is weatherstripping or other sealing material. It is also used to identify A/C leaks, vacuum leaks and
evaporative emission noises. The Ultrasonic Leak Detector includes a multi-directional transmitter (operating
in the ultrasonic range) and a hand-held detector. The transmitter is placed inside the vehicle. On the
outside of the vehicle, the hand-held detector is used to sweep the area of the suspected leak. As the
source of the leak is approached, a beeping sound is produced which increases in both speed and
frequency.
Write-Up Job Aid
To assist the service advisor and the technician, a Write-Up Job Aid used during the interview process is
included with this material. The Write-Up Job Aid serves as a place to record all important symptom
information.
1: Customer Interview
The diagnostic process starts with the customer interview. The service advisor must obtain as much
information as possible about the symptom and take a test drive with the customer. There are many ways a
customer will describe NVH symptoms and this will help minimize confusion arising from descriptive
language differences. It is important that the symptom is correctly interpreted and the customer descriptions
are recorded. During the interview, complete the write-up job aid and ask the following questions:
z When was it first noticed?

z Did it appear suddenly or gradually?
z Did any abnormal occurrence coincide with or precede its appearance?
Use the information gained from the customer to accurately begin the diagnostic process.
2: Pre-Drive Check
It is important to do a pre-drive check before road testing the vehicle. A pre-drive check verifies that the
vehicle is relatively safe to drive and eliminates any obvious faults on the vehicle.
The pre-drive check consists of a brief visual inspection. During this brief inspection, take note of anything
that will compromise safety during the road test and make those repairs/adjustments before taking the
vehicle on the road.
3: Preparing for the Road Test
Observe the following when preparing for the road test:
z Review the information recorded on the write-up job aid. It is important to know the specific symptom
the customer has with the vehicle.
z Do not be misled by the reported location of the noise/vibration. The cause can actually be some
distance away.
z Conduct the road test on a quiet street where it is safe to duplicate the vibration/noise. The ideal
testing route is an open, low-traffic area where it is possible to operate the vehicle at the speed in
which the condition occurs.
z While observing that they are not related to the symptom, eliminate the following:
If possible, lower the radio antenna in order to minimize turbulence.
Identify anything that could potentially make noise or be a source of wind noise.
Inspect the vehicle for add-on items that create vibration/noise.
Turn off the radio and the heating and cooling system blower.
z The engine speed is an important factor in arriving at a final conclusion. Therefore, connect a
diagnostic tool, Vetronix, or an accurate tachometer to the engine, even if the vehicle has a
tachometer. This will make sure of an exact engine speed reading.
4: Verify the Customer Concern
Verify the customer concern by carrying out a road test, an engine run-up test or both.
The decision to carry out a road test, an engine run-up test or both depends on the type of NVH symptom. A
road test may be necessary if the symptom relates to the suspension system or is sensitive to torque. A
Drive Engine Run-Up (DERU) or a Neutral Engine Run-Up (NERU) test identifies noises and vibrations
relating to engine and drivetrain rpm. Remember, a condition will not always be identifiable by carrying out
these tests, however, they will eliminate many possibilities if carried out correctly.
5: Road Test
NOTE: It may be necessary to have the customer ride along or drive the vehicle to point out the symptom.
During the road test, take into consideration the customer's driving habits and the driving conditions. The
customer's concern just may be an acceptable operating condition for that vehicle.
The following is a brief overview of each test in the order in which it appears. A review of this information
helps to quickly identify the most appropriate process necessary to make a successful diagnosis. After
reviewing this information, select and carry out the appropriate test(s), proceeding to the next step of this
process.
z The Slow Acceleration Test is normally the first test to carry out when identifying an NVH symptom,
especially when a road test with the customer is not possible.
z The Heavy Acceleration Test helps to determine if the symptom is torque-related.
z The Neutral Coast Down Speed Test helps to determine if the symptom is vehicle speed-related.
z The Downshift Speed Test helps to determine if the symptom is engine speed-related.
z The Steering Input Test helps to determine how the wheel bearings and other suspension
components contribute to a vehicle speed-related symptom.
z The Brake Test helps to identify vibrations or noise that are brake related.
z The Road Test Over Bumps helps isolate a noise that occurs when driving over a rough or bumpy
surface.
z The Engine Run-Up Tests consist of the Neutral Engine Run-Up (NERU) Test and the Drive Engine
Run-Up (DERU) Load Test. These tests help to determine if the symptom is engine speed-related.
z The Neutral Engine Run-Up (NERU) Test is used as a follow-up test to the Downshift Speed Test
when the symptom occurs at idle.
z The Drive Engine Run-Up (DERU) Load Test helps to identify vibration/noise sensitive to engine load
or torque. It also helps to reproduce engine speed-related symptoms that cannot be duplicated when
carrying out the Neutral Engine Run-Up (NERU) Test or the Neutral Coast Down Test.
z The Engine Accessory Test helps to locate faulty belts and accessories that cause engine speed-
related symptoms.
z The Vehicle Cold Soak Procedure helps to identify symptoms occurring during initial start-up and
when an extended time lapse occurs between vehicle usage.
Slow Acceleration Test
To carry out this test, proceed as follows:
z Slowly accelerate to the speed where the reported symptom occurs. Note the vehicle speed, the
engine rpm and, if possible, determine the vibration frequency.
z Attempt to identify from what part of the vehicle the symptom is coming.
z Attempt to identify the source of the symptom.
z If the source of the symptom has been identified as a result of this test, proceed to the appropriate
section for further diagnosis and repair. If the source has not been identified, continue with the road
test.
Heavy Acceleration Test
z Accelerate hard from 0-64 km/h (0-40 mph).

z Decelerate in a lower gear.
z The symptom is torque-related if duplicated while carrying out this test.
test.
Neutral Coast Down Speed Test
z Drive at a higher rate of speed than where the symptom occurred when carrying out the Slow
Acceleration Test.
z Place the transmission in NEUTRAL and coast down past the speed where the symptom occurs.
z The symptom is vehicle speed-related if duplicated while carrying out this test. This eliminates the
engine and the torque converter as sources.
z If the symptom was not duplicated while carrying out this test, carry out the Downshift Speed Test to
verify if the symptom is engine speed related.
test.
Downshift Speed Test
z Shift into a lower gear than the gear used when carrying out the Slow Acceleration Test.
z Drive at the engine rpm where the symptom occurs.
z The symptom is engine speed related if duplicated while carrying out this test. This eliminates the
tires, wheels, brakes and the suspension components as sources.
z If necessary, repeat this test using other gears and NEUTRAL to verify the results.
test.
Steering Input Test
z Drive at the speed where the symptom occurs, while making sweeping turns in both directions.
z If the symptom goes away or gets worse, the wheel bearings, hubs, U-joints (contained in the axles of
Four-Wheel Drive (4WD) applications), and tire tread wear are all possible sources.
test.
Brake Test
z With the brake released, accelerate the vehicle. While coasting (brake pedal released) to a stop in
NEUTRAL, note any abnormal rate of deceleration. Abnormal deceleration could indicate a parking
brake or service brake that is not fully releasing.

z Warm the brakes by slowing the vehicle a few times from 80-32 km/h (50-20 mph) using light braking
applications.
z Accelerate to 89-97 km/h (55-60 mph). Moderately apply the brakes and slow the vehicle to a stop.
z A brake vibration can be felt in the steering wheel, seat or brake pedal. A brake noise can be heard
upon brake application and should diminish when the brake is released. For vehicles with separate
park brake shoes, noise or vibration from the parking brake system will not be affected by applying
the hydraulic brakes. On these systems, the parking brake system requires inspection if a parking
brake concern is suspected.
brake section(s) for further diagnosis and repair. If the source has not been identified, continue with
the road test.
Road Test Over Bumps
z Drive the vehicle over a bump or rough surface one wheel at a time to determine if the noise is
coming from the front or the back and the left or the right side of the vehicle.
test.
Neutral Engine Run-Up (NERU) Test
z Install a tachometer.
z Increase the engine rpm up from an idle to approximately 4,000 rpm while in PARK on Front Wheel
Drive (FWD) vehicles with automatic transmissions, or NEUTRAL for all other vehicles. Note the
engine rpm and, if possible, determine the vibration frequency.
z Attempt to identify what part of the vehicle the symptom is coming from.
z Attempt to identify the source of the symptom.
test.
Drive Engine Run-Up (DERU) Load Test
the risk of vehicle movement during this procedure. Failure to follow these instructions may result in
NOTICE: Do not carry out the Engine Load Test for more than 5 seconds or damage to the
transmission or transaxle may result.
z Block the front and rear wheels.

z Apply the parking brake and the service brake.
z Install a tachometer.
z Shift the transmission into DRIVE, and increase and decrease the engine rpm between an idle to
approximately 2,000 rpm. Note the engine rpm and, if possible, determine the vibration frequency.
z Repeat the test in REVERSE.
z If the vibration/noise is duplicated when carrying out this test, inspect the engine and transmission or
transaxle mounts.
z If the symptom is definitely engine speed-related, carry out the Engine Accessory Test to narrow
down the source.
test.
Engine Accessory Test
the risk of vehicle movement during this procedure. Failure to follow these instructions may result in
NOTICE: Limit engine running time to one minute or less with belts removed or serious engine
damage will result.
NOTE: Use a frequency measurement tool to pinpoint accessory vibrations. A listening device, such as an
EngineEAR, will also help to identify noises from specific accessories.
z Remove the accessory drive belt(s).

z Increase the engine rpm to where the symptom occurs.
z If the vibration/noise is duplicated when carrying out this test, the belt(s) and accessories are not
sources.
z If the vibration/noise was not duplicated when carrying out this test, install the accessory belt(s), one
at a time, to locate the source.
test.
Vehicle Cold Soak Procedure
To carry out this procedure, proceed as follows:
z Test preparations include matching customer conditions (if known). If not known, document the test
conditions: gear selection and engine rpm. Monitor the vibration/noise duration with a watch for up to
3 minutes.
z Park the vehicle where testing will occur. The vehicle must remain at or below the symptom
temperature (if known) for 6-8 hours.
z Before starting the engine, conduct a visual inspection under the hood.
z Turn the key on, but do not start the engine. Listen for the fuel pump, ABS and air suspension system
noises.
z Start the engine.
z Isolate the vibration/noise by carefully listening. Move around the vehicle while listening to find the
general location of the vibration/noise. Then, search for a more precise location by using a
stethoscope or EngineEAR.
test.
Classify NVH Symptom
For NVH concerns, it is necessary to classify the customer's concern into one of the 3 categories: noise,
vibration or harshness. The reason for this is that a customer concern may consist of a combination of
symptoms involving noise and vibration, or vibration and harshness. In cases where there are combination
symptoms, determine which diagnostic path to follow: noise, vibration or harshness. For example, if a
customer has a concern involving a noise and a vibration, and it is determined that it is vehicle speed-
related, follow the vibration diagnostic path.
Noise Symptoms
Once a symptom is classified as a noise, the particular conditions under which the noise occurs need to be
identified. These conditions are identified and verified during the road test. For example, a noise may only
occur while turning. The next step is to determine which systems on the vehicle are related to that condition.
In this case, the steering system and wheel/tire system may be suspect. After identifying possible systems, a
preliminary inspection of these systems should be done. If the source of noise is still unidentified, use a
listening device (such as the ChassisEAR) to pinpoint the source. Once the source has been identified,
determine if this source is related to the suspected system previously identified. If it is related, then complete
the repair to resolve the customer concern. If it is unrelated, then it is possible that the source of the noise is
a reactor to a noise being transmitted through a transfer path. If this is the case, repairing the reactor will not
resolve the customer concern. The transfer path must be identified and a determination made if the noise is
normal, but accentuated by the transfer path (conductor), or if the originator is the fault causing excessive
noise to transfer to another component through a conductor. There is a relationship between systems
identified as related to conditions and the noise transfer path. In some cases, the condition under which the
noise occurs has nothing to do with the identified source. This relationship is important in the diagnosis of
noise concerns. It is the first clue that the identified source of noise might be a reactor and that further
investigation is needed to diagnose a possible noise transfer path concern. Based on the results from the
road test, make a determination of which action in the symptom chart to take first.
Vibration Symptoms
Most vibrations consist of movements back and forth or up and down that repeat. Every time the vibrating
component goes through its complete range of motion and returns to the starting point is called a cycle. The
rate at which these cycles occur within a given time is called the frequency. Frequency is measured in
cycles per second or Hertz (Hz). One cycle per second equals one Hz. Once the frequency of a vibration is
known, calculations can be done to determine the system that is the source of the concern.
Order of Vibration
The order of a vibration refers to how often the vibration is present in one revolution of the component. For
example, a vibration that is present once each revolution of a component would be a first order vibration. A
vibration present twice each revolution of the component would be a second order vibration. Vibration orders
do not have to be whole numbers, they can have decimal values such as 1.5 order vibration or 3.08 order
vibration.
The concept of order of vibration is important to remember when the measured frequency of a vibration does
not seem to match the frequency calculations of any of the likely systems or components. As the order
increases, the frequency of the vibration will also increase by a multiple of that number.
For example, vibration may be present where the frequency is measured at 14 Hz. After doing the
necessary calculations it is determined the first order tire and wheel frequency is 7 Hz and the first order
driveshaft frequency is 22 Hz. Based on this information it can be determined the vibration is most likely a
second order tire and wheel vibration: 7 Hz (first order tire and wheel frequency) multiplied by 2 (second
order) equals 14 Hz (second order tire and wheel frequency).
Relationship of Vibration Frequency to Order of Vibration
After carrying out the road test as described in this section, the vibration was determined to be either
vehicle-speed related or engine-speed related. That determination will identify the vibration frequency
calculations that should be done.
Vibration Type Calculate

Vehicle-speed related Tire-speed vibration frequency
Driveshaft-speed vibration frequency

Engine-speed related Engine vibration frequency
Engine accessory vibration frequency
Engine firing vibration frequency
In calculating and using frequency readings, it is important to remember the direct relationship between Hz
and rpm. One Hz is equal to 60 rpm. This is easy to remember; think of Hz as cycles per second. There are
60 seconds in a minute, therefore multiply Hz reading by 60 to get rpm. Conversely, divide rpm by 60 to get
Hz.
Use the Frequency and RPM Calculations Worksheet to calculate system/component frequencies. The
worksheet provides the necessary steps to determine each system/component group frequency.
Frequency Calculations
Calculating Tire and Wheel Frequency
For a vibration concern, use the vehicle speed to determine tire/wheel frequency and rpm. Calculate tire and
wheel rpm and frequency by carrying out the following:
z Measure the diameter of the tire.

z Record the speed at which the vibration occurs.
z Obtain the corresponding tire and wheel rpm and frequency from the Tire Speed and Frequency
Chart.
z If the vehicle speed is not listed, calculate the tire and wheel frequency as follows:
Divide the vehicle speed at which the vibration occurs by 16 km/h (10 mph). Multiply that
number by the 16 km/h (10 mph) tire rpm listed for that tire diameter in the chart. Then divide
that number by 60.
For example, if calculating the frequency based on vehicle speed in km/h for a 64 km/h
vibration with 835 mm tires, divide 64 km/h by 16 km/h = 4. Multiply 4 by 105 rpm = 420. Divide
420 by 60 seconds = 7 Hz at 64 km/h.
If calculating the frequency based on vehicle speed in mph for a 40 mph vibration with 33 inch
tires, divide 40 mph by 10 mph = 4. Multiply 4 by 105 rpm = 420. Divide 420 by 60 seconds = 7
Hz at 40 mph.
The calculated frequency of 7 Hz is the first order tire and wheel vibration; the second order
tire and wheel vibration would be twice this number at 14 Hz; the third order tire and wheel
vibration would be 21 Hz; and so on.
Tire Speed and Frequency Chart

Tire Diameter Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz Tire RPM/Hz
mm (in) @ 16 km/h (10 mph) @ 80 km/h (50 mph) @ 97 km/h (60 mph) @ 113 km/h
(70 mph)
483 (19) 182 910/15 1,092/18 1,274/21
508 (20) 173 865/14 1,038/17 1,211/20
533 (21) 165 825/14 990/16 1,155/19
560 (22) 158 790/13 948/16 1,106/18
585 (23) 151 755/13 906/15 1,057/18
610 (24) 145 725/12 870/14 1,015/17
635 (25) 139 695/12 834/14 973/16
660 (26) 134 670/11 804/13 938/16
685 (27) 129 645/11 774/13 903/15
710 (28) 124 620/10 744/12 868/14
735 (29) 119 595/10 714/12 833/14
760 (30) 115 575/10 690/11 805/13
785 (31) 111 555/9 666/11 777/13
810 (32) 108 540/9 648/11 756/13
835 (33) 105 525/9 630/10 735/12
864 (34) 102 510/8 612/10 714/12
Calculating Driveshaft Frequency
Knowing the tire and wheel frequency allows for easy calculation of driveshaft frequency. The driveshaft
drives the tires through the rear axle. Therefore, to determine driveshaft frequency, multiply tire and wheel
frequency by the ratio of the rear axle. Calculate driveshaft frequency by performing the following steps:
z Obtain the axle ratio of the vehicle. Suppose the vehicle has a vibration problem at 64 km/h (40 mph)
and a rear axle ratio of 2.93:1.
z Multiply the tire and wheel frequency of 7 Hz (calculated previously) with the rear axle ratio of 2.93:1.
This results in a driveshaft frequency of 21 Hz at a vehicle speed of 64 km/h (40 mph).
The calculated frequency of 21 Hz is the first order driveshaft frequency; the second order frequency of the
driveshaft is twice this number, or 42 Hz; and so on.
Calculating Engine Frequency
Use the engine rpm where the vibration symptom occurs to determine engine frequency. Calculate engine
frequency by dividing the engine rpm by 60 (the number of seconds in a minute). For example, if the
corresponding engine rpm of a vibration concern on a vehicle is 2,400 rpm, the resulting engine frequency is
40 Hz. Therefore, a 40 Hz vibration is a first order engine vibration. For purposes of vibration diagnosis, the
engine also includes the torque converter and exhaust system.
Calculating Engine Accessory Frequency
Belt-driven engine accessories often produce vibrations at different frequencies than the engine itself. This is
because the drive ratio created by the different size pulleys causes them to rotate at different speeds.
Determining engine accessory frequency is comparable to calculating driveshaft frequency.
Calculate engine accessory frequency by performing the following steps:
z Determine the size ratio factor between the accessory pulley and the crankshaft pulley. For example,
if the diameter of the crankshaft pulley is 6 inches and the accessory pulley diameter is 2 inches, the
accessory pulley rotates 3 times for every crankshaft rotation (6 divided by 2).
z Multiply the engine rpm where the vibration condition occurs by the number of times the accessory
pulley is rotating per crankshaft revolution. For example, if the engine rpm is 2,400 rpm, the
accessory is rotating at 7,200 rpm (2,400 rpm multiplied by 3).
z Divide the accessory rpm by 60 (the number of seconds in a minute). In this example, the engine
accessory frequency is 120 Hz (7,200 divided by 60).
Calculating Engine Firing Frequency
Engine firing frequency is a term used to describe the pulses an engine creates from the firing of the
cylinders. Engine firing frequency depends on how many cylinders an engine has. The number of times an
engine fires a cylinder with each crankshaft revolution is equal to one-half the number of cylinders. A 4-
cylinder engine fires 2 cylinders with each crankshaft revolution. Two revolutions of the crankshaft fire all 4
cylinders. A 6-cylinder engine fires 3 cylinders with each crankshaft revolution. An 8-cylinder engine fires 4
cylinders for each crankshaft revolution.
Calculate engine firing frequency by performing the following steps:
z Multiply the engine rpm where the vibration symptom occurs by the number of cylinders fired with
each crankshaft revolution. For example, a vehicle with a 6-cylinder engine experiences a vibration
concern at 2,400 rpm. The engine is firing the cylinders at 7,200 times per minute (3 multiplied by
2,400).
z Divide this number by 60 (the number of seconds in a minute) to obtain the engine firing frequency. In
this example, the engine firing frequency is 120 Hz (7,200 divided by 60) at 2,400 rpm.
Frequency and RPM Calculations Worksheet
Harshness Symptoms
Harshness is customer perception which gives the impression of no isolation from the tire/wheel and
suspension system. Harshness may be caused by road conditions, temperature changes, component
damage and/or incorrect customer modifications on original components/specifications. Customers usually
experience harshness when the vehicle is driving over bumps or potholes and in cold weather conditions.
Harshness can also be experienced with excessive tire pressure, sporty tires, heavy-duty springs and
shocks, or other vehicle modifications. Some aftermarket tires, even with the correct size, may change
vehicle behavior and produce customer concerns. The first step in diagnosing a harshness concern is to
determine if the concern was experienced only in certain specific operating conditions, such as large
potholes or extremely cold weather. In these cases, harshness should be considered normal. A known good
vehicle can be driven under the same conditions and the rides can be compared to determine whether the
concern is normal or vehicle specific. The second step is to check tire pressure and make sure it was set
within vehicle specifications. The third step is to inspect for aftermarket or modified components and
determine if they are the cause of the harshness complaint. If the harshness concern persists after the
above steps, it is possible that some components are damaged. Based on the results from the road test,
make a determination of which action in the symptom chart to take first.
NVH Symptom Chart Categories
A good diagnostic process is a logical sequence of steps that lead to the identification of a causal system.
Use the symptom and possible system categories as follows:
z Identify the operating condition that the vehicle is exhibiting.

z Match the operating condition to the symptom.
z Verify the symptom.
z Calculate the frequency and order of the symptom.
z Identify which category or system(s) could cause the symptom.
z Refer to the section indicated to identify and diagnose the symptom or confirm that the system is not
the source of the condition.
Use the diagnostic instructions in this section along with the necessary listed tools to identify the vibration
order and to isolate the symptom and the possible systems associated with that symptom. Then based on
the results from the road test, make a determination of which action in the symptom chart to take first. Since
it is possible any one of multiple systems may be the cause of the symptom, it may be necessary to use a
process of elimination type diagnostic approach to pinpoint the concern. Refer to the section(s) indicated to
identify and isolate the cause or rule that system out as being the causal system for the symptom.
Vehicle-Speed Related Vibrations
NOTE: Any assembly that is out of balance will only cause a first order vibration, it will not cause a higher
order vibration.
When a vehicle-speed related vibration is present, both tire-speed related vibration and driveshaft-speed
related vibration calculations should be carried out.
Symptom Chart — Tire-Speed Related Vibrations
Symptom Chart — Tire-Speed Related Vibrations

Condition Possible Sources Action
z First order tire vibration z Tire or wheel z REFER to Section 204-

04 .
z Wheel bearings z REFER to Section 204-
00 .
z Drive axle z REFER to Section 205-
00 .
z Halfshaft z REFER to Section 205-
00 .
z Brake rotor or z REFER to Section 206-
drum 00 .
z Second order tire z Tire or wheel z REFER to Section 204-
vibration 04 .
z Third order tire vibration z Tire or wheel z REFER to Section 204-
04 .
z Drive axle z REFER to Section 205-
00 .
z Driveshaft z REFER to Section 205-
00 .
z Halfshaft z REFER to Section 205-
00 .
Symptom Chart — Driveshaft-Speed Related Vibrations
Symptom Chart — Driveshaft-Speed Related Vibrations
NOTE: Any assembly that is out of balance will only cause a first order vibration, it will
not cause a higher order vibration.
z First order z Driveshaft z REFER to Section 205-00 .
driveshaft
vibration
z Rear drive z REFER to Section 205-00 .
axle/differential
z Second z U-joint z REFER to Section 205-00 .
order
driveshaft
vibration
z Output shaft bushing in z Refer to the appropriate section in
transmission/transaxle Group 307 for the procedure.
Refer to the appropriate section in
Group 308 for the procedure. GO
to the Symptom Chart in the
appropriate section.
z Third order z Rear drive z REFER to Section 205-00 .
driveshaft axle/differential
vibration
Symptom Chart — Engine-Speed Related Vibrations
Symptom Chart — Engine-Speed Related Vibrations
NOTE: When an engine-speed related vibration is present, engine, engine accessory and
engine firing calculations should be carried out.
NOTE: Any assembly that is out of balance will only cause a first order vibration, it will
not cause a higher order vibration.
NOTE: Some engine-speed related vibrations are normal though they should not be felt in
the passenger compartment.
z 0.5 order z Engine z REFER to Section 303-00 .
engine
vibration
z First through z Engine z REFER to Section 303-00 .
sixth order
engine
vibration
z Transmission/transaxle z Refer to the appropriate section in
Group 307 for the procedure.
z Engine mounts z REFER to Section 303-00 .
z Transmission/transaxle z Refer to the appropriate section in
mounts Group 307 for the procedure.
z Exhaust system z REFER to Section 309-00 .
z Belt driven z Engine pulley z REFER to Section 303-00 .
accessory
speed
vibration
z Coolant pump z REFER to Section 303-00 .
z Generator z REFER to Section 414-00 .
z A/C compressor z REFER to Section 412-00 .
z Power steering pump z REFER to Section 211-00B .
z Vacuum pump z REFER to Section 303-00 .
z Accessory drive belt z REFER to Section 303-00 .
Symptom Chart — Noise, Air Leaks or Water Leaks
Symptom Chart — Noise, Air Leaks or Water Leaks

z Wind noise, air z Body z REFER to the Symptom Chart in
or water leaks Section 501-00 .
z Roof opening panel z REFER to the Symptom Chart in

Section 501-00 .
z Belt driven z Accessory drive belt z REFER to Section 303-05 .
accessory z Pulleys
noise/squeal or
chirping
z Front end noise z Front suspension z REFER to Section 204-00 .
while driving
vehicle
z Drive axle or z REFER to Section 205-00 .
differential
z Brake system z REFER to Section 206-00 .
z Steering linkage or z REFER to Section 211-00A for
gear Electronic Power Assist Steering
(EPAS) or Section 211-00B for
Hydraulic Power Assist Steering
(HPAS).
z Transmission/transaxle z Refer to the appropriate section
in Group 307 for the procedure.
Refer to the appropriate section
GO to the Symptom Chart in the
z Engine z REFER to Section 303-00 .
z Body z REFER to the Symptom Chart in
Section 501-00 .
z Rear end noise z Rear suspension z REFER to Section 204-00 .
while driving
vehicle
z Drive axle or z REFER to Section 205-00 .
differential
z Brake system z REFER to Section 206-00 .
Section 501-00 .
z Noise with z Engine z REFER to Section 303-00 .
vehicle stopped
z Power steering pump z REFER to Section 211-00B .

z Generator z REFER to Section 414-00 .
z A/C compressor z REFER to Section 412-00 .
Section 501-00 .
Symptom Chart — Harshness
Symptom Chart — Harshness

z Harsh vehicle ride z Front suspension z REFER to Section 204-00 .
z Rear suspension z REFER to Section 204-00 .
SECTION 204-00: Suspension System — General Information 2014 F-150 Workshop Manual
SPECIFICATIONS Procedure revision date: 10/25/2013
Material
Item Specification Fill
Capacity
Motorcraft® Wheel and Tire — —
Cleaner
ZC-37-A
Alignment Specifications
Item LH RH Total/Split
Rear Wheel Drive (RWD)
Camber -0.2° ± 0.75° -0.4° ± 0.75° 0.2° ± 0.75°
Caster 3.9° ± 1.0° 4.3° ± 1.0° -0.4° ± 0.75°
Total toe (front) — — 0.20° ± 0.20°
Thrust angle (rear) — — 0.0° ± 0.50°
Four-Wheel Drive (4WD) (all except SVT Raptor)
Camber -0.2° ± 0.75° -0.4° ± 0.75° 0.2° ± 0.75°
Caster 3.8° ± 1.0° 4.2° ± 1.0° -0.4° ± 0.75°
Total toe (front) — — 0.20° ± 0.20°
Four-Wheel Drive (4WD) (SVT Raptor)
Camber -0.45° ± 0.75° -0.45° ± 0.75° 0.2° ± 0.75°
Caster 3.7° ± 1.0° 4.1° ± 1.0° 0.0° ± 0.75°
Total toe (front) — — 0.20° ± 0.20°
General Specifications
Item Specification
Ball Joint Deflection, All Vehicles
Lower 0-0.8 mm (0-0.032 in)
Upper 0-0.2 mm (0-0.008 in)
Ride Height — Four-Wheel Drive (4WD) Crew Cab
145-in wheelbase, 3.5L GTDI
Front 114 mm (4.488 in)
± 12 mm (0.472 in)
Rear 163 mm (6.417 in)
± 12 mm (0.472 in)
145-in wheelbase, 3.5L GTDI (Max Trailer
Tow)
Front 116 mm (4.488 in)
± 12 mm (0.472 in)
Rear 164 mm (6.456 in)
± 12 mm (0.472 in)
145-in wheelbase, 5.0L
Front 113 mm (4.448 in)
± 12 mm (0.472 in)
Rear 163 mm (6.417 in)
± 12 mm (0.472 in)
145-in wheelbase, 6.2L (Max Trailer Tow)
Front 107 mm (4.212 in)
± 12 mm (0.472 in)
Rear 149 mm (5.866 in)
± 12 mm (0.472 in)
145-in wheelbase, 6.2L (Harley/Lariat Ltd)
Front 107 mm (4.212 in)
± 12 mm (0.472 in)
Rear 146 mm (5.748 in)
± 12 mm (0.472 in)
Front 114 mm (4.488 in)
± 12 mm (0.472 in)
Rear 162 mm (6.377 in)
± 12 mm (0.472 in)
Tow)
Front 113 mm (4.448 in)
± 12 mm (0.472 in)
Rear 164 mm (6.456 in)
± 12 mm (0.472 in)
Front 114 mm (4.488 in)
± 12 mm (0.472 in)
Rear 160 mm (6.299 in)
± 12 mm (0.472 in)
Ride Height — 4WD Heavy Duty
Regular cab, 145-in wheelbase, 3.5L GTDI
Front 110 mm (4.330 in)
± 12 mm (0.472 in)
Rear 198 mm (7.795 in)
± 12 mm (0.472 in)
Regular cab, 145-in wheelbase, 5.0L
Front 109 mm (4.291 in)
± 12 mm (0.472 in)
Rear 197 mm (7.755 in)
± 12 mm (0.472 in)
SuperCab, 163-in wheelbase, 3.5L GTDI
Front 115 mm (4.527 in)
± 12 mm (0.472 in)
Rear 182 mm (7.165 in)
± 12 mm (0.472 in)
SuperCab, 163-in wheelbase, 5.0L
Front 113 mm (4.448 in)
± 12 mm (0.472 in)
Rear 181 mm (7.125 in)
± 12 mm (0.472 in)
Ride Height — 4WD Regular Cab
Front 111 mm (4.370 in)
± 12 mm (0.472 in)
Rear 174 mm (6.850 in)
± 12 mm (0.472 in)
Front 112 mm (4.409 in)
± 12 mm (0.472 in)
Rear 172 mm (6.771 in)
± 12 mm (0.472 in)
145-in wheelbase, 3.5L 2 GTDI
Front 111 mm (4.370 in)
± 12 mm (0.472 in)
Rear 185 mm (7.283 in)
± 12 mm (0.472 in)
Front 111 mm (4.370 in)
± 12 mm (0.472 in)
Rear 190 mm (7.480 in)
± 12 mm (0.472 in)
Front 112 mm (4.409 in)
± 12 mm (0.472 in)
Rear 185 mm (7.283 in)
± 12 mm (0.472 in)
Ride Height — 4WD SuperCab
Front 113 mm (4.448 in)
± 12 mm (0.472 in)
Rear 171 mm (6.732 in)
± 12 mm (0.472 in)
Tow)
Front 112 mm (4.409 in)
± 12 mm (0.472 in)
Rear 172 mm (6.771 in)
± 12 mm (0.472 in)
Front 112 mm (4.409 in)
± 12 mm (0.472 in)
Rear 175 mm (6.889 in)
± 12 mm (0.472 in)
Front 111 mm (4.370 in)
± 12 mm (0.472 in)
Rear 169 mm (6.653 in)
± 12 mm (0.472 in)
Ride Height — Rear Wheel Drive (RWD) Crew Cab

Front 108 mm (4.251 in)
± 12 mm (0.472 in)
Rear 162 mm (6.377 in)
± 12 mm (0.472 in)
Tow)
Front 108 mm (4.251 in)
± 12 mm (0.472 in)
Rear 163 mm (6.417 in)
± 12 mm (0.472 in)
Front 114 mm (4.488 in)
± 12 mm (0.472 in)
Rear 167 mm (6.574 in)
± 12 mm (0.472 in)
Front 109 mm (4.291 in)
± 12 mm (0.472 in)
Rear 163 mm (6.417 in)
± 12 mm (0.472 in)
145-in wheelbase, 6.2L (Max Trailer Tow)
Front 103 mm (4.055 in)
± 12 mm (0.472 in)
Rear 148 mm (5.826 in)
± 12 mm (0.472 in)
145-in wheelbase, 6.2L (Harley/Lariat Ltd)
Front 102 mm (4.015 in)
± 12 mm (0.472 in)
Rear 145 mm (5.708 in)
± 12 mm (0.472 in)
Front 109 mm (4.291 in)
± 12 mm (0.472 in)
Rear 164 mm (6.456 in)
± 12 mm (0.472 in)
Tow)
Front 108 mm (4.251 in)
± 12 mm (0.472 in)
Rear 165 mm (6.496 in)
± 12 mm (0.472 in)
Front 109 mm (4.291 in)
± 12 mm (0.472 in)
Rear 162 mm (6.377 in)
± 12 mm (0.472 in)
Ride Height — RWD Heavy Duty
Regular cab, 145-in wheelbase, 3.5L GTDI
Front 114 mm (4.488 in)
± 12 mm (0.472 in)
Rear 195 mm (7.677 in)
± 12 mm (0.472 in)
Regular cab, 145-in wheelbase, 5.0L
Front 113 mm (4.448 in)
± 12 mm (0.472 in)
Rear 193 mm (7.598 in)
± 12 mm (0.472 in)
SuperCab, 163-in wheelbase, 3.5L GTDI
Front 118 mm (4.645 in)
± 12 mm (0.472 in)
Rear 182 mm (7.165 in)
± 12 mm (0.472 in)
SuperCab, 163-in wheelbase, 5.0L
Front 116 mm (4.566 in)
± 12 mm (0.472 in)
Rear 179 mm (7.047 in)
± 12 mm (0.472 in)
Ride Height — RWD Regular Cab
Front 106 mm (4.173 in)
± 12 mm (0.472 in)
Rear 170 mm (6.692 in)
± 12 mm (0.472 in)
Front 115 mm (4.527 in)
± 12 mm (0.472 in)
Rear 170 mm (6.692 in)
± 12 mm (0.472 in)
Front 112 mm (4.409 in)
± 12 mm (0.472 in)
Rear 186 mm (7.322 in)
± 12 mm (0.472 in)
Front 113 mm (4.448 in)
± 12 mm (0.472 in)
Rear 186 mm (7.322 in)
± 12 mm (0.472 in)
Front 107 mm (4.212 in)
± 12 mm (0.472 in)
Rear 182 mm (7.165 in)
± 12 mm (0.472 in)
Ride Height — RWD SuperCab
Front 114 mm (4.488 in)
± 12 mm (0.472 in)
Rear 169 mm (6.653 in)
± 12 mm (0.472 in)
Tow)
Front 113 mm (4.448 in)
± 12 mm (0.472 in)
Rear 169 mm (6.653 in)
± 12 mm (0.472 in)

Front 114 mm (4.488 in)
± 12 mm (0.472 in)
Rear 174 mm (6.850 in)
± 12 mm (0.472 in)
Front 114 mm (4.488 in)
± 12 mm (0.472 in)
Rear 169 mm (6.653 in)
± 12 mm (0.472 in)
Ride Height — 4WD (SVT Raptor)
Regular Cab, 5.4L
Front 129 mm (5.078 in)
± 12 mm (0.472 in)
Rear 242 mm (9.527 in)
± 12 mm (0.472 in)
SuperCab, 6.2L
Front 130 mm (5.1188 in)
± 12 mm (0.472 in)
Rear 242 mm (9.527 in)
± 12 mm (0.472 in)
Crew Cab, 6.2L
Front 127 mm (4.999 in)
± 12 mm (0.472 in)
Rear 242 mm (9.527 in)
± 12 mm (0.472 in)
Tire Inflation
Tires See safety certification sticker located on driver door
jamb
Vehicle Lean (side-to-side height differences), All Vehicles
Front — maximum 7 mm (0.28 in)
Rear — maximum 8 mm (0.32 in)
Torque Specifications
Description Nm lb-ft
Front Suspension
Cam bolts 350 258
Stabilizer bar bracket nuts 55 41
Stabilizer bar link lower nuts 80 59
Tie-rod jam nuts 103 76
Wheel Alignment Angles
Camber
Negative and Positive Camber
Camber is the vertical tilt of the wheel when viewed from the front. Camber can be positive or negative and
has a direct effect on tire wear.
Caster
Item Description
1 True vertical
2 Positive caster
3 Ball joint centerline
4 Pivot centerline
Caster is the deviation from vertical of an imaginary line drawn through the ball joints when viewed from the
side. The caster specifications in this section will give the vehicle the best directional stability characteristics
when loaded and driven. The caster setting is not related to tire wear.
Toe
Positive Toe (Toe In)
Negative Toe (Toe Out)
The vehicle toe setting affects tire wear and directional stability.
Incorrect Thrust Angle (Dogtracking)
Item Description
1 Vertical centerline
2 Axle centerline
3 Thrust angle
Incorrect thrust angle (dogtracking) is the condition in which the rear axle is not square to the chassis.
Heavily crowned roads can give the illusion of dogtracking.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to
maintain a straight path down a level road.
Shimmy
Shimmy, as observed by the driver, is large, consistent, rotational oscillations of the steering wheel resulting
from large, side-to-side (lateral) tire/wheel movements.
Shimmy is usually experienced near 64 km/h (40 mph) and can begin or be amplified when the tire contacts
pot holes or irregularities in the road surface.
Nibble
Sometimes confused with shimmy, nibble is a condition resulting from tire interaction with various road
surfaces and observed by the driver as small rotational oscillations of the steering wheel. For wheel and tire
diagnosis, refer to Section 204-04 .
Poor Returnability/Sticky Steering
Poor returnability and sticky steering is used to described the poor return of the steering wheel to center
after a turn or the steering correction is completed.
Drift/Pull
Pull is a tugging sensation, felt by the hands on the steering wheel, that must be overcome to keep the
vehicle going straight.
Drift describes what a vehicle with this condition does with hands off the steering wheel.
z A vehicle-related drift/pull, on a flat road, will cause a consistent deviation from the straight-ahead
path and require constant steering input in the opposite direction to counteract the effect.
z Drift/pull may be induced by conditions external to the vehicle (for example: wind, road crown).
Poor Groove Feel
Poor groove feel is characterized by little or no buildup of turning effort felt in the steering wheel as the
wheel is rocked slowly left and right within very small turns around center or straight-ahead (under 20
degrees of steering wheel turn). Efforts may be said to be "flat on center".
z Under 20 degrees of turn, most of the turning effort that builds up comes from the mesh of gear teeth
in the steering gear. In this range, the steering wheel is not yet turned enough to feel the effort from
the self-aligning forces at the road wheel or tire patch.
z In the diagnosis of a roadability problem, it is important to understand the difference between wander
and poor groove feel.
Suspension System
Inspection and Verification
1. Road test.
z Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are
apparent, refer to Section 100-04 .
2. Inspect tires.
z Check the tire pressure with all normal loads in the vehicle and the tires cold. Refer to the
Vehicle Certification (VC) label.
z Verify that all tires are sized to specification. Refer to the VC label.
z Inspect the tires for incorrect wear and damage. Install new tires as necessary.
3. Inspect chassis and underbody.
4. Inspect for aftermarket equipment.

z Check for aftermarket changes to the steering, suspension, wheel and tire components (such
as competition, heavy duty, etc.). The specifications shown in this manual do not apply to
vehicles equipped with aftermarket equipment.
Visual Inspection Chart

Mechanical
z Front wheel bearing(s)
z Loose or damaged front or rear suspension components
z Loose, damaged or missing suspension fastener(s)
z Incorrect spring usage
z Damaged or sagging spring(s)
z Damaged or leaking shock absorber(s)
z Worn or damaged suspension bushing(s)
z Loose, worn or damaged steering system components
z Damaged axle components
5. If an obvious cause for an observed or reported condition is found, correct the cause (if possible)
before proceeding to the next step.
6. If the fault is not visually evident, GO to Symptom Chart - Suspension System or GO to Symptom
Chart - NVH .
Symptom Chart — Suspension System
Symptom Chart — Suspension System

z Incorrect thrust z Rear z INSPECT the rear suspension
angle (dogtracking) suspension system. CHECK the rear alignment
components for the correct thrust angle.
REPAIR or INSTALL new
suspension components as
necessary. REFER to Section 204-
02 .
z Vehicle drifts/pulls z Unevenly loaded z GO to Pinpoint Test A .
or overloaded
vehicle
z Tires/tire
pressure
z Alignment is not
within
specification
z Brake drag
z Steering
components
z Front bottoming or z Worn, damaged z MEASURE the ride height. REFER
riding low or incorrect to Ride Height Measurement in this
springs section. INSTALL new springs as
necessary. Refer to the appropriate
section in Group 204 for the
procedure.
z Worn front z INSTALL new shock absorbers as
shock absorbers necessary. Refer to the appropriate
procedure.
z Abnormal/incorrect z Incorrect tire z ADJUST the tire pressure. REFER
tire wear pressure (rapid to the Vehicle Certification (VC)
center rib or label. REFER to Section 204-04
inner and outer Diagnosis and Testing for further
edge wear) tire wear diagnosis.
z Incorrect tire z REFER to Section 100-03 .
rotation intervals
z High-speed z REFER to Section 204-04
cornering Diagnosis and Testing for further
z Excessive front tire wear diagnosis.
or rear toe (inner
or outer edge
wear)
z Excessive
negative or
positive camber
(inner or outer
edge wear)
z Front or rear z INSPECT the front and rear
suspension suspension system. REPAIR or
components INSTALL new suspension
components as necessary. Refer to
the appropriate section in Group
204 for the procedure.
z Sticky steering, z Binding ball z REFER to the Ball Joint Inspection

poor returnability joints Component Test in this section.
z Steering z INSPECT the steering system.
components INSTALL new components as
necessary. REFER to Section 211-
02 .
z Caster out of z CHECK the wheel alignment.
specification REFER to Camber and Caster
Adjustment in this section. ADJUST
as necessary.
z Steering wheel off- z Unequal front z CHECK the wheel alignment.
center toe setting (side- REFER to Toe Adjustment — Front
to-side) in this section. ADJUST as
necessary.
necessary. For vehicles equipped
with Electronic Power Assist
Steering (EPAS), refer to Section
211-00A . For vehicles equipped
with Hydraulic Power Assist
Steering (HPAS), refer to Section
211-00B .
z Sway or roll z Overloaded, z NOTIFY the customer of incorrect
unevenly or vehicle loading.
incorrectly
loaded vehicle
z Loose wheel nut z TIGHTEN the wheel nut(s) to
(s) specification. REFER to Section
204-04 .
z Shock absorber z INSTALL new shock absorbers as
(s) necessary. Refer to the appropriate
procedure.
z Loose stabilizer z TIGHTEN the bolts to specification.
bracket-to-frame Refer to the appropriate section in
bolts Group 204 for the procedure.
z Worn stabilizer z INSTALL new stabilizer bar
bar bushings or bushings or links as necessary.
links Refer to the appropriate section in
z Damaged or z INSTALL a new stabilizer bar as
broken stabilizer necessary. Refer to the appropriate
bar section in Group 204 for the
procedure.
z Damaged spring z INSTALL new springs as
(s) necessary. Refer to the appropriate
procedure.
z Vehicle leans to z Unevenly loaded z NOTIFY the customer of incorrect
one side or overloaded vehicle loading.
vehicle
z Front or rear z MEASURE the ride height. REFER
suspension to Ride Height Measurement in this

components section. If the ride height is not
within specification, INSPECT the
front and rear suspension systems.
INSTALL new suspension
the appropriate section in Group
z Wander z Overloaded, z NOTIFY the customer of incorrect
unevenly or vehicle loading.
incorrectly
loaded vehicle
z Ball joint(s) z INSPECT the ball joints. REFER to
the Ball Joint Inspection
Component Test in this section.
z Loose, worn or z INSPECT the wheel bearings.
damaged front INSTALL new wheel bearings as
wheel bearing(s) necessary.
z Loose, worn or z INSTALL new suspension
damaged component(s) as necessary. Refer
suspension to the appropriate section in Group
component(s) 204 for the procedure.
z Loose z INSPECT the suspension
suspension fasteners. TIGHTEN to
fasteners specification. Refer to the
appropriate section in Group 204
for the procedure.
necessary. For vehicles equipped
with Electronic Power Assist
Steering (EPAS), refer to Section
211-00A . For vehicles equipped
with Hydraulic Power Assist
Steering (HPAS), refer to Section
211-00B .
z Wheel alignment z ADJUST as necessary. REFER to
(excessive total Toe Adjustment — Front in this
front toe out) section.
Symptom Chart — NVH
NOTE: NVH symptoms should be identified using the diagnostic tools that are available.
For a list of these tools, an explanation of their uses and a glossary of common terms,
refer to Section 100-04 . Since it is possible any one of multiple systems may be the cause
of a symptom, it may be necessary to use a process of elimination type of diagnostic
approach to pinpoint the responsible system. If this is not the causal system for the
symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.
z Squeak or grunt — noise z Front stabilizer z Under these conditions, the
from the front or rear bar insulators noise is acceptable.

suspension, occurs more in z Leaf spring
cold ambient temperature bushings
with or without the
presence of moisture. More
noticeable over rough
roads or when turning
z Clunk — noise from the z Loose front z INSPECT for loose nuts or
front suspension, occurs in suspension bolts. TIGHTEN to
and out of turns specification. Refer to the
appropriate section in Group
z Clunk — noise from the z Loose rear z INSPECT for loose or
rear suspension, occurs suspension damaged rear suspension
when shifting from components components. REPAIR or
REVERSE to DRIVE INSTALL new components
as necessary. REFER to
Section 204-02 .
z Click or pop — noise from z Worn or z CARRY OUT a ball joint
the front suspension. More damaged ball inspection. INSTALL new
noticeable over rough joint(s) ball joint(s) or control arm(s)
roads or over bumps as necessary. REFER to
Section 204-00 .
z Front suspension noise — z Front z INSPECT the front
a squeak, creak or rattle suspension suspension. INSTALL new
noise. Occurs mostly over components components as necessary.
bumps or rough roads z Loose or Refer to the appropriate
damaged shock section in Group 204 for the
absorber(s) or procedure.
shock absorber
bushing(s)
z Damaged
spring or spring
mount(s)
z Damaged or
worn
control/radius
arm bushing(s)
z Worn or
damaged
stabilizer bar
bushings or link
(s)
z Rear suspension noise — z Loose or z INSPECT the rear
a squeak, creak or rattle damaged rear suspension. INSTALL new
noise. Occurs mostly over shock absorber components as necessary.
bumps or rough roads (s) or shock REFER to Section 204-02 .
absorber
bushing(s)
z Rear leaf spring
tip isolator or
bushing
z Damaged leaf
spring or leaf
spring mount(s)
z Worn or
damaged
stabilizer bar
bushing(s) or
link(s)
z Rear leaf spring z NOTE: To avoid the re-
or bushing occurrence of noise, make
contaminated sure that all contamination
with dirt, sand and moisture trapped
or mud between the individual leaf
spring components have
been completely removed.
z NOTE: Do not apply any
lubricant or grease to the
leaf springs as this will
attract dirt and moisture.
PRESSURE WASH the leaf

springs between the
individual spring leafs and
the gaps between the spring
bushings, mounting brackets
and shackles to remove any
trapped debris. USE
compressed (shop) air to
remove any remaining
debris and to completely dry
between all of the individual
spring components.
z Shudder — occurs during z Incorrect ride z REFER to Section 205-00
acceleration from a slow height causing for driveline angle diagnosis.
speed or stop incorrect
driveline angle
z Shimmy z Loose wheel nut z TIGHTEN the nut(s) to
(s) specification. REFER to
Section 204-04 .
z Loose front z TIGHTEN the fastener(s) to
suspension specification. Refer to the
fastener(s) appropriate section in Group
z Loose front z INSPECT the front wheel
wheel bearing bearing(s). INSTALL new
(s) bearing(s) as necessary.
Refer to the appropriate
procedure.
z Shock absorber z INSTALL new shock
(s) absorbers as necessary.
procedure.
z Shimmy — most noticeable z Excessive z CHECK the wheel
on coast/deceleration. Also positive caster alignment. REFER to
hard steering condition Camber and Caster
Adjustment in this section.
ADJUST as necessary.
z Rough/harsh ride z Incorrect tire z ADJUST the tire pressure.

pressure REFER to the VC label.
z Shock absorber z INSTALL new shock
(s) absorbers as necessary.
procedure.
z Spring(s) z MEASURE the ride height.
REFER to Ride Height
Measurement in this section.
INSTALL new springs as
necessary. Refer to the
z Loose, worn or z INSTALL new suspension
damaged component(s) as necessary.
suspension Refer to the appropriate
component(s) section in Group 204 for the
procedure.
Pinpoint Tests
Pinpoint Test A: Vehicle Drifts/Pulls
This pinpoint test is intended to diagnose the following:

z Unevenly loaded vehicle
z Tire pressure
z Tire forces
z Brake drag
z Incorrect vehicle alignment
z Steering system
PINPOINT TEST A: VEHICLE DRIFTS/PULLS
Test Step Result / Action to Take

A1 CHECK FOR UNEVENLY LOADED VEHICLE
z Visually check the vehicle for an uneven Yes
loading condition. ADVISE the customer of uneven loading
z Is the vehicle unevenly loaded? condition.
No
GO to A2 .
A2 CHECK THE TIRE PRESSURES AND TIRE
CONDITIONS
z Check the tire pressures. Refer to the Vehicle Yes
Certification (VC) label located on the driver GO to A3 .
door jamb. Check the tires for
uneven/abnormal wear. Refer to Diagnosis and No

Testing — Wheels and Tires in Section 204- ADJUST the tire pressures to the specified
04 . pressure or INSTALL new tires as necessary.
z Are the tire pressures and tire conditions
OK?
A3 ISOLATE TIRE DRIFT/PULL CONDITION
z Cross the front wheel and tire assemblies from Yes
left-to-right. Refer to Section 204-04 . If the vehicle drifts/pulls in the opposite
z Does the vehicle drift/pull? direction, tire forces are causing the drift/pull.
ROTATE the wheel and tire assemblies front-
to-rear. REFER to Section 204-04 . If the
vehicle drifts/pulls in the same direction, GO to
A4 .
No
Tire forces were causing the drift/pull and the
concern has been corrected.
A4 CHECK FOR BRAKE DRAG
z Spin all 4 wheel and tire assemblies by hand Yes
and check for brake drag. GO to A5 .
z Do the wheels spin freely?
No
REFER to Section 206-00 to diagnose brake
drag condition.
A5 CHECK THE WHEEL ALIGNMENT
z Using alignment equipment and the Yes
manufacturer's instructions, check the wheel ADJUST the alignment as necessary. REFER
alignment. to General Procedures in this section.
z Is the wheel alignment out of specification?
No
REFER to Section 211-00A or Section 211-
00B to diagnose steering system
drift/pull/wander condition.
Component Tests
Ball Joint Inspection
1. Prior to inspecting the ball joints for wear, inspect the wheel bearings. Refer to Section 100-04 .
2. NOTE: In order to obtain accurate measurements, the suspension must be in full rebound with the
weight of the vehicle supported by the frame.
Raise and support the vehicle by the frame to allow the wheels to hang in the rebound position.
3. Inspect the ball joint and ball joint boot for damage.
z If the ball joint or ball joint boot is damaged, install a new ball joint as necessary. Refer to
Section 204-01A for Rear Wheel Drive (RWD) vehicles and Section 204-01B for Four-Wheel
Drive (4WD) vehicles.
NOTE: Carry out Steps 4 through 6 to inspect the lower ball joint. Carry out Steps 7 through 9 to inspect the
upper ball joint.
4. NOTICE: Do not use any tools or equipment to move the wheel and tire assembly or
suspension components while checking for relative movement. Suspension damage can
occur. The use of tools or equipment will also create relative movement that may not exist
when using hand force. Relative movement must be measured using hand force only.
NOTE: The weight of the wheel and tire assembly must be overcome to obtain an accurate
measurement on the dial indicator.
Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on
the wheel and tire assembly by hand. Note any relative vertical movement between the wheel knuckle
and lower arm at the lower ball joint.
z If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint.
z If relative movement is found, continue with Step 5.
5. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as
possible with the vertical axis (center line) of the ball joint.
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the lower
control arm and the wheel knuckle or ball joint stud.
6. Measure the ball joint deflection while an assistant pushes up and pulls down on the wheel and tire
assembly, by hand.
z If the deflection exceeds the specification, a new ball joint must be installed. Refer to Section
204-01A for RWD vehicles and Section 204-01B for 4WD vehicles.
z If the deflection meets or is below the specification, continue with the procedure.
7. NOTICE: Do not use any tools or equipment to move the wheel and tire assembly or
suspension components while checking for relative movement. Suspension damage can
occur. The use of tools or equipment will also create relative movement that may not exist
when using hand force. Relative movement must be measured using hand force only.
Inspect the ball joint for relative movement by alternately pulling downward and pushing upward on
the upper control arm by hand. Note any relative vertical movement between the wheel knuckle and
upper arm at the upper ball joint.
z If relative movement is not felt or seen, the ball joint is OK. Do not install a new ball joint.
z If relative movement is found, continue with Step 8.
8. NOTE: In order to obtain an accurate measurement, the dial indicator should be aligned as close as
possible with the vertical axis of the ball joint.
To measure ball joint deflection, attach a suitable dial indicator with a flexible arm between the upper
control arm and the wheel knuckle or ball joint stud.
9. Measure the ball joint deflection while an assistant pushes up and then pulls down on the upper
control arm, by hand.
z If the deflection exceeds the specification, a new ball joint must be installed. Refer to Section
204-01A for RWD vehicles and Section 204-01B for 4WD vehicles.
z If the deflection meets or is below the specification, no further action is required.
GENERAL PROCEDURES Procedure revision date: 10/25/2013
Camber and Caster Adjustment
NOTICE: Do not remove the stabilizer bar brackets until the stabilizer links have been disconnected
or damage to the stabilizer bar links may occur.
NOTE: To allow for adjustment of the lower arm in the frame slots, the lower arm bolts and nuts must be
removed and discarded. They are replaced with cam bolt kit 3C333. The vehicle should be supported by the
frame to ease movement of the lower arm in the slot.
1. Using alignment equipment and the manufacturers instructions, measure the front caster and camber.
z Refer to Alignment Specifications in the Specifications portion of this section for optimal
alignment settings.
z If the caster and camber values are not within specification, go to the next step.
2. Remove and discard the lower arm front and rear nuts and bolts.
3. NOTICE: Do not hold the stabilizer link boot with any tool as damage to the boot will occur.
NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nuts.
Remove and discard the stabilizer bar link lower nuts.
4. Remove the 4 stabilizer bar bracket nuts, 2 stabilizer bar brackets and position the stabilizer bar
aside.
z Discard the nuts.
5. Remove the stabilizer bar bracket bolts and plate assembly.
6. Install the front cam bolt kit and loosely install the nut.
7. Install the rear cam bolt kit and loosely install the nut.
8. To adjust the caster and camber, refer to the following chart.

z Adjustments that require moving the front and the rear of the lower arm should be made
equally.
Adjustment Front of Lower Arm Rear of Lower Arm

Increase caster In Out
Decrease caster Out In
Increase camber In In
Decrease camber Out Out
Increase caster and camber simultaneously In —
Decrease caster and camber simultaneously Out —
9. With the weight of the vehicle resting on the wheel and tire assemblies, hold the front cam bolt and
tighten the nut to 350 Nm (258 lb-ft).
10. With the weight of the vehicle resting on the wheel and tire assemblies, hold the rear cam bolt and
tighten the nut to 350 Nm (258 lb-ft).
11. Install the 2 stabilizer bar bracket bolts and plate assembly.
12. Position the stabilizer bar, install the 2 stabilizer bar brackets and the 4 new stabilizer bar bracket
nuts.
z Tighten the nuts to 55 Nm (41 lb-ft).
13. NOTICE: Do not hold the stabilizer link boot with any tool as damage to the boot will occur.
NOTE: Use the hex-holding feature to prevent the stud from turning while installing the nuts.
Install the 2 new stabilizer bar link lower nuts.

z Tighten the nuts to 80 Nm (59 lb-ft).
14. Check and, if necessary, adjust the front toe. For additional information, refer to Toe Adjustment —
Front in this section.
Ride Height Measurement
Front Ride Height Measurement
Item Description
1 Ride height = 2 - 3
2 Measurement 2
3 Measurement 3
NOTE: Make sure that the vehicle is positioned on a flat, level surface and the tires are inflated to the
correct pressure. Vehicle should have at least one-half tank of fuel.
1. Position a suitable surface gauge (such as Starrett 57D Surface Gauge) on a flat, level surface and
adjust the gauge arm until the scriber point is located in the center of the rearward lower arm bolt.
z Lock the surface gauge in this position.
2. With the surface gauge positioned on a flat, level surface, record the measurement of the surface
gauge position (measurement 2).
3. Position the surface gauge on the same flat, level surface as used in Step 1 and adjust the gauge
arm until the scriber point is located at the lowest point on the wheel knuckle.
z Lock the surface gauge in this position.
4. With the surface gauge positioned on a flat, level surface, record the measurement of the surface
gauge position (measurement 3).
5. Subtract measurement 3 from measurement 2 to obtain the front ride height.

z Refer to Specifications in this section.
Rear Ride Height Measurement (All Except SVT Raptor)
Item Description
1 Ride height
2 Rear axle jounce stop
3 Top of the rear axle tube
correct pressure. Vehicle should have at lease one-half tank of fuel.
1. Measure the distance between the rear axle jounce stop (Item 2) and the top of the rear axle tube
(Item 3) to obtain the rear ride height (Item 1).
Rear Ride Height Measurement (SVT Raptor)
Item Description
1 Ride height
2 Rear frame rail
3 Top of the rear axle tube
correct pressure. Vehicle should have at lease one-half tank of fuel.
1. Measure the distance between the rear frame rail (Item 2) and the top of the rear axle tube (Item 3) to
obtain the rear ride height (Item 1).
Toe Adjustment — Front
1. Using alignment equipment and the manufacturer's instructions, measure the front toe.
z Refer to Alignment Specifications in the Specifications portion of this section for optimal
alignment settings.
z If the front toe values are not within specification, go to the next step.
2. Start the engine and center the steering wheel.
3. Turn the engine off and, using a suitable steering wheel holding device, lock the steering wheel in the
straight-ahead position.
4. Remove the steering gear bellows clamp(s).
5. Loosen the tie-rod end jam nut(s).
6. NOTE: Do not allow the steering gear bellows to twist while rotating the tie rod.
Rotate the tie rod(s) to achieve the desired toe setting.
7. NOTICE: Make sure to hold the tie-rod end stationary while tightening the jam nut or damage
to the boot may occur.
NOTE: Make sure that the toe settings are not disturbed while tightening the jam nuts.
Tighten the tie-rod end jam nut(s) to 103 Nm (76 lb-ft).
8. Install the steering gear bellows clamp(s).
SECTION 204-01A: Front Suspension — Rear Wheel Drive (RWD) 2014 F-150 Workshop Manual
Description Nm lb-ft lb-in
Brake disc shield bolts 17 — 150
Brake hose bracket bolt 12 — 106
Lower arm forward and rearward nuts 350 258 —
Lower ball joint nut 175 129 —
Shock absorber lower nuts 90 66 —
Shock absorber upper mount nuts 63 46 —
Shock rod nut 55 41 —
Stabilizer bar bracket nuts 55 41 —
Stabilizer bar link nuts 70 52 —
Tie-rod end nut 115 85 —
Upper arm-to-frame nuts 150 111 —
Upper ball joint nut 115 85 —
Wheel bearing and wheel hub bolts 175 129 —
Wheel speed sensor bolt 18 — 159
Wheel speed sensor harness bracket bolt 12 — 106
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Front Suspension
The Rear Wheel Drive (RWD) front suspension consists of the following components:
z Lower ball joints

z Lower control arms
z Shock absorber and coil spring assemblies
z Stabilizer bar and links
z Upper control arms
z Wheel bearings and wheel hubs
z Wheel knuckles
z Wheel studs
The vehicle is equipped with a front coil spring suspension. This independent-type suspension utilizes a
stabilizer bar to aid in vehicle stability. The wheel hub and wheel bearing are sealed units and are serviced
as assemblies. The lower ball joints can be serviced independently from the lower arms.
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Front Suspension
Refer to Section 204-00 .
REMOVAL AND INSTALLATION Procedure revision date: 10/25/2013
Ball Joint — Lower
Special Tool(s)
Installer/Remover, Ball Joint
204-358
Installer/Remover, C-Frame and

Screw
205-086
Removal
1. Remove the wheel knuckle. Refer to Wheel Knuckle .
2.
3. Special Tool(s): Installer/Remover, C-Frame and Screw 205-086. Remover, Ball Joint 204-358/4.
Installation
1. NOTICE: Do not damage the lower ball joint boot when installing the C-Frame and Screw
Installer/Remover and Ball Joint Installer/Remover or premature failure of the ball joint may
occur.
Special Tool(s): Installer/Remover, C-Frame and Screw 205-086. Remover, Ball Joint 204-358/3.
Remover, Ball Joint 204-358/5. Remover, Ball Joint 204-358/6.
2. NOTE: Make sure the ball joint snap ring is fully seated.
3. Install the wheel knuckle. Refer to Wheel Knuckle .
Lower Arm
Special Tool(s)
Separator, Ball Joint
204-592
Removal
NOTICE: Suspension fasteners are critical parts that affect the performance of vital components and
systems. Failure of these fasteners may result in major service expense. Use the same or equivalent
parts if replacement is necessary. Do not use a replacement part of lesser quality or substitute
design. Tighten fasteners as specified.
1. Measure the distance from the center of the hub to the lip of the fender with the vehicle in a level,
static ground position (curb height).
2. Remove the wheel and tire. Refer to Section 204-04 .
3. NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut.
4.
5.
6. NOTICE: Do not use a prying device or separator fork between the ball joint and the wheel
knuckle. Damage to the ball joint or ball joint seal may result.
NOTICE: Use care when releasing the lower arm and wheel knuckle into the resting position or
damage to the ball joint seal may occur.
Special Tool(s): Separator, Ball Joint 204-592.
7.
Installation
1. NOTICE: Tighten the suspension bushing fasteners with the suspension loaded or with the
weight of the vehicle resting on the wheels and tires, otherwise incorrect clamp load and
bushing damage may occur.
Finger tight at this stage.
2.
3.
z Tighten to 175 Nm (129 lb-ft).
4.
6. Use a suitable jack to raise the suspension until the distance between the center of the hub and the
lip of the fender is equal to the measurement taken during removal (curb height).
7.
8. Install the wheel and tire. Refer to Section 204-04 .
9. Check and, if necessary, align the front end. Refer to Section 204-00 .
Shock Absorber and Spring Assembly
Special Tool(s)
204-592
Removal
2. NOTICE: Do not use a hammer to separate the outer tie-rod end from the wheel knuckle or
damage to the wheel knuckle may result.
NOTICE: Use care when installing the tie rod separator or damage to the outer tie-rod end boot
may occur.
General Equipment: Tie-rod Separator.
3.
4.
5. NOTE: Be sure not to damage the ball joint boot when installing the Ball Joint Separator.
7.
8.
9.
10. NOTE: If the individual spring and/or shock components are not being serviced, continue to the
installation procedure.
NOTE: For reference during assembly, index the upper mount, spring and shock absorber.
Compress the spring until the tension is released from the shock absorber.
General Equipment: Spring Compressor.
11. NOTE: Use the hex-holding feature to prevent the shock rod from turning while removing the nut.
12.
Installation
1.
2. NOTE: Align the index marks made during disassembly.
3. NOTE: Use the hex-holding feature to prevent the shock rod from turning while installing the nut.
While holding the shock rod, install the new shock absorber and the shock rod nut.
4.
5.
6.
7.
9.
z Tighten to 12 Nm (106 lb-in).
10.
Stabilizer Bar and Link
Removal and Installation
1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 .
On both sides.
z To install, tighten to 70 Nm (52 lb-ft).
3. NOTICE: The raised ring on the stabilizer bar must be encapsulated inside the inner groove of
the stabilizer bar bushing on the driver side of the vehicle for proper installation.
On both sides.
4. Inspect and, if necessary, install new stabilizer bar bushings.
5. To install, reverse the removal procedure.
Upper Arm
Removal
2. Remove the shock absorber and spring assembly. Refer to Shock Absorber and Spring Assembly .
3.
Installation
2. Install the shock absorber and spring assembly. Refer to Shock Absorber and Spring Assembly .
4.
Wheel Bearing and Wheel Hub
1. NOTE: The wheel speed sensor electrical connector is located in the engine compartment secured to
the fender apron.
3.
z To install, tighten to 12 Nm (106 lb-in).
4. Remove the brake disc. Refer to Section 206-03 .
5.
Wheel Knuckle
Special Tool(s)
204-592
Removal
1. Remove the wheel bearing and wheel hub. Refer to Wheel Bearing and Wheel Hub .
may occur.
3.
4.
6.
8. If necessary.
Installation
1. If necessary.
2.
3.
4.
5.
6. Install the wheel bearing and wheel hub. Refer to Wheel Bearing and Wheel Hub .
Wheel Studs
Special Tool(s)
Screw
211-023 (T74P-3044-A1)
Removal
2. Special Tool(s): Installer/Remover, C-Frame and Screw 211-023.
Installation
1. NOTE: Make sure to use washers that have an ID that is larger than the OD of the wheel stud
serrations. Use enough washers (approximately 3 to 4) to allow the wheel stud to fully seat against
the hub flange.
z Tighten the wheel nut until the wheel stud is seated against the hub flange.
z Discard the wheel nut.
2. Install the brake disc. Refer to Section 206-03 .
SECTION 204-01B: Front Suspension — Four Wheel Drive (4WD) 2014 F-150 Workshop Manual
Material
Capacity
Motorcraft® Metal Brake Parts — —
Cleaner (US) / Motorcraft® Brake
Parts Cleaner (Canada)
PM-4-A or PM-4-B (US); CPM-4
(Canada)
Motorcraft® Metal Surface Prep — —
ZC-31-A
Brake hose bracket bolt 12 — 106
Halfshaft nut 40 30 —
Integrated Wheel End (IWE) bolts 12 — 106
Lower arm forward and rearward nuts 350 258 —
Lower ball joint nut 175 129 —
Shock absorber lower nut (SVT Raptor) 550 406 —
Shock absorber lower nuts 90 66 —
Shock absorber upper mount nuts 63 46 —
Shock rod nut 55 41 —
Skid plate bolts 48 35 —
Stabilizer bar bracket nuts 55 41 —
Stabilizer bar link nuts 70 52 —
Stabilizer bar link nuts (SVT Raptor) 80 59 —
Upper arm-to-frame nuts 150 111 —
Wheel bearing and wheel hub bolts 175 129 —
Wheel speed sensor bolt 18 — 159
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Front Suspension
The Four-Wheel Drive (4WD) front suspension consists of the following components:
z Ball joints
z Coil springs
z Lower control arms
z Shock absorbers
z Stabilizer bar and links
z Upper control arms
z Wheel bearing and wheel hubs
z Wheel knuckles
z Wheel studs
The vehicle is equipped with a front coil spring suspension. This independent-type front suspension utilizes
a stabilizer bar to aid in vehicle stability. The wheel hub and wheel bearing are sealed units and are serviced
as an assembly. The lower ball joints can be serviced independently from the lower arm.
Front Suspension
Shock Absorber and Spring Assembly — SVT Raptor
Special Tool(s)
204-592
Removal
2.
3.
may occur.
6.
7. Special Tool(s): Separator, Ball Joint 204-592.
8.
10. NOTE: SVT Raptor similar.
11.
14.
Installation
1.
4.
5. NOTE: SVT Raptor similar
6.
7.
8. NOTICE: SVT Raptor: Do not tighten the lower shock nut until the installation procedure is
complete and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect
clamp load and bushing damage may occur.
11.
12.
14.
Ball Joint — Lower
Special Tool(s)
Installer/Remover, Ball Joint
204-358

Screw
205-086
Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A
Removal
All vehicles
1. Remove the wheel knuckle. Refer to Wheel Knuckle .
2.
3. Special Tool(s): Installer/Remover, C-Frame and Screw 205-086. Remover, Ball Joint 204-358/4.
SVT Raptor
4. Materials: Motorcraft® Metal Surface Prep ZC-31-A.
5. NOTICE: If there is evidence of cracks or damage, a new lower arm must be installed.
Installation
SVT Raptor
1. NOTICE: Use care to prevent adhesive from contacting the ball joint boot or damage to the
boot may occur, causing premature ball joint failure.
NOTE: To allow the adhesive to fully cure, the vehicle must not be driven on the road for at least one
hour after the installation of a new ball joint.
Materials: Adhesive (supplied with kit).
All vehicles
2. NOTICE: Do not damage the lower ball joint boot when installing the C-Frame and Screw
Installer/Remover and Ball Joint Installer/Remover or premature failure of the ball joint may
occur.
Special Tool(s): Installer/Remover, C-Frame and Screw 205-086. Remover, Ball Joint 204-358/3.
Remover, Ball Joint 204-358/5. Remover, Ball Joint 204-358/6.
3. NOTE: Make sure the ball joint snap ring is fully seated.
SVT Raptor
4. Using a clean shop towel and the specified surface cleaner, wipe any excess adhesive from the ball
joint and lower arm.
All vehicles
5. Install the wheel knuckle. Refer to Wheel Knuckle .
Lower Arm
Special Tool(s)
204-592
Removal
All vehicles
All except SVT Raptor
4.
SVT Raptor
6.
All vehicles
7.
9.
Installation
All vehicles
NOTICE: SVT Raptor: Do not tighten the shock absorber lower nut, lower arm forward nut or lower
arm rearward nut until the installation procedure is complete and the weight of the vehicle is resting
on the wheel and tire assemblies.
2.
3.
SVT Raptor
4. Finger tight at this stage.
All except SVT Raptor
6.
All vehicles
9.
SVT Raptor
10.
All vehicles
12. Check and, if necessary, align the front end. Refer to Section 204-00 .
Shock Absorber and Spring Assembly — SVT Raptor
Special Tool(s)
204-592
Removal
2.
3.
may occur.
6.
7. Special Tool(s): Separator, Ball Joint 204-592.
8.
11.
14.
Installation
1.
4.
5. NOTE: SVT Raptor similar
6.
7.
8. NOTICE: SVT Raptor: Do not tighten the lower shock nut until the installation procedure is
complete and the weight of the vehicle is resting on the wheel and tire assemblies or incorrect
clamp load and bushing damage may occur.
11.
12.
14.
Shock Absorber and Spring Assembly
Special Tool(s)
204-592
Removal
the fender apron.
3.
4.
5.
may occur.
7.
8.
9.
11.
14.
15.
16.
19.
Installation
1.
4.
5.
6.
8.
9.
10.
11.
12.
13. NOTICE: Measure the depth of the Constant Velocity (CV) shaft threaded end to the inner
bearing race (shown in illustration). The minimum depth is 15.5 mm (0.61 in). If the depth is
less than 15.5 mm (0.61 in) rotate the CV shaft to clear a binding condition between the
Integrated Wheel End (IWE) and CV splines. Installing the axle nut and tightening without the
proper depth of protrusion will result in damage to the IWE .
Measure the CV shaft threaded end to the inner bearing race.
14. NOTICE: Verify the spline engagement by checking for spline lash before installing the axle
nut or component damage may occur.
15.
16.
the fender apron.
Stabilizer Bar and Link
NOTE: Use the hex-holding feature to prevent the stud from turning while removing the nut(s).
On both sides.
z (SVT Raptor) To install, tighten to 80 Nm (59 lb-ft).
3. If equipped.
4. NOTICE: The raised ring on the stabilizer bar must be encapsulated inside the inner groove of
the stabilizer bar bushing on the driver side of the vehicle for proper installation.
On both sides.
5. Inspect and, if necessary, install new stabilizer bar bushings.
Upper Arm
Removal
2. Remove the shock absorber and spring assembly. Refer to Shock Absorber and Spring Assembly or
Shock Absorber and Spring Assembly — SVT Raptor .
3.
Installation
2. Install the shock absorber and spring assembly. Refer to Shock Absorber and Spring Assembly or
Shock Absorber and Spring Assembly — SVT Raptor .
4.
Wheel Bearing and Wheel Hub
the fender apron.
3.
5.
6.
7.
Installation
1. NOTICE: If the original wheel bearing and wheel hub is being installed, install a new wheel hub
O-ring seal or damage to the wheel bearing may occur.
2. NOTICE: Measure the depth of the Constant Velocity (CV) shaft threaded end to the inner
bearing race (shown in illustration). The minimum depth is 15.5 mm (0.61 in). If the depth is
less than 15.5 mm (0.61 in) rotate the CV shaft to clear a binding condition between the
Integrated Wheel End (IWE) and CV splines. Installing the axle nut and tightening without the
proper depth of protrusion will result in damage to the IWE .
4.
6.
the fender apron.
Wheel Knuckle
Special Tool(s)
204-592
Removal
may occur.
3.
4.
5.
7.
9. If necessary.
Installation
1. If necessary.
2.
3.
4.
5.
6.
Wheel Studs
For additional information, refer to Section 204-01A .
SECTION 204-02: Rear Suspension 2014 F-150 Workshop Manual

Shock absorber nuts 90 66 —
Shock absorber shield bolts (SVT Raptor) 4 — 35
Spring shackle-to-frame nut 185 136 —
Spring-to-frame nut 350 258 —
Spring-to-shackle nut 185 136 —
Spring U-bolt nuts a — — —
Jounce bumper-to-frame bolt 35 26 —
a Refer to the procedure in this section

Rear Suspension

Leaf Spring Tip Isolator
1. Position and lift the vehicle on a hoist to unload the leaf spring assembly. Refer to Section 100-02 .
2. NOTE: It is very important to use a non-metallic wedge or corrosion protection can be compromised.
Use a non-metallic wedge (such as a rubber door stop or rubber coated pry bar) near the leaf tip
insulator and wedge the leaf spring apart.
3. Using a locally obtained pvc cable saw, cut the top of the leaf tip insert off and remove the insert.
4. Thoroughly rinse the leaf tip insert area with brake clean and a clean shop rag to remove debris from
the leaf tip insert seating area.
5. If required trim service tip insert post to aid installation between the leaves.
6. Once dry, install the new leaf spring tip insert and remove the non-metallic wedge.
7. Repeat steps 2-6 for remaining leaf tip inserts.
8. Lower the vehicle and wash the leaf spring assembly to remove any remaining dirt or debris using a
power washer or direct stream of water.
9. Using shop air, dry the leaf spring assembly thoroughly.

Shock Absorber
All Except SVT Raptor
Item Part Number Description

1 W506545 Shock absorber lower bolt
2 W520214 Shock absorber lower nut
3 18125 Shock absorber
4 W506545 Shock absorber upper bolt
5 W520214 Shock absorber upper nut
SVT Raptor

4 W506545 Shock absorber upper bolt
5 W520214 Shock absorber upper nut
6 18159 Shock absorber shield
7 18A149-B Shock absorber shield bolt (3 required)
8 18A149-C Shock absorber shield washer
and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may
result in serious personal injury.
struts can extend unassisted. Failure to follow this instruction may result in serious personal injury.
NOTICE: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to make sure of correct retention of these parts.
All Vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-
02 .
2. Using a suitable jack, support the axle.
SVT Raptor
3. NOTE: Chase the threads in the shock prior to installing the screws. This is needed to prevent
potential breaking the screws or reaching torque prior to full run-down.
Remove the shock absorber shield.

z Remove and discard the three shield bolts and remove the shield.
z To install, tighten the three new bolts to 4 Nm (25 lb-in).
All Vehicles
4. Remove and discard the shock absorber upper nut and bolt.
z To install, tighten the new nut to 90 Nm (66 lb-ft).
5. Remove the shock absorber lower nut, lower bolt and the shock absorber.
z Discard the nut and bolt.
z To install, tighten the new nut to 90 Nm (66 lb-ft).

Spring

1 W709627 Spring-to-frame bolt
2 W714297 Spring-to-frame nut
3 W705518 Spring shackle-to-frame nut
4 W715654 Spring shackle-to-frame bolt
5 W520215 U-bolt nut (4 required)
6 5798 U-bolt plate
7 5705 U-bolt (2 required)
8 5560 Spring
12 W705518 Spring-to-shackle nut
13 W715654 Spring-to-shackle bolt
NOTE: SVT Raptor shown, others similar.

14 5A799 Spring spacer — Four-Wheel Drive (4WD) only
Removal
and strut tube are gas pressurized and could explode if heated. Failure to follow this instruction may
struts can extend unassisted. Failure to follow this instruction may result in serious personal injury.
NOTICE: Suspension fasteners are critical parts because they affect performance of vital
components and systems and their failure may result in major service expense. New parts must be
installed with the same part numbers or equivalent part, if replacement is necessary. Do not use a
replacement part of lesser quality or substitute design. Torque values must be used as specified
during reassembly to make sure of correct retention of these parts.
All vehicles
1. Remove the wheel and tire. For additional information, refer to Section 204-04 .
2. Using a suitable jack, support the axle.
3. Remove the shock absorber lower nut and bolt.

4. Remove the 4 U-bolt nuts, the U-bolt plate and the 2 U-bolts.
z Discard the nuts and the U-bolts.
5. For the LH spring, lower the fuel tank to gain access to the spring shackle-to-frame bolt. For
additional information, refer to Section 310-01 .
6. For the RH spring, remove the muffler to gain access to the spring-to-frame bolt. For additional
information, refer to Section 309-00 .
7. Remove and discard the spring-to-frame nut and bolt.
8. Remove and discard the spring shackle-to-frame nut and bolt.
9. NOTE: Only lower the axle enough to gain access to remove the spring.
Lower the jack and remove the spring and shackle assembly.
10. If necessary, remove the spring-to-shackle nut, bolt and spring shackle.
Four-Wheel Drive (4WD) vehicles
11. Remove the Four-Wheel Drive (4WD) spring spacer.
Installation
4WD vehicles
NOTE: The SVT Raptor spring spacer must be positioned with the jounce bumper pad inboard and the
arrow facing the front of the vehicle.
All other vehicles, the arrow on the spring spacer must face toward the front of the vehicle according to the
wheelbase application. Use specifications on spring spacer.
1. NOTE: The protrusion on the spring spacer should face toward the front of the vehicle on 157 inch
wheelbase applications and face toward the rear on 126 inch wheelbase applications.
Position the spring spacer and make sure that it is correctly seated between the axle and spring with
the arrow pointed to the front of the vehicle according to the wheelbase application.
All vehicles
2. If necessary, install a new shackle-to-spring bolt and nut.
z Tighten until snug.
3. Position the spring and install a new spring shackle-to-frame bolt and nut.
4. Position the U-bolt plate and install the new U-bolts and nuts.
5. Install a new spring-to-frame bolt and nut.

6. Install a new shock absorber lower bolt and nut.

7. Install the wheel and tire. For additional information, refer to Section 204-04 .
8. Lower the vehicle until the weight of the vehicle is resting on the wheels and tires (curb height).
9. Tighten the spring shackle-to-frame nut to 185 Nm (136 lb-ft).
10. Tighten the spring-to-frame nut to 350 Nm (258 lb-ft).
11. If necessary, tighten the spring-to-shackle nut to 185 Nm (136 lb-ft).
12. For the LH spring, raise the fuel tank. For additional information, refer to Section 310-01 .
13. For the RH spring, install the muffler. For additional information, refer to Section 309-00 .
14. Tighten the U-bolt nuts in 4 stages.

z Stage 1: Tighten in a cross pattern to 35 Nm (26 lb-ft).
15. Tighten the shock absorber lower nut to 90 Nm (66 lb-ft).
SECTION 204-04: Wheels and Tires 2014 F-150 Workshop Manual

Material
Capacity
High Temperature Nickel Anti- — —
Seize Lubricant
XL-2
Motorcraft® Wheel and Tire — —
Cleaner
ZC-37-A
Item Specification
Tire Inflation
Tires See Safety Certification Label on driver door jamb
Wheel Weights
Wheel weight Use a wheel weight manufacturer's rim gauge to determine the correct wheel weight
type application
Description Nm lb-in
Valve stem-to-Tire Pressure Monitoring System (TPMS) sensor screw 1.5 13
a — —
Wheel nuts
a Refer to the procedure in this section.

Wheels And Tires
Safety Precautions
injury.
can result in tire bead damage or tire separation from the wheel. Failure to follow this instruction
may result in serious personal injury to technician or vehicle occupant(s).
tire. Tire sealants may be flammable and can burn or explode if exposed to an ignition source.
Failure to follow this instruction may result in serious personal injury.
z load carrying capacity.

z diameter, width and offset.
z pilot hole and bolt circle.
Combined load carrying capacity of replacement wheels for a given axle, must be equal to or greater
than that axle's gross axle weight rating (GAWR) identified on the vehicle's Safety Compliance
Certification label. All other specifications should be evaluated by measurement of both the original
wheel and the replacement wheel. If specifications are not equivalent, the safety and handling of the
vehicle may be degraded, which may result in serious injury to the vehicle occupant(s).
instruction may result in serious personal injury.
much as possible by pushing in valve core plunger prior to removing the core. Escaping air can
carry particles that can injure the eyes. Failure to follow these instructions may result in serious
personal injury.
(such as P-metric versus LT-metric or all-season versus all-terrain) as those originally provided by
Ford. The recommended tire and wheel size may be found on either the Safety Compliance
Certification Label or the Tire Label, which is located on the B-pillar or edge of the driver's door. If
the information is not found on these labels, consult a Ford dealer. Use of any tire or wheel not
recommended by Ford can affect the safety and performance of the vehicle, which could result in an
increased risk of loss of vehicle control, vehicle rollover, personal injury and death. Additionally, the
use of non-recommended tires and wheels could cause steering, suspension, axle or transfer
case/power transfer unit failure.
NOTICE: Do not clean aluminum wheels with steel wool, abrasive-type cleaners or strong
detergents. Damage to the wheel finish may occur. Use Wheel and Tire Cleaner ZC-37-A or -B or
equivalent.
Factory-installed tires and wheels are designed to operate satisfactorily with loads up to and including full-
rated load capacity when inflated to recommended inflation pressures.
Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering,
excessively rapid acceleration and unnecessary sharp braking increase tire wear.
To equalize tire wear, the tires should be rotated at recommended intervals.
Tire Pressure Monitoring System (TPMS)
The Tire Pressure Monitoring System (TPMS) includes:
z the Body Control Module (BCM), located behind the passenger side kick panel.
z the Tire Pressure Monitor (TPM) module, located behind the instrument panel on the RH side near
the glove box.
z four valve stem mounted tire pressure sensors.
z an Instrument Panel Cluster (IPC) warning indicator.
z message center warnings.
Tire Pressure Monitor (TPM) Module
The TPM module is a radio receiver that collects the tire pressure data from the TPMS tire pressure
sensors. The TPM module passes the tire pressure data to the BCM , where the BCM applies a
predetermined pass/fail criteria.
The BCM compares the information of each tire pressure message against a pressure limit. If the BCM
determines that the tire pressure has fallen below the minimum pressure, the BCM communicates this to the
IPC on the vehicle communication network.
Tire Pressure Monitoring System (TPMS) Pressure Sensor
The BCM uses tire pressure sensors to monitor the tire pressure in the 4 road tires. The sensors transmit
radio frequency signals to the BCM approximately once every 60 seconds when the vehicle speed exceeds
32 km/h (20 mph).
The tire pressure sensors are battery operated and mounted to the valve stem.
Instrument Panel Cluster (IPC) and Message Center
The IPC illuminates the TPMS warning indicator when it receives a TPMS warning indicator on request from
the BCM and displays the appropriate message(s) in the message center.
For additional information on the IPC and message center, refer to Section 413-01 .

DISASSEMBLY AND ASSEMBLY Procedure revision date: 10/25/2013
Wheel and Tire
Special Tool(s)
Digital Tire Pressure Gauge
204-354
Part
Item Number Description
1 1508 Tire
2 1007 Wheel
3 1700 Valve stem and screw (also part of 1A189)
4 1A189 Tire Pressure Monitoring System (TPMS) sensor (a new
sensor assembly includes W714266 screw and 1700
valve stem and cap)
5 — Valve stem-to- TPMS sensor screw (part of 1700)
6 1A163 Valve stem cap (also part of 1A189)
Disassembly
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors,
follow the correct procedures for hazardous material disposal. Failure to follow these instructions
NOTICE: Failure to follow the instructions below may result in damage to the Tire Pressure
Monitoring System (TPMS) sensor.
NOTICE: The Tire Pressure Monitoring System (TPMS) sensor is mounted to the valve stem.
Removal of the valve stem requires dismounting the tire from the wheel and removal of the TPMS
sensor.
NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure that
accurate values are obtained.
1. Remove the wheel and tire. For additional information, refer to Wheel and Tire in this section.
2. NOTICE: The valve stem is connected to the Tire Pressure Monitoring System (TPMS) sensor.
Do not pull the valve stem from the wheel, or damage to the sensor will occur.
Remove the valve stem core and fully deflate all air from the tire.
z If a new Tire Pressure Monitoring System (TPMS) sensor is being installed, remove and
discard the valve stem-to-sensor screw and the sensor.
NOTICE: Do not allow the tire beads to move beyond the wheel mid-plane (middle of the wheel) when
separating the beads from the wheels, damage to the Tire Pressure Monitoring System (TPMS)
sensor may occur.
3. NOTICE: Tire and valve stem position is critical to prevent damage to the Tire Pressure
Monitoring System (TPMS) sensor when using a paddle-type bead separator.
NOTE: Some machines may have a nylon roller bead separator at the 12 o'clock position instead of
the paddle-type bead separator at the 3 o'clock position.
Position the wheel and tire assembly on a suitable tire machine and separate both beads of the tire
from the wheel.
z For a paddle-type tire machine, position the valve stem at the 12 o'clock or 6 o'clock position
and the paddle at the 3 o'clock position.
z For a roller-type tire machine, align the valve stem with the roller at any position.
4. NOTE: Index-mark the valve stem and wheel weight positions on the tire.
Place the wheel and tire assembly on the turntable of the tire machine with the valve stem at the
11:30 position and the machine arm at the 12 o'clock position and dismount the outer bead from the
wheel.
5. Reset the wheel and tire assembly on the turntable of the tire machine with the valve stem at the
11:30 position and the machine arm at the 12 o'clock position and dismount the inner bead from the
wheel.
6. NOTE: A new valve stem must be installed whenever a new tire or wheel is installed.
Remove the TPMS sensor in the following sequence.

1. Using a T10 Torx, remove the valve stem-to- TPMS sensor screw.
2. Carefully and firmly, pull the sensor straight down and separate it from the valve stem.
7. NOTICE: Use care not to damage the wheel surface when removing the valve stem.
Using a suitable valve stem puller and a wood block, remove the valve stem from the wheel.
8. NOTE: When installing a new wheel, always install a new valve stem and sensor screw. Reuse the
TPMS sensor from the previous wheel if possible. The TPMS will not have to be trained if the sensor
is reused.
If the TPMS sensor is being reused, inspect the TPMS sensor for damage and install a new sensor
as necessary.
Assembly
NOTICE: Damage to the Tire Pressure Monitoring System (TPMS) sensor may result if the tire
mounting is not carried out as instructed.
1. NOTICE: To prevent Tire Pressure Monitoring System (TPMS) sensor and valve stem damage,
the valve stem must be installed onto the TPMS sensor and then installed into the wheel as an
assembly.
Install a new valve stem onto the TPMS sensor.

z Tighten the new valve stem-to- TPMS sensor screw to 1.5 Nm (13 lb-in).
2. NOTICE: It is important to pull the valve stem and Tire Pressure Monitoring System (TPMS)
sensor assembly through the wheel rim hole in a direction parallel to the valve stem hole axis.
If the assembly is pulled through at an angle, damage to the valve stem and sensor assembly
may occur.
NOTICE: Use care not to damage the wheel surface when installing the valve stem and Tire
Pressure Monitoring System (TPMS) sensor assembly.
Lubricate the valve stem with soapy water and install the valve stem and TPMS sensor assembly into
the wheel using a block of wood and a suitable valve stem installer.
3. Make sure the valve stem rubber is fully seated against the wheel.
4. NOTE: Lubricate the tire beads using a suitable fast-drying, corrosion-inhibiting tire bead lubricant.
NOTE: Do not mount the tire at this time.
Position the wheel on the turntable of the tire machine, then lubricate and position the bottom bead of
the tire on the wheel.
5. Position the wheel to align the valve stem with the machine arm, at the 6 o'clock position, and mount
the bottom bead of the tire.
6. Reposition the wheel to align the valve stem with the machine arm at the 6 o'clock position, and
mount the top bead of the tire.
7. NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to make sure
that accurate values are obtained.
Inflate the tire to the pressure specified on the Vehicle Certification (VC) label located on the driver
door or door pillar.
z Proceed to Step 8 if the tire beads do not seat at the specified inflation pressure.
8.
of the tire in order to seat the beads, follow all steps listed below. Failure to follow these steps
The following steps should only be carried out if the tire beads cannot be seated by inflating
the tire up to the maximum inflation pressure listed on the tire sidewall.
1. Relubricate the tire bead and wheel bead seat area.
2. Install a remote valve and pressure gauge.
3. Wear eye and ear protection and stand at a minimum of 3.65 m (12 ft) away from the wheel
and tire assembly.
4. Inflate the tire using the remote valve and tire gauge until the beads have seated or until the
pressure gauge is 138 kPa (20 psi) more than maximum inflation pressure on tire sidewall. If
beads have not seated, deflate the tire and proceed to the next step.
5. Place the wheel and tire assembly in an OSHA-approved tire safety cage.
6. Inflate the tire using the remote valve and pressure gauge until the beads have seated or until
the pressure gauge is 276 kPa (40 psi) more than maximum inflation pressure on the tire
sidewall. Do not exceed 276 kPa (40 psi) above the maximum pressure on tire sidewall.
Install a new tire if the beads do not seat at this pressure.
9. Install the wheel and tire. For additional information, refer to Wheel and Tire in this section.

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES Procedure revision date: 10/25/2013
Tire Pressure Monitoring System (TPMS) Sensor
Disassembly
1. NOTE: The Tire Pressure Monitoring System (TPMS) sensor cannot be removed without disassembly
of the wheel and tire.
Disassemble the wheel and tire. For additional information, refer to Wheel and Tire in this section.

Tire Pressure Monitoring System (TPMS)
Special Tool(s)
Activation Tool, Tire Pressure
Monitor
204-363

204-354
Vehicle Communication Module

(VCM) and Integrated Diagnostic
System (IDS)
software with appropriate
hardware, or equivalent scan tool
Principles of Operation
chemicals if exposed to extreme mechanical damage. If these chemicals contact the skin or eyes,
flush immediately with water for a minimum of 15 minutes and get prompt medical attention. If any
part of the battery is swallowed, contact a physician immediately. When disposing of TPMS sensors,
follow the correct procedures for hazardous material disposal. Failure to follow these instructions
The Tire Pressure Monitor (TPM) module monitors the tire pressure of all 4 road tires. The wheel-mounted
tire pressure sensors transmit signals via radio frequency to the TPM module. The TPM module is a radio
receiver that collects the tire pressure data from the tire pressure sensors. The TPMS sensor radio
transmissions are sent once approximately every 60 seconds when the vehicle speed exceeds 32 km/h (20
mph). The data is then sent to the Body Control Module (BCM) where a predetermined pass/fail criteria is
applied. The BCM compares each TPMS sensor transmission against a low-pressure limit. If it has been
determined that the tire pressure has fallen below this limit, the BCM communicates this on the vehicle
communication bus to the Instrument Panel Cluster (IPC). The IPC then illuminates the TPMS warning
indicator and displays the appropriate message(s) in the message center.
Ambient Temperature Change and Tire Pressure
Tire pressures fluctuate with temperature changes. For this reason, tire pressure must be set to specification
when tires are at outdoor ambient temperatures. If the vehicle is allowed to warm up to shop temperatures,
and the outside temperature is less than shop temperature, the tire inflation pressure must be adjusted
accordingly.
If the tires are inflated to specification at shop temperatures, and the vehicle is moved outdoors when the
outdoor ambient temperature is significantly lower, the tire pressure may drop enough to be detected by the
TPMS and activate the TPMS warning indicator.
As the ambient temperature decreases by 6°C (10°F), tire pressure decreases 7 kPa (1 psi). Adjust the tire
pressure by 7 kPa (1 psi) for each 6°C (10°F) ambient temperature drop as necessary to keep the tire at the
specified Vehicle Certification (VC) label pressure. Refer to the following tables to adjust the tire pressure
indoors for colder outside temperatures.
Tire Pressure Monitoring System (TPMS) Warning Indicator and Message Center Messages
The TPMS warning indicator and vehicle message center sometimes display faults that cannot be resolved
by the customer. Treat these messages as TPMS faults that must be serviced.
Tire Pressure Monitoring System (TPMS) Warning Indicator Illuminates Continuously
NOTE: When directed to train or re-train any TPMS sensors, use only the sensor training procedure
outlined in Tire Pressure Monitoring System (TPMS) Sensor Training . Do not use the TPMS reset
procedure outlined in the Owner's Literature as this procedure will not program new sensors to the module.
The TPMS warning indicator remains on continuously and the message center displays LOW TIRE
PRESSURE when any of the tire pressures are low. When this condition exists, adjust the tire pressure to
the recommended cold pressure indicated on the VC label.
NOTE: The TPMS sensors do not transmit when the vehicle is stationary. If the vehicle has been stationary
for more than 30 minutes, it is necessary to wake up the sensors so that they transmit the latest tire
pressure information to the TPM module.
If the vehicle has been stationary for more than 30 minutes, carry out the Tire Pressure Monitoring System
(TPMS) Sensor Activation procedure in this section.
TPMS Warning Indicator Flashes
The TPMS warning indicator flashes for 70 seconds, then remains ON continuously when the ignition switch
is turned to the ON position and 1 or more of the following conditions exists:
z Tire Pressure Sensor Fault — The message center displays TIRE PRESSURE SENSOR FAULT
when a TPMS sensor is malfunctioning. GO to Symptom Chart .
z No communication with the BCM . The TPMS indicator is illuminated when the IPC has not received
any signals from the BCM for more than 5 seconds. The message center displays TIRE PRESSURE
MONITOR FAULT. GO to Symptom Chart .
z Tire Pressure Monitor Fault — The message center displays TIRE PRESSURE MONITOR FAULT
when the TPMS is malfunctioning or communication with the IPC has been lost. GO to Symptom
Chart .
The TP_STAT PID can be used to determine why the TPMS warning indicator is flashing.
Tire Pressure Monitoring System (TPMS) PID Definitions and Intermittent Troubleshooting
TPMS Status PID
The TPM monitors the TPMS status. The current status can be viewed by accessing the TPMS status PID :
TPMS_STAT using the scan tool. This helps identify the current system status and may aid in diagnosing
the system. The PID has 4 valid states:
1. TPMS_STAT = SENSOR FAULT.

z If the module has not received the tire pressure status from 1 to 3 TPMS sensors for 20
minutes when the vehicle speed is above 32 km/h (20 mph), the PID displays SENSOR
FAULT.
2. TPMS_STAT = SYSTEM FAULT.

z If the module has not received the tire pressure status from all 4 TPMS sensors for 20 minutes
and the vehicle speed is above 32 km/h (20 mph), the PID displays SYSTEM FAULT.
3. TPMS_STAT = LOW.
z If the module has detected that at least 1 TPMS sensor is reporting low tire pressure, the PID
displays LOW.
4. TPMS_STAT = SYSTEM ACTIVE.

z If the TPMS is functioning normally, the PID displays SYSTEM ACTIVE.
TPMS Last Warning Event PID Definitions
The TPMS uses the TPMS last warning event PIDs to store detailed information about the last 5 times the
TPMS warning indicator was activated. These PIDs can be used to acquire more information about a
particular TPMS event, but must be used carefully.
EVT1_AGE_IGN through EVT5_AGE_IGN
The number of key cycles since the TPMS indicator was activated. This PID cycles from zero to 255. Default
is $00, this can be used to determine how long ago a TPMS event occurred and the time (in key cycles)
between events.
EVT1_TR_LOC through EVT5_TR_LOC
This is the last programmed location for the sensor identifier causing each TPMS event. Due to tire rotation,
the sensor may no longer be at the original location. It is suggested that all the PIDs be recorded, the
system retrained, and then the sensor identifier PIDs be used to pinpoint the actual location of each sensor.
EVT1_PRESS through EVT5_PRESS
This is the tire pressure associated with each TPMS warning indicator event. This can be used along with
the function code to clearly identify the TPMS events that were strictly due to low pressure. It can also be
used to determine when a sensor is transmitting inaccurate tire pressure.
EVT1_SNSR_ST through EVT5_SNSR_ST
Describes the warning status of each TPMS event by using the information received from the TPMS status
(TPMS_STAT) PID . If there is a communication issue, the status could be Normal.
z Unknown
z Normal (normal operation)
z Low (low pressure event)
z Fault (sensor fault or system fault)
EVT1_SNSR_ID through EVT5_SNSR_ID
This is the identifier of the sensor involved in each TPMS event. EVT1 is the most recent event that
triggered the TPMS warning indicator. Default is $ 00 00 00 00.
Wheel Rotation and Sensor Training Techniques
Moving a Problem Sensor/Wheel to a Different Position
If a sensor in a certain location has caused several events, yet the sensor trains and seems to operate
normally, moving that particular wheel to a different location on the vehicle is a good way to isolate the issue
to a certain sensor/wheel location. Rotate the wheels and road test the vehicle. This can be done in an
attempt to replicate the issue. This determines if the issue followed the sensor or remained in the original
sensor location.
Training Sensors in a Different Order
This is a technique to get past a left front sensor that may not be responding to determine if the remaining
sensors train to the module. This can help save time determining if other sensors are having issues or if the
module is experiencing training difficulties with a certain location.
Training Known Good Sensors From Another Vehicle
Training known good sensors from another vehicle cannot differentiate between a faulted module and Radio
Frequency Interference (RFI), as some noise source could be preventing the TPM module from receiving
the tire pressure status from the original sensors as well as the known good sensors. This technique can be
used to differentiate between a sensor and module issue. If the TPM module cannot train any of the sensors
on the same vehicle, and likewise cannot train known good sensors from another vehicle, then the issue is
with the TPM module or RFI and not with the original sensors. The original sensors should not be replaced.
Items That Cause RFI
Non-OEM Equipment
The following equipment has been found to sometimes cause RFI :
z Video equipment has been found to cause RFI especially when the video and power supply lines are
near the TPMS .
z Car alarms (even those installed by dealerships) have been found to create enough RFI to cause the
TPMS to malfunction or lose considerable range. These car alarms can sometimes be difficult to
locate, as they are usually hidden somewhere out of the way for reduced accessibility.
z Many different in-vehicle cell phone chargers have been found to cause considerable RFI . The
vehicles with the power point closest to the TPM module are the most affected. It must be noted that
most cell phone chargers do not produce high levels of RFI all the time. This depends on the state of
charge of the cell phone battery. The phone must be almost completely discharged in some cases.
z Power supplies and DC/AC inverters typically create a lot of RFI . Most consumer grade equipment
has very little filtering or shielding.
OEM Modules
In some cases, the RFI may actually be caused by a module or ground on the vehicle. Depending on the
severity of the issue, a dirty ground, improperly built ground shield or module can disable the system.
Modules that have microcontrollers using clock circuits to create the timing pulses for the microprocessor
may radiate RFI .
Using Customer's Electronics to Pinpoint the Radio Frequency Interference (RFI) Source
This can be a way to determine the cause of an issue well before the sensors and module are replaced with
little or no affect on the system performance. Since this takes more up-front work, it relies on working with
the customer to determine what equipment was being used at the time of the event.
Options for Eliminating Intermittent TPMS Conditions Caused by RFI
z If an OEM component or customer device is causing an RFI issue, replace the device.
z If a phone charger is causing an RFI issue, the customer should consult their cell phone provider to
acquire a different phone charger.
z If a device such as a dealer-installed alarm is causing an RFI issue, move the device to another
location on the vehicle. In the case of a portable device, move the power cord to another power point
location.
In summary, if the RFI source is present and cannot be moved or replaced, the intermittent issue remains.
The TPMS system must accept RFI and the unwanted system operation it can cause.
1. Verify the customer concern. Keep the following items in mind when diagnosing any TPMS related
issue:
z The tire pressure sensors are not designed to be used with aftermarket wheels. The use of
run-flat tires (tires with steel body cord plies in the tire sidewall) that are not originally
equipped, may block the TPMS signal and are not recommended.
z Non-OEM modifications made to the vehicle may result in false TPMS warnings.
z Swapping wheels on vehicles with the same TPMS sensors sets a fault if the sensors are not
trained. Refer to Tire Pressure Monitoring System (TPMS) Sensor Training in this section.
z The tire pressure calibrations in the TPM for the system cannot be changed to use lower tire
pressures than those listed on the Vehicle Certification (VC) label.
z Certain non-OEM electronic equipment may cause RFI and false TPMS warnings. To aid in
diagnosis, obtain information from the owner regarding any equipment that has been added or
was in use at the time the TPMS fault occurred.
z It may be necessary to disconnect any electronic add-on equipment to verify its impact on
TPMS operation. For intermittent cases, it may be necessary to ask the customer to provide
portable electronic equipment to verify its impact on the system.
2. Visually inspect for obvious signs of mechanical or electrical damage.

Mechanical Electrical
z Low tire pressure z Body Control Module (BCM) fuse 26 (5A)
z Spare tire installed as a road wheel z Wiring, terminals or connectors
z Sensors not trained after a tire rotation z TPM missing or damaged
z Tire Pressure Monitoring System (TPMS) z Aftermarket electronic accessories (in-car
sensor damaged or missing chargers or supplies, DC/AC inverters, video
z Incorrect TPMS sensor installed screens, car alarms)
z TPMS sensor installed incorrectly
z Non-OEM wheels installed (aftermarket
rims)
z Non-OEM equipped run-flat tires or rigid
sidewall tires (19.5" steel carcass heavy-
duty tires) installed
z Other non-OEM modifications (roll cages,
service barriers, part racks, ladder racks)
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible)
4. NOTE: Make sure to use the latest scan tool software release.
If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
5. NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground from
the DLC are provided to the VCM .
If the scan tool does not communicate with the VCM :

z check the VCM connection to the vehicle.
z check the scan tool connection to the VCM .
z refer to Section 418-00 , No Power To The Scan Tool, to diagnose no power to the scan tool.
6. If the scan tool does not communicate with the vehicle:

z verify the ignition key is in the ON position.
z verify the scan tool operation with a known good vehicle.
z refer to Section 418-00 , The PCM Does Not Respond To the Scan Tool, to diagnose no
response from the PCM.
7. Carry out the network test.

z If the scan tool responds with no communication for one or more modules, refer to Section
418-00 .
z If the network test passes, retrieve and record Continuous Memory Diagnostic Trouble Codes
(CMDTCs).
8. Clear the CMDTCs and carry out the self-test diagnostics for the BCM and the TPM module.
9. If the DTCs retrieved are related to the concern, go to the BCM DTC Chart or the TPM Module DTC
Chart. For all other DTCs, refer to the Diagnostic Trouble Code (DTC) Chart in Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart .
DTC Charts
Body Control Module (BCM) DTC Chart

DTC Description Action
B1182:00 Tire Pressure Monitoring GO to Pinpoint Test F .
System (TPMS): No Sub Type
Information
B1182:55 Tire Pressure Monitoring This DTC is only present when a new BCM is installed, the
System (TPMS): Not BCM is flashed or is reconfigured. TRAIN the tire pressure
Configured sensors. REFER to Tire Pressure Monitoring System
(TPMS) Sensor Training in this section.
B124D:02 Tire Pressure Sensor: General NOTE: If the vehicle has been stationary for more than 30
Signal Failure minutes, the sensors go into sleep mode to conserve battery
power. It may be necessary to wake them up so they
transmit the latest tire pressure information to the TPM
module.
ACTIVATE the TPMS sensors. REFER to Tire Pressure

Monitoring System (TPMS) Sensor Activation in this section.
REPEAT the self-test. If DTC B124D:02 is retrieved again,

GO to Pinpoint Test F .
B1251:00 Tire Pressure Sensor Low GO to Pinpoint Test H .
Battery: No Sub Type
Information
B1254:51 Right Rear (Outside on Dual This DTC is only present when a new BCM is installed, the
Wheel) Tire Pressure Sensor BCM is flashed or reconfigured. TRAIN the tire pressure
and Transmitter Assembly: Not sensors. REFER to Tire Pressure Monitoring System
Programmed (TPMS) Sensor Training in this section.
B1255:51 Left Rear (Outside on Dual This DTC is only present when a new BCM is installed, the
Wheel) Tire Pressure Sensor BCM is flashed or reconfigured. TRAIN the tire pressure
and Transmitter Assembly: Not sensors. REFER to Tire Pressure Monitoring System
Programmed (TPMS) Sensor Training in this section.
C1A56:51 Left Front Tire Pressure Sensor This DTC is only present when a new BCM is installed, the
and Transmitter Assembly: Not BCM is flashed or reconfigured. TRAIN the tire pressure
Programmed sensors. REFER to Tire Pressure Monitoring System
C1A58:51 Right Front Tire Pressure This DTC is only present when a new BCM is installed, the
Sensor and Transmitter BCM is flashed or reconfigured. TRAIN the tire pressure
Assembly: Not Programmed sensors. REFER to Tire Pressure Monitoring System
All other — REFER to Section 419-10 .
DTCs
Tire Pressure Monitor (TPM) Module DTC Chart

B1D55:01 Antenna #2: General Electrical Failure REFER to Section 303-06 .
U0140:87 Lost Communication with Body Control GO to Pinpoint Test I .
Module: Missing Message
U0422:68 Invalid Data Received from Body Control RETRIEVE and REPAIR all non-network DTCs
Module (BCM): Event Information in the BCM . REFER to Section 419-10 .
Symptom Chart
Symptom Chart
NOTE: For vehicles with different front and rear tire pressures, the tire pressures must be
adjusted and the tire pressure sensors must be trained following a tire rotation. Failure to
train the sensors results in a false low tire pressure event, causing the Tire Pressure
Monitoring System (TPMS) indicator to illuminate.
For vehicles with the same tire pressure for front and rear tires, training the sensors is
not necessary after a tire rotation.
Failure of a TPMS component may not cause the message center to display a fault
message or store a DTC. The Symptom Chart is a starting point to begin diagnosis of
these concerns.
z The Tire Pressure z Spare tire currently in z GO to Pinpoint Test
Monitoring System (TPMS) use D.
warning indicator is on z Tire pressure not set to
continuously and the specifications listed on
message center displays the Vehicle Certification
LOW TIRE PRESSURE (VC) label
z TPMS sensors not
trained following tire
rotation
z TPMS sensor(s)
z The Body Control Module z Stoplamp switch z GO to Pinpoint Test
(BCM) cannot enter sensor concern E.
training mode when using z Ignition switch concern
the TPMS sensor training z BCM
procedure
z The TPMS warning z Not all TPMS sensors z GO to Pinpoint Test
indicator illuminates with are installed F.
DTCs present z TPMS sensors not
trained
z TPMS sensor(s)
z Intermittent TPMS
operation due to Radio
Frequency Interference
(RFI)
z TPM module wiring
z TPM module
z BCM wiring
z BCM
z The TPMS warning z Communication z REFER to Section
indicator illuminates with no network concern 413-01 to diagnose
DTCs present z Instrument Panel the TPMS warning
Cluster (IPC) indicator is always
on.
z One or more TPMS sensors z TPMS sensor(s) z FOLLOW the
do not train and DTCs are z Vehicle communication diagnostics for the
present issue DTC(s) retrieved.
z Intermittent TPMS REFER to DTC
operation due to RFI Charts in this
z TPM module wiring section.
z TPM module
z BCM wiring
z BCM
z One or more TPMS sensors z TPMS sensor(s) z GO to Pinpoint Test
do not train and no DTCs z Radio Frequency G.
are present Interference (RFI)
Pinpoint Tests
Pinpoint Test D: The Tire Pressure Monitoring System (TPMS) Warning Indicator Is ON Continuously
and The Message Center Displays LOW TIRE PRESSURE
Normal Operation
The Tire Pressure Monitor (TPM) module monitors the air pressure of all 4 road tires. The wheel-mounted
tire pressure sensors transmit data via radio frequency signals to the TPM module. The TPM module is a
radio receiver that collects the air pressure data from the Tire Pressure Monitoring System (TPMS) tire
pressure sensors. The data is then sent to the Body Control Module (BCM) where a predetermined pass/fail
criteria is applied. The TPMS sensor radio transmissions are sent approximately once every 60 seconds
when the vehicle speed exceeds 32 km/h (20 mph). The BCM compares each TPMS sensor transmission
against a low-pressure limit. If it has been determined that the tire pressure has fallen below this limit, the
BCM communicates this on the vehicle communication bus to the Instrument Panel Cluster (IPC). The IPC
then illuminates the TPMS warning indicator and displays the appropriate message(s) in the message
center .
This symptom can also be caused by a spare tire currently being used in place of a road tire. Make sure that
the spare tire is not currently in use. On vehicles with different front and rear tire pressures, if the sensors
are not trained following a tire rotation, this symptom may result. Advise the customer that on vehicles with
different front and rear tire pressures, the sensors must be trained as directed in the Owner's Literature.

z Spare tire currently in use
z Tire pressure not set to specifications listed on the Vehicle Certification (VC) label
z TPMS sensors not trained following tire rotation
z TPMS sensor(s)
PINPOINT TEST D: THE TPMS WARNING INDICATOR IS ON CONTINUOUSLY AND THE MESSAGE
CENTER DISPLAYS LOW TIRE PRESSURE
NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure that
accurate values are obtained.
NOTE: If a warranty case is opened for an actual TPMS fault, document and include the actual tire pressure
data in all warranty communications.

D1 CHECK FOR LOW TIRE PRESSURE
z Using the Digital Tire Pressure Gauge, measure and record Yes
the air pressure in all 4 tires. The system is operating
z Adjust the pressure for those found to be below the correctly at this time. The
specification listed on the VC label. concern was caused by low tire
z Activate each sensor at least twice with the training tool or pressure.
customer activation tool to make sure the TPM module gets
the latest air pressure data. Refer to Tire Pressure Monitoring No
System (TPMS) Sensor Activation or drive the vehicle for at GO to D2 .
least 2 minutes above 32 km/h (20 mph) to clear the low
pressure warning. Do not train the sensors at this time.
z Has the TPMS warning indicator gone out?
D2 CHECK FOR SPARE TIRE IN USE
Yes
NOTE: The spare tire is not programmable even if it is
REPAIR and REMOUNT the
equipped with a TPMS sensor. If a damaged road wheel is wheel to the vehicle. REFER to
located in the cargo area, the sensor may still be recognized Wheel and Tire in this section.
by the TPMS as low. Make sure the spare tire is not currently ADJUST tire pressures to the
in use. To restore TPMS functionality, repair the damaged required pressure as defined
road wheel and re-mount it to the vehicle. on the VC label located in the
z Check spare tire location. driver door jam.
z Is the spare tire in use?
No
GO to D3 .
D3 CHECK IF THE TIRES WERE ROTATED WITHOUT TPMS
SENSOR TRAINING
NOTE: If the TPMS sensors at the front of the vehicle are still Yes
trained in the rear positions but inflated to the front air The tires have been rotated
pressures, the TPMS warning indicator illuminates without training the sensors.
continuously. TRAIN the sensors. REFER to
Tire Pressure Monitoring
z Ignition ON. System (TPMS) Sensor
z Enter the following diagnostic mode on the scan tool: Training in this section.
DataLogger — BCM .
z Monitor and record the following BCM PIDs: No
Left Front Tire Pressure (TPM_PRES_LF) GO to D4 .
Right Front Tire Pressure (TPM_PRES_RF)
Left Rear Tire Pressure (TPM_PRES_LRO)
Right Rear Tire Pressure (TPM_PRES_RRO)
z Do the rear PIDs show front air pressures and the front
PIDs show rear air pressures?
D4 CHECK FOR STUCK TPMS SENSOR
z Monitor and record the following BCM PIDs: Yes
Left Front Tire Pressure (TPM_PRES_LF) REFER to Section 413-01 to
Right Front Tire Pressure (TPM_PRES_RF) diagnose the TPMS warning
Left Rear Tire Pressure (TPM_PRES_LRO) indicator is always on.
Right Rear Tire Pressure (TPM_PRES_RRO)
z Using the Digital Tire Pressure Gauge, measure the actual tire No
pressures. INSTALL a new TPMS sensor
z Compare the air pressure PIDs with the actual air pressures. (s) for the sensor(s) in
z Do the compared tire pressure values match within ± 5 question. REFER to Tire
psi? Pressure Monitoring System
(TPMS) Sensor in this section.
Pinpoint Test E: The Body Control Module (BCM) Cannot Enter Sensor Training Mode When Using
the Tire Pressure Monitoring System (TPMS) Sensor Training Procedure
Normal Operation
For the Body Control Module (BCM) to enter Tire Pressure Monitoring System (TPMS) sensor training
mode, the BCM must receive valid inputs from the stoplamp switch (off) and ignition switch (run), and it must
receive valid vehicle speed sensor input (0 km/h [0 mph]). Refer to Tire Pressure Monitoring System (TPMS)
Sensor Training in this section for the complete sensor training procedure.

z Stoplamp switch concern
z Ignition switch concern
z BCM
PINPOINT TEST E: THE BCM CANNOT ENTER SENSOR TRAINING MODE WHEN USING THE TPM
SENSOR TRAINING PROCEDURE

E1 CHECK THE STOPLAMP OPERATION
z Ignition ON. Yes
z Press and release the brake pedal while GO to E2 .
monitoring the stoplamps.
z Do the stoplamps operate properly? No
REFER to Section 417-01 to continue diagnosis
of the stoplamp switch.
E2 CHECK THE IGNITION SWITCH INPUT
z Ignition ON. Yes
z Enter the following diagnostic mode on the GO to E3 .
scan tool: BCM DataLogger.
z Monitor the BCM ignition switch PID No
(IGN_SW_STATE) with the ignition in the REFER to Section 211-05 to continue diagnosis
RUN position. of the ignition switch.
z Does the PID indicate the correct ignition
switch position?
E3 CHECK FOR VEHICLE SPEED-RELATED
DTCs IN THE BCM
z Carry out the BCM self-test. Yes
z Are any vehicle speed-related DTCs REFER to the BCM DTC Chart in Section 419-
present? 10 .
No
GO to E4 .
E4 CHECK FOR CORRECT BCM OPERATION
z Disconnect all the BCM connectors. Yes
z Check the connectors for: INSTALL a new BCM . REFER to Section 419-
corrosion 10 . TEST the system for normal operation.
damaged pins
pushed-out pins No
z Connect all the BCM connectors and make The system is operating correctly at this time.
sure that they are seated correctly. The concern may have been caused by a loose
z Operate the system and verify the concern is or corroded connector.
still present.
z Is the concern still present?
Pinpoint Test F: The Tire Pressure Monitoring System (TPMS) Warning Indicator Illuminates With
DTCs Present
Normal Operation
If there is a fault with 1, 2 or 3 of the Tire Pressure Monitoring System (TPMS) sensors, DTC B124D:02 sets.
The TPMS warning indicator flashes for 70 seconds and then remains on continuously when the ignition
switch is turned to the ON position and the message center displays TIRE PRESSURE SENSOR FAULT.
If the TPM module does not get a response from all 4 of the TPMS sensors and transfers that information to
the BCM , DTC B1182:00 sets and the message center displays TIRE PRESSURE MONITOR FAULT.
It should be noted that TPMS sensor communication to the TPM module can be interrupted by radio
frequency noise, which can cause intermittent issues that are not vehicle concerns. Radio frequency noise is
generated by electrical motors and appliance operation, cellular telephones, remote transmitters, power
inverters and portable entertainment equipment. Anytime the TPMS sensor training procedure is performed
successfully, the warning indicator is extinguished and the vehicle must be driven for 18-20 minutes before
the TPM module sets a fault.
z DTC B1182:00 (Tire Pressure Monitoring System (TPMS): No Sub Type Information) — set by the
BCM when all 4 of the tire pressure sensors are faulted, not responding or not heard by the TPM
module.
z DTC B124D:02 (Tire Pressure Sensor: General Signal Failure) — set by the BCM when 1, 2 or 3 of
the tire pressure sensors are faulted, not responding or not heard by the TPM module.
z TPMS_STAT PID = SENSOR FAULT — when the BCM does not receive the tire pressure status for
1 to 3 TPMS sensors from the TPM module for 20 minutes with vehicle speed above 32 km/h (20
mph).
z TP_STAT PID = SYSTEM FAULT when the BCM does not receive a signal transmission from all 4
TPMS sensors from the TPM module for 20 minutes with vehicle speed above 32 km/h (20 mph).

z Not all TPMS sensors are installed
z TPMS sensors not trained
z TPMS sensor(s)
z TPM module wiring
z TPM module
z BCM wiring
z BCM
PINPOINT TEST F: THE TPMS WARNING INDICATOR ILLUMINATES WITH DTCs PRESENT
NOTE: If a warranty case is opened for an actual TPMS fault, document and include the actual tire pressure
data in all warranty communications.
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors go into a "sleep mode" to
conserve battery power. It is necessary to wake them up so that they transmit the latest tire pressure
information to the TPM module.

F1 VERIFY TPM MODULE
COMMUNICATION
z Ignition ON. Yes
z Using a scan tool, carry out the GO to F2 .
Network Test.
z Does the TPM module pass the No
Network Test? REFER to Section 418-00 to diagnose the TPM module
does not respond to the scan tool.
F2 CHECK THE SENSOR IDENTIFIER
PIDs AND SYSTEM STATUS PID
z Enter the following diagnostic mode Yes
on the scan tool: DataLogger — GO to F3 .
BCM .
z Read and record the following No
PIDs : If the TPMS_STAT PID displays SYSTEM FAULT, GO to
Left Front Tire Transmitter F4 .
Identifier (TPM_S_ID_LF)
Right Front Tire Transmitter
Identifier (TPM_S_ID_RF)
Left Rear Tire Transmitter
Identifier (TPM_S_ID_LRO)
Right Rear Tire Transmitter
Identifier (TPM_S_ID_RRO)
z Monitor the TPMS system status
(TPMS_STAT) PID .
z Does the TPMS_STAT PID
display SENSOR FAULT?
F3 CARRY OUT THE SENSOR
TRAINING PROCEDURE (SENSOR
FAULT)
z Train all 4 tire pressure sensors. Yes
Refer to Tire Pressure Monitoring Using the scan tool, LOCATE the updated TPMS sensor
System (TPMS) Sensor Training in identifiers trained to the BCM module. COMPARE these
this section. values to those recorded prior to the TPMS sensor
z Did all of the tire pressure training procedure. Disregarding sensor position, any
sensors transmit correctly and sensor identifiers that do not match those retrieved from
did the horn sound when each the module were changed, but not retrained. The sensors
TPMS sensor transmitted to the are now trained to the vehicle, diagnosis is complete.
TPM module? DOCUMENT all TPMS sensor identifiers on the
applicable warranty claim.
TEST the system for normal operation.
No
Before installing a new sensor(s) : If a sensor does not
respond to the Tire Pressure Monitor Activation Tool,
MOVE the vehicle to rotate the wheels at least one-fourth
of a turn and ATTEMPT to activate the same sensor
again. If the sensor still fails to train, ATTEMPT to train
the sensor with the vehicle doors open. If the sensor(s)
fails to train a second time, INSTALL a new TPMS sensor
(s) for the sensor(s) in question. REFER to Tire Pressure
Monitoring System (TPMS) Sensor in this section.
F4 CARRY OUT THE SENSOR
TRAINING PROCEDURE (SYSTEM
FAULT)
z Train all 4 tire pressure sensors. Yes
Refer to Tire Pressure Monitoring Using the scan tool, LOCATE the updated TPMS sensor
System (TPMS) Sensor Training in identifiers trained to the BCM module. COMPARE these
this section. values to those recorded prior to the Tire Pressure
z Did all of the tire pressure Monitoring System (TPMS) Sensor Training procedure.
sensors transmit correctly and Disregarding sensor position, any sensor identifiers that
did the horn sound when each do not match those retrieved from the module were
TPMS sensor transmitted to the changed, but not retrained. The sensors are now trained
TPM module? to the vehicle, diagnosis is complete. DOCUMENT all
TPMS sensor identifiers on the applicable warranty claim.
No
Before installing a TPM module : If sensors do not
respond to the Tire Pressure Monitor Activation Tool,
MOVE the vehicle to rotate the wheels at least one-fourth
of a turn and ATTEMPT to activate the same sensors
again. If the sensors still fail to train, ATTEMPT to train
the sensors with the vehicle doors open. If the sensors
still fail to train, INSTALL a new TPM module. REFER to
Tire Pressure Monitor (TPM) Module in this section. TEST
the system for normal operation. If the concern is still
present, GO to F5 .
F5 CHECK FOR CORRECT BCM
OPERATION
z Disconnect all the BCM electrical Yes
connectors. NOTE: The TPMS sensors may not be present.
z Check the connectors for: DISMOUNT the tire. REFER to Wheel and Tire in this
corrosion section. VERIFY the TPMS sensors are present and
damaged pins mounted to the wheels. If missing, INSTALL new TPMS
pushed-out pins sensors.
z Connect all the BCM connectors
and make sure that they are seated If the TPMS sensors are present, INSTALL a new BCM .
correctly. REFER to Section 419-10 . CLEAR the DTCs. REPEAT
z Operate the system and verify the the self-test.
concern is still present.
z Is the concern still present? No
The system is operating correctly at this time. The
concern may have been caused by a loose or corroded
connector. CLEAR the DTCs. REPEAT the self-test.
Pinpoint Test G: One Or More TPMS Sensors Do Not Train And No DTCs Are Present
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors go into a sleep mode to
conserve battery power. It becomes necessary to wake them up so they transmit the latest tire pressure
information to the TPM module. For additional information, refer to Tire Pressure Monitoring System (TPMS)
Sensor Activation in this section.
Normal Operation
The TPM module monitors the tire pressure of all 4 road tires. The wheel-mounted tire pressure sensors
transmit signals via radio frequency to the Tire Pressure Monitor (TPM) module. The TPM module is a radio
receiver that collects the tire pressure data from the tire pressure sensors. The TPMS sensor radio
transmissions are sent approximately once every 60 seconds when the vehicle speed exceeds 32 km/h (20
mph). The BCM learns the position on the vehicle of each TPMS sensor through the training process. Refer
to Tire Pressure Monitoring System (TPMS) Sensor Training in this section for the complete sensor training
procedure.

z TPMS sensors
z Radio Frequency Interference (RFI)
PINPOINT TEST G: ONE OR MORE TPMS SENSORS DO NOT TRAIN AND NO DTCs ARE PRESENT

G1 ATTEMPT TO TRAIN THE TPMS SENSORS
NOTE: Banded TPMS sensors are not Yes

compatible with the valve mounted TPMS The system is operating correctly at this time.
sensor system. The concern may have been caused by RFI .
NOTE: The BCM has a 2-minute time limit No
between sensor responses. If the BCM does If one or more TPMS sensors trained, GO to
not recognize any 1 of the 4 tire pressure G2 . If none of the TPMS sensors trained, GO
sensors during this time limit, the horn sounds to Pinpoint Test E .
twice, the message center displays TIRE NOT
TRAINED REPEAT, and the entire procedure
must be repeated.
z Train all 4 TPMS sensors. Refer to Tire
Pressure Monitoring System (TPMS) Sensor
Training in this section.
z Do all of the TPMS sensors train?
G2 CHECK FOR RADIO FREQUENCY
INTERFERENCE
z Ignition ON. Yes
z Move the vehicle to rotate the wheels at least The system is operating correctly at this time.
one-fourth turn. The concern may have been caused by RFI .
z Train all 4 TPMS sensors. Refer to Tire
Pressure Monitoring System (TPMS) Sensor No
Training in this section. ATTEMPT to train the TPMS sensor(s) with
z Did the TPMS sensor(s) train? the doors open. If the TPMS sensor(s) still do
not train INSTALL a new TPMS sensor(s) for
the sensor(s) in question. REFER to Tire
Pressure Monitoring System (TPMS) Sensor
in this section. TEST the system for normal
operation.
Pinpoint Test H: DTC B1251:00
Normal Operation
z DTC B1251:00 (Tire Pressure Sensor Low Battery: No Sub Type Information) — This DTC sets in
continuous memory in the Body Control Module (BCM) when there is a fault in the Tire Pressure
Monitoring System (TPMS), such as a damaged or missing TPMS sensor(s), or when attempting to
train a TPMS sensor(s) with a low battery. The TPMS warning indicator flashes for 70 seconds then
illuminates continuously when the ignition switch is turned to the ON position. The message center
also displays TIRE PRESSURE SENSOR FAULT.

z TPMS sensor(s)
PINPOINT TEST H: DTC B1251:00

H1 TRAIN THE TPMS SENSORS TO
DETERMINE THE INOPERATIVE
SENSOR
z Train all 4 TPMS sensors. Refer to Yes

Tire Pressure Monitoring System CLEAR the DTCs. REPEAT the self-test. TEST the
(TPMS) Sensor Training in this system for normal operation.
section.
z Did all of the TPMS sensors No
transmit correctly when each If the TPMS sensors fail to train, REFER to Wheel
TPMS sensor transmitted to the Rotation And Sensor Training Techniques in this
TPM module? section.
If the TPMS sensor(s) fails to train a second time,

INSTALL a new TPMS sensor(s) for the sensor(s) in
question. REFER to Tire Pressure Monitoring System
(TPMS) Sensor in this section.
Pinpoint Test I: DTC U0140:87
Normal Operation
z DTC U0140:87 (Lost Communication With Body Control Module: Missing Message) — This DTC is
set by the Tire Pressure Monitor (TPM) module in continuous memory if data messages received
from the BCM are missing.
z Communication network concern

z TPM module
z BCM
PINPOINT TEST I: DTC U0140:87

I1 VERIFY THE CUSTOMER
CONCERN
z Ignition ON. Yes
z Verify there is an observable GO to I2 .
symptom present.
z Is an observable symptom No
present? The system is operating normally at this time. The DTC may
have been set due to high network traffic or an intermittent
fault condition.
I2 CHECK THE COMMUNICATION
NETWORK
z Ignition ON. Yes
z Using a scan tool, carry out the GO to I3 .
Network Test.
z Do both the BCM and the No
TPM module pass the If either module does not pass the Network Test, REFER to
Network Test? Section 418-00 to diagnose the BCM does not respond to the
scan tool or the TPM module does not respond to the scan
tool.
I3 CHECK THE TPM MODULE
CMDTCs
z Using a scan tool, carry out the Yes
TPM module self-test. GO to I4 .
z Using a scan tool, clear the
TPM module DTCs. No
z Ignition OFF. The system is operating correctly at this time. The DTC may
z Wait 10 seconds. have been set due to high network traffic or an intermittent
z Ignition ON. fault condition.
z Using a scan tool, carry out the
TPM module self-test.
z Is DTC U0140:87 retrieved
again?
I4 CHECK FOR DTCs IN THE BCM
BCM self-test. TPM module DTC U0140:87 may have been set due to a
z Is DTC U3003:16 or U3003:17 voltage issue in the BCM . REFER to the BCM DTC Chart in
present? Section 419-10 .
No
GO to I5 .
I5 CHECK FOR DTC U0140,
U0140:00, OR U0140:87 SET IN
OTHER MODULES
z Clear the CMDTCs from all Yes
modules. INSTALL a new BCM . REFER to Section 419-10 . CLEAR all
z Ignition OFF. continuous DTCs. REPEAT the self-test.
z Ignition ON.
z Wait 10 seconds. No
z Using a scan tool, retrieve the INSTALL a new TPM module. REFER to Tire Pressure
CMDTCs from all modules. Monitor (TPM) Module in this section. TEST the system for
z Is DTC U0140, U0140:00, or normal operation.
U0140:87 set in more than
one module?

Wheels And Tires
Special Tool(s)
204-354
Hunter Road Force® Wheel

Balancer
GSP9700 Series
injury.
Verify the customer concern by carrying out a road test on a smooth road. If any vibrations are apparent, GO
to Symptom Chart - NVH .
To maximize tire performance, inspect for signs of incorrect inflation and uneven wear, which may indicate a
need for balancing, rotation or front suspension alignment.
Correct tire pressure and driving techniques have an important influence on tire life. Heavy cornering,
excessively rapid acceleration and unnecessary sharp braking increase tire wear.
Replacement tires must follow the recommended:
z tire sizes.
z speed rating.
z load range.
z tire construction type.
The use of any other tire/wheel size, load range or type can seriously affect:
z ride.
z handling.
z speedometer/odometer calibration.
z vehicle ground clearance.
z tire clearance between the body and chassis.

z wheel bearing life.
z braking performance.
New wheels need to be installed when the vehicle wheels:
z are bent.
z are cracked.
z are dented.
z are heavily corroded.
z are leaking.
z have elongated wheel hub bolt holes.
z have excessive lateral or radial runout.
Use only the tire sizes recommended on the tire label located on the driver door or door pillar attached to the
vehicle. Larger or smaller tires can damage the vehicle, affect durability and require changing the
speedometer calibration. Make sure wheel size and offsets match those recommended for the tire in use.
1. Inspect the tires for signs of uneven wear. Refer to the following descriptions to identify the type of
wear and for the appropriate repair action to be carried out.
2. Check the tires for:

z cuts.
z stone bruises.
z abrasions.
z blisters.
z embedded objects.
3. Check the valve stems for:

z cracks.
z cuts.
Install a new valve stem when damage is found or any time a new tire is installed.
4. Tread wear indicators are molded into the bottom of the tread grooves. Install a new tire when the
indicator bands become less than 2/32 inch.
Tire Wear
Tire wear is commonly defined as a loss of tread depth. Tire tread wear occurs due to friction with the
contact surface (road/pavement). The tread should wear down uniformly all the way around the
circumference of the tire and all the way across the tread face. When this does not occur, the tire may have
abnormal/incorrect wear.
Normal Tire Wear
Normal tire wear is identified as even wear around and across the tread. Because there are many factors
(driving style, road surfaces, type of vehicle, type of tire) that can affect tire wear, there is no absolute
mileage expectation for a normal wear condition. A tire is considered worn-out when the tread has worn to
the level of the tread wear indicators.
Abnormal/Incorrect Tire Wear
Abnormal/incorrect tire wear is identified as tire wear that is not even around or across the tread, creating
performance-related issues.
Abnormal/incorrect tire wear can be caused by numerous factors, some of which include driving style
(aggressive, passive), climate (hot, cold), road conditions, vehicle loading and maintenance (correct tire
pressure, rotation intervals and balance). It is important to determine the root cause of wear on a vehicle
before carrying out repair. Tires exhibiting abnormal/incorrect tire wear may still be serviceable provided that
the minimum tread depth is greater than 2/32 inch and the tire is not causing a vehicle performance
(noise/vibration) concern.
Some abnormal/incorrect wear patterns look the same all the way around the tread of the tire, other wear
patterns are not consistent and can occur in various spots on the tread area. The underlying causes of the 6
wear categories are different. Refer to the following descriptions to identify the type of wear and the
appropriate repair action to be carried out.
Inner Edge/Shoulder Wear
Inner edge (or shoulder) wear occurs on the inside edge of the tire and is usually caused by excessive toe
out and/or excessive negative camber. If the tread depth of the outer shoulder is at least 50% greater than
the tread depth of the inner shoulder, the tire is experiencing inner edge/shoulder wear. Visually inspect the
tires to determine whether the tires have this type of wear. In some instances, the tread depth of each rib
may need to be measured and compared it to that of the shoulder.
NOTE: RF tire shown, others similar.
Outer Edge/Shoulder Wear
Outer edge (or shoulder) wear occurs on the outside edge of the tire and is usually caused by excessive toe
in and/or excessive positive camber. If the tread depth of the inner shoulder is at least 50% greater than the
tread depth of the outer shoulder, the tire is experiencing outer edge/shoulder wear. Visually inspect the tires
to determine whether the tires have this type of wear. In some instances, the tread depth of each rib may
need to be measured and compared to that of the shoulder.
NOTE: RF tire shown, others similar.
Heel/Toe Wear
Heel/toe wear (also known as feathering) occurs along the outside or inside edge/shoulder of the tire.
Visually inspect the tires in both the inside and outside shoulder ribs to determine whether the tires have this
type of wear. In some instances, the difference in tread depth of leading versus trailing edge of each lug in
the inside and outside shoulder rib may need to be measured.
Diagonal Wear
Diagonal wear occurs diagonally across the tread area and around the circumference of the tire. To
determine whether tires have this type of wear, visually inspect the tires to determine if the wear pattern runs
diagonally across the tread and around the circumference of the tire. In some instances, the difference in
tread depth along the diagonal wear pattern may need to be measured.
Symptom Chart — Tire Wear
Symptom Chart — Tire Wear
NOTE: For suspension system and additional alignment diagnosis, refer to Section 204-
00 .
z Inner z Excessive toe out z GO to Pinpoint Test A .
edge/shoulder and/or negative
wear camber
z Incorrect wheel and z GO to Pinpoint Test A .
tire assembly
rotation intervals
z High-speed z GO to Pinpoint Test A .
cornering
z Outer z Excessive toe in z GO to Pinpoint Test B .
edge/shoulder and/or positive
wear camber
z Incorrect wheel and z GO to Pinpoint Test B .
tire assembly
rotation intervals
z High-speed z GO to Pinpoint Test B .
cornering
z Heel/toe wear z Excessive toe z ROTATE the wheel and tire
in/out assemblies. REFER to Wheel and
z Incorrect wheel and Tire Rotation in this section. CHECK
tire assembly the alignment, ADJUST as
rotation intervals necessary.
z Diagonal wear z Excessive toe z GO to Pinpoint Test C .
in/out
z Incorrect tire z GO to Pinpoint Test C .
rotation intervals
z Loose, worn or z REFER to Section 204-00 .
damaged
suspension
components
symptom, refer back to for the next likely system and continue diagnosis.
z Wobble or z Bent wheel z INSTALL a new wheel as necessary.
shimmy
z Damaged tire z INSTALL a new tire as necessary.
z Loose wheel z TIGHTEN to specification.
nuts
z High-speed z Tires/wheels z REFER to Wheel and Tire Runout

shake Component Tests in this section.
z Vehicle z Tires/wheels z REFER to Wheel and Tire Runout
vibration Component Tests in this section.
Pinpoint Tests
For a description of the various tire wear patterns, refer to Inspection and Verification.
For vehicles with different front and rear tire pressures (such as E-Series and certain F-Series), adjust the
tire pressures and train he tire pressure sensors following a tire rotation. Refer to Tire Pressure Monitoring
System (TPMS) Sensor Training in this section. Failure to train the sensors results in a false low tire
pressure event, causing the Tire Pressure Monitoring System (TPMS) indicator to illuminate.
For vehicles with the same tire pressure for front and rear tires, tire rotation does not affect the system.
Pinpoint Test A: Inner Edge/Shoulder Wear

z Excessive toe out and/or negative camber
z Incorrect wheel and tire assembly rotation intervals
z High-speed cornering
PINPOINT TEST A: INNER EDGE/SHOULDER WEAR

A1 MEASURE THE TREAD DEPTH
z Using a tread depth gauge or similar Yes
tool, measure the inside ROTATE the wheel and tire assemblies. REFER to
edge/shoulder tread depth. Wheel and Tire Rotation in this section.
z Is the tread depth greater than 2/32
inch? CHECK and ADJUST the toe to nominal +0.15 degrees
(toe in). CHECK and ADJUST caster and camber to
nominal. REFER to Section 204-00 .
No
INSTALL a new tire(s). CHECK and ADJUST the toe to
nominal. CHECK and ADJUST caster and camber to
Pinpoint Test B: Outer Edge/Shoulder Wear

z Excessive toe in and/or positive camber
z Incorrect wheel and tire assembly rotation intervals
z High-speed cornering
PINPOINT TEST B: OUTER EDGE/SHOULDER WEAR

B1 MEASURE THE TREAD DEPTH
z Using a tread depth gauge or similar Yes
tool, measure the outside ROTATE the wheel and tire assemblies. REFER to
edge/shoulder tread depth. Wheel and Tire Rotation in this section.
z Is the tread depth greater than 2/32
inch? CHECK and ADJUST the toe to nominal -0.15 degrees
(toe out). CHECK and ADJUST caster and camber to
No
INSTALL a new tire(s). CHECK and ADJUST the toe to
nominal. CHECK and ADJUST caster and camber to
Pinpoint Test C: Diagonal Wear

z Incorrect tire rotation intervals
z Excessive toe in/out
z Loose, worn or damaged suspension components
PINPOINT TEST C: DIAGONAL WEAR

C1 MEASURE THE
TREAD DEPTH
z Using a tread depth Yes
gauge or similar If no performance concerns (noise/vibration) are present, the tire can
tool, measure the remain in service. CHECK the air pressure in the tires, ADJUST as
tread depth of the necessary. ROTATE the wheel and tire assemblies. REFER to Wheel and
wear pattern. Tire Rotation in this section. INSPECT for loose, worn or damaged
z Is the tread depth suspension components. INSTALL new components as necessary.
greater than 2/32 CHECK the alignment and ADJUST as necessary. REFER to Section
inch? 204-00 .
No
INSTALL a new tire(s). CHECK the air pressure in the tires, ADJUST as
necessary. ROTATE the wheel and tire assemblies. REFER to Wheel and
Tire Rotation in this section. INSPECT for loose, worn or damaged
suspension components. INSTALL new components as necessary.
CHECK the alignment and ADJUST as necessary. REFER to Section
204-00 .
Component Tests
Radial Runout
Radial runout is the egg-shaped deviation from a perfect circle and is measured perpendicular to the
circumference. On a wheel and tire assembly, this means measuring the center tire tread rib. The center rib
is indicative of the condition of the tire as a whole. Total runout is the difference between the maximum-to-
minimum gauge reading. The high spot is the location of maximum runout.
Item Description
1 High spot
2 Low spot
Loaded Runout Measurement (Hunter Road Force® 9700 Series Wheel Balancer)
NOTE: Diagnosis of tire/wheel vibration should not be performed on tires with less than 320 km (200 mi).
Some initial tire/wheel vibration issues (such as flat spotting) correct themselves after the tires have been in
service for 320 km (200 mi).
This procedure is intended to assist with the diagnosis of wheel and tire assembly runout and/or force
variation issues.
The Hunter Road Force® 9700 Series Wheel Balancer measures the wheel and tire assembly's loaded
runout and the tire's radial spring rate. The balancer then converts the runout into pounds of force (termed
as Road Force®). Measuring loaded runout (Road Force®) is more effective than measuring unloaded
runout using a dial indicator.
1. Using a tire crayon, record the vehicle position on the inner sidewall of all 4 tires.
2. Remove the wheel and tire assemblies. For additional information, refer to Wheel and Tire in this
section.
3. NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure
Make sure the tire pressures are set to the correct pressure as indicated on the Vehicle Certification
(VC) label.
4. NOTICE: Make sure the correct wheel balancer adapters are used when mounting the
assembly to the wheel balancer or damage to the wheel may occur.
NOTE: Make sure the wheel and tire assembly is clean and free of foreign material prior to
installation on the balancer.
NOTE: The wheel balancer inflation station must be turned OFF for tires with inflation pressures of
414 kPa (60 psi) or above.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer
adapters as shown. Refer to the list of recommended wheel balancer adapters on the PTS website.
Item Description
1 Wheel balancer
2 Cone
3 Wheel and tire assembly
4 Finger plate
5 Balancer wing nut
5. Measure the Road Force®.

z Temporarily mark the high spot and the Road Force® value on the sidewall of the tire. If the
wheel and tire assembly Road Force® value is not within specification, carry out the Match
Mounting procedure to optimize the wheel and tire assembly.
z If the wheel and tire assembly Road Force® value is within specification, permanently mark the
high spot and the Road Force® value on the inward sidewall of the tire for reference during
future wheel and tire service. Balance the assembly and install the wheel and tire on the
vehicle using the Wheel-to-Hub Optimization procedure.
Vehicle Maximum allowable Road Force® value

F-150 with P-metric tires 11 kg (25 lb)
F-150 with LT-metric tires 16 kg (35 lb)
Runout Measurement (Dial Indicator)
NOTE: Diagnosis of tire/wheel vibration should not be performed on tires with less than 320 km (200 mi).
Some initial tire/wheel vibration issues (such as flat spotting) correct themselves after the tires have been in
service for 320 km (200 mi).
NOTE: Loaded runout measurements are the preferred method for verifying tire serviceability. While a dial
indicator can be used to optimize the position of the tire on the wheel, the unloaded runout measurement
cannot accurately determine if the tire should be removed from service.
Use the following procedures if normal diagnostics leads to a potential runout issue.
Some vehicles may exhibit a wheel and tire vibration caused by excessive runout. Radial runout
measurements can be taken using a dial indicator and should be measured with the wheel and tire
assembly mounted on a suitable wheel balancer. Make sure the dial indicator is mounted securely to
eliminate gauge movement when measuring runout.
1. NOTE: Use only the Digital Tire Pressure Gauge any time tire pressures are measured to be sure
Make sure the tire pressures are set to the correct pressure as indicated on the VC label.
2. Using a tire crayon, record the vehicle position on the inner sidewall of all 4 tires.
3. Remove the wheel and tire assemblies. Refer to Wheel and Tire in this section.
4. NOTICE: Make sure the correct wheel balancer adapters are used when mounting the
assembly to the wheel balancer or damage to the wheel may occur.
NOTE: Make sure the wheel and tire assembly is clean and free of foreign material prior to
installation on the balancer.
Mount the wheel and tire assembly on a suitable wheel balancer using the correct wheel balancer
adapters as shown. Refer to the list of recommended wheel balancer adapters on the PTS website.
Item Description
1 Wheel balancer
2 Cone
3 Wheel and tire assembly
4 Finger plate
5 Balancer wing nut
5. NOTE: Apply masking tape on the center tread rib to allow for a smoother measuring surface. Some
fluctuation of the gauge reading is expected. Observe the overall sweep of the gauge from the
highest to the lowest spot on the tire.
Position the dial indicator and stand with the dial indicator on the center tread rib.
z Rotate the wheel and tire assembly (or wheel) to locate the low spot.
z Adjust the runout gauge to read 0.
z Rotate the wheel and tire assembly one complete revolution to make sure the low spot has
been found and the dial indicator returns to 0.
6. While slowly and constantly rotating the wheel and tire assembly (or wheel), measure the radial
runout.
z Note the variance (runout) from 0 on the dial of the gauge.
z If the runout reading of a wheel and tire assembly is greater than 1.14 mm (0.045 in), locate
and temporarily mark the high spot and runout reading on the sidewall of the tire and carry out
the Match Mounting procedure to optimize the wheel and tire assembly.
z If the runout reading of a wheel and tire assembly is 1.14 mm (0.045 in) or less, permanently
mark the high spot and the runout reading on the inner sidewall of the tire for reference during
future wheel and tire service. Balance the assembly and install the wheel and tire on the
vehicle using the Wheel-to-Hub Optimization procedure.
Match Mounting
NOTE: Road Force® values in illustrations are shown in pounds.
Match mounting is a technique used to reduce radial runout or Road Force® on wheel and tire assemblies.
Excessive runout is a source of ride quality complaints and match mounting can be used to minimize the
runout. Match mounting can be accomplished by changing the position of the tire on the wheel.
1. Position the wheel and tire assembly on a tire machine and put a reference mark on the tire sidewall
at the valve stem position.
Item Description
1 Valve stem
2 Reference mark
2. NOTICE: For tires equipped with a Tire Pressure Monitoring System (TPMS), the sensor may
be damaged by incorrect tire mounting or dismounting. Dismount the tire from the wheel as
instructed in the Disassembly and Assembly procedure. Failure to follow these instructions
may result in component damage.
NOTE: Always make sure that the final high spot and measurement values are permanently marked
on the inner sidewall of the tire for reference during future wheel and tire service.
Using a suitable tire machine, separate the tire beads from the wheel.
z Lubricate the tire beads using a suitable fast drying, corrosion inhibiting tire bead lubricant.
z Position the tire 180 degrees (halfway around) on the rim so the valve stem reference mark is
opposite the valve stem.
3. Reinflate the wheel and tire assembly to the specified air pressure and measure the assembly again
using the dial indicator or Hunter Road Force® 9700 Series Wheel Balancer. Mark the second high
spot on the tire.
z If the runout or Road Force® is reduced to within specifications, the concern has been
resolved. Balance the assembly and install on the vehicle using the Wheel-to-Hub Optimization
procedure.
4. If the second runout or Road Force® measurement is still not within specification and both high spots
are close to each other (within 101.6 mm [4 in]), the root cause is probably the tire (the high spot
followed the tire).
z To be sure the tire is causing the high runout, it is necessary to have 2 runout or Road Force®
measurements that are not within specification and the high spots must be in approximately
the same location on the tire's sidewall. If the tire is the cause, install a new tire, balance the
assembly and install on the vehicle using the Wheel-to-Hub Optimization procedure.
z If the second high spot is not within 101.6 mm (4 in) of the first high spot, proceed to the next
step.
Item Description
1 First high spot on the tire
2 Second high spot on the tire
5. If the second high spot is still above specification and within 101.6 mm (4 in) of being opposite the
first high spot on the wheel, the root cause is probably the wheel (the high spot followed the wheel).
Dismount the tire from the wheel, mount the wheel on a balancer and check the wheel runout. If the
wheel runout exceeds 1.14 mm (0.045 in), install a new wheel, balance the assembly and install on
the vehicle using the Wheel-to-Hub Optimization procedure.
Item Description
6. NOTE: If the second high spot did not follow the wheel or the tire and the runout is still not within
specification, improvements may be made by rotating the tire 90 degrees (one-fourth turn).
Draw an arrow on the tire sidewall from the second high spot towards the first high spot (in the
shortest direction).
z Separate the tire beads from the wheel and rotate the tire 90 degrees (one-fourth turn) in the
direction of the arrow.
Item Description
Wheel-to-Hub Optimization
Wheel-to-hub optimization is important. Use the clearance between the wheel and hub to offset or neutralize
the Road Force® or runout of the wheel and tire assembly. For every 0.001 inch of wheel-to-hub clearance,
the Road Force® can be affected between 1 and 3 pounds depending on the tire stiffness.
NOTE: The example below illustrates how the clearance between the wheel and the hub can be used to
offset the high spot of radial runout or Road Force®. Following the procedure will make sure of the best
optimization.
1. Position the wheel and tire assembly on the vehicle so the high spot location is at the 6 o'clock
position and install the wheel nuts by hand until snug.
2. NOTE: Do not allow the full weight of the vehicle to rest on the tires while tightening the wheel nuts.
Lower the vehicle until the tires make contact with the ground, slightly loading the suspension.
Tighten the wheel nuts as described in this section.

Tire Pressure Monitoring System (TPMS) Sensor Activation
Special Tool(s)
Monitor
204-363, or Customer Activation
Tool, Tire Pressure Monitor
NOTE: The tire pressure sensors will go into a "sleep mode" when a vehicle is stationary to conserve battery
power. The sensors do not transmit information while in sleep mode. It will be necessary to wake them up so
they will transmit the latest tire pressure information.
1. Turn the ignition switch to the ON position.
2. Position the Tire Pressure Monitor Activation Tool against the LF tire sidewall at the tire valve stem.
3. NOTE: The Tire Pressure Monitor Activation Tool will provide feedback in the form of a flashing green
light and a beep sound for each successful response from a tire pressure sensor. This feedback may
not always be present, do not rely on it as a confirmation that the module heard a particular sensor.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle to
rotate the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the
sensor still does not respond, attempt to activate the same sensor again using the customer
activation tool (if available). If the sensor still fails to train, attempt to train the sensor with the vehicle
doors open.
Press the test button on the Tire Pressure Monitor Activation Tool to activate the sensor. Activate the
sensor at least 2 times.
4. Repeat Steps 2 and 3 for the remaining tires.
5. If the Tire Pressure Monitoring System (TPMS) indicator remains illuminated after adjusting and
activating each sensor, refer to the Symptom Chart in Diagnosis and Testing in this section.

Tire Pressure Monitoring System (TPMS) Sensor Training
Special Tool(s)
Monitor
204-363

System (IDS)
NOTE: If the vehicle has been stationary for more than 30 minutes, the sensors will go into a "sleep mode"
to conserve battery power. It will be necessary to wake them up so they will transmit the latest tire pressure
information to the BCM . For additional information, refer to Tire Pressure Monitoring System (TPMS)
Sensor Activation in this section.
NOTE: The Tire Pressure Monitoring System (TPMS) Training procedure must be done on a single vehicle,
in an area without radio frequency noise and at least 1 m (3 ft) away from other vehicles equipped with a
Tire Pressure Monitoring System (TPMS).
Radio frequency noise is generated by electrical motors and appliance operation, cellular telephones,
remote transmitters, power inverters and portable entertainment equipment.
NOTE: If a sensor does not respond to the Tire Pressure Monitor Activation Tool, move the vehicle to rotate
the wheels at least one-fourth of a turn and attempt to activate the same sensor again. If the sensor still
does not respond, attempt to activate the same sensor again using the customer activation tool (if available).
If the sensor still fails to train, attempt to train the sensor with the vehicle doors open.
NOTE: The BCM has a 2-minute time limit between sensor responses. If the BCM does not recognize any 1
of the 4 tire pressure sensors during this time limit, the horn will sound twice and the message center (if
equipped) will display TIRE NOT TRAINED REPEAT and the entire procedure must be repeated.
NOTE: For vehicles with different front and rear tire pressures (such as the E-Series and certain F-Series),
the tire pressure sensors must be trained following a tire rotation. Failure to train the sensors will cause the
TPMS indicator to illuminate. For vehicles with the same tire pressure for front and rear tires, tire rotation will
not affect the system.
NOTE: Refer to Description and Operation, Push Button Start System Ignition Modules in Section 211-05 to
review the procedures for achieving the various ignition states on vehicles with this feature.
1. NOTE: An animated version of this procedure is available on-line.
Turn the ignition switch to the OFF position, then press and release the brake pedal.
2. Cycle the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
3. Press and release the brake pedal.
4. Turn the ignition switch to the OFF position.
5. Turn the ignition switch from the OFF position to the RUN position 3 times, ending in the RUN
position.
z The horn will sound once and the TPMS indicator will flash if the training mode has been
entered successfully. If equipped, the message center will display TRAIN LF TIRE.
6. NOTE: It may take up to 6 seconds to activate a tire pressure sensor. During this time, the Tire
Pressure Monitor Activation Tool must remain in place at the valve stem.
Place the Tire Pressure Monitor Activation Tool on the LF tire sidewall at the valve stem. Press and
release the test button on the Tire Pressure Monitor Activation Tool. The horn will sound briefly to
indicate that the tire pressure sensor has been recognized by the BCM .
7. Within 2 minutes of the horn sounding, place the Tire Pressure Monitor Activation Tool on the RF tire
sidewall at the valve stem and press and release the test button to train the RF tire pressure sensor.
8. NOTE: Do not wait more than 2 minutes between training each sensor or the BCM will time out and
the entire procedure must be repeated.
Repeat Step 7 for the RR and LR tires.

The procedure is completed after the last tire has been trained. When the training procedure is
complete, the message center (if equipped) will display TIRE TRAINING COMPLETE.
For vehicles not equipped with a message center, successful completion of the training procedure will
be verified by turning the ignition switch to the OFF position without the horn sounding. If the horn
sounds twice when the switch is turned to the OFF position, the training procedure was not
successful.
9. Using the scan tool, locate the updated TPMS sensor identifiers trained to the BCM and document
them on the applicable warranty claim.
10. NOTE: This step is required to clear DTC C2780, cause the BCM to exit the manufacturing mode and
to make sure there are no other concerns with a newly programmed BCM .
If the sensors are being trained due to the installation of a new BCM , clear any DTCs and carry out
the BCM On-Demand Self Test.

Wheel and Tire Rotation
NOTE: This procedure is intended for vehicles equipped with Tire Pressure Monitoring System (TPMS) and
different front and rear tire pressures.
1. Remove the wheel and tire assemblies. For additional information, refer to Wheel and Tire in this
section.
2. NOTE: The front tires are shown at the top of the illustration.
Rotate the wheel and tire assemblies as shown.

z Cross the front tires and move them to the rear of the vehicle.
z Move the rear tires (without crossing) to the front of the vehicle.
3. Install the wheel and tire assemblies. For additional information, refer to Wheel and Tire in this
section.
4. Adjust the tire pressures. For additional information, refer to the Vehicle Certification (VC) label
located on the driver door jamb.
5. NOTE: The tire pressures must be adjusted and the tire pressure sensors must be trained following a
tire rotation. Failure to train the sensors will result in a false low tire pressure event, which will cause
the TPMS indicator to illuminate.
Train the TPMS sensors. For additional information, refer to Tire Pressure Monitoring System (TPMS)
Sensor Training in this section.

Tire Pressure Monitor (TPM) Module

1 19A435 TPMS module mounting bracket
2 W707628 TPMS screw (1 required)
3 15K602 Tire Pressure Monitoring System (TPMS) module
4 — TPMS module electrical connector (part of 14401)

5 — External antenna coax connector
Removal
NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges,
damage may result.
1. Remove the RH instrument panel side finish panel.
2. Open the glove compartment door and while pushing in on the glove compartment tab, position the
glove compartment downwards.
3. Remove the screw from the TPMS module mounting bracket.
4. Disconnect the TPMS module electrical connector and the external antenna connector.
5. Separate the TPMS module from the TPMS module mounting bracket.
Installation

Wheel and Tire
Material
Item Specification
High Temperature Nickel Anti-Seize —
Lubricant
XL-2
NOTE: Typical 6 lug wheel shown, 7 lug similar.

1 1130 Center cap (if equipped)
2 1012 Wheel nut (6 or 7 required)
3 — Wheel and tire assembly
Removal
02 .
2. NOTICE: Do not use heat to loosen a seized wheel nut or damage to the wheel and wheel
bearing can occur.
Remove the 6 or 7 wheel nuts.
3. Remove the wheel and tire assembly.
Installation
1.
material present on the mounting surface of the wheel and the mounting surface of the wheel
hub, brake drum or brake disc. Make sure that any fasteners that attach the rotor to the hub
are secured so they do not interfere with the mounting surfaces of the wheel. Failure to follow
these instructions when installing wheels may result in the wheel nuts loosening and the
wheel coming off while the vehicle is in motion, which could result in loss of control, leading
to serious injury or death to vehicle occupant(s).
NOTICE: Make sure to apply a thin coat of anti-seize lubrication only to the interface between
the wheel pilot bore and the hub pilot. Do not allow the anti-seize to make contact with the
wheel-to-brake disc/drum mounting surface, wheel studs, wheel nuts, brake pads or brake
disc friction surfaces or damage to components may occur.
Clean the wheel mounting surfaces and apply a thin coat of anti-seize to the wheel hub pilot surface
(wheel only).
2. Install the wheel and tire assembly.
3.
Wheels can loosen after initial tightening. Failure to follow this instruction may result in
serious injury to vehicle occupant(s).
NOTICE: Failure to tighten the wheel nuts in a star/cross pattern can result in high brake disc
runout, which will speed up the development of brake roughness, shudder and vibration.
NOTE: The wheel nut torque specification is for clean, dry wheel stud and wheel nut threads.
Install the 6 or 7 wheel nuts by hand.

z Tighten the wheel nuts in a star/cross pattern.
SECTION 205-00: Driveline System — General Information 2014 F-150 Workshop Manual
Material
Capacity
Motorcraft® High Contrast — —
Hypoid Gear Marking Compound
XG-14
Threadlock and Sealer WSK-M2G351- —
TA-25 A5
Item Specification
Drive pinion flange runout 0.25 mm (0.010 in)
Maximum allowable driveshaft runout 0.50 mm (0.020 in)
Minimum Traction-Lok breakaway torque 27 Nm (20 lb-ft)
U-joint operating angle 0.5°-3.0°
Driveline System
The driveline consists of the following:
z Front drive axle

z Rear drive axle
z Front axle halfshafts
z Front driveshaft
z Rear driveshaft
z Center support bearings
z CV joints
z U-joints and flanges
z Flex couplers
The source of the drivetrain power is generated by the engine and delivered to the transmission. The
driveline transfers the engine torque through the driveshaft to the axle. The rear driveshaft is connected to
the output shaft of the transmission or transfer case and to the rear axle. The front driveshaft is connected to
the transfer case and to the front axle. Slip yokes are used to allow for any changes to the length of the
driveshaft. Changes in length are self-adjusted up in the driveshaft slip mechanism. The engine torque
enters the axle through the drive pinion, which rotates the ring gear. The ring gear is mounted to the
differential case, which contains the gears that transmit power to the rear axle shafts or front halfshafts.
These shafts and halfshafts rotate the drive wheels. The Electronic Locking Differential (ELD) rear axle
assembly, except for the differential case and its internal components, is identical to the conventional rear
axle. The ELD employs an electronically operated magnetic coil to engage the unit. The Traction-Lok rear
axle assembly, except for the differential case and its internal components, is identical to the conventional
rear axle. The Traction-Lok employs 2 multi-disc differential clutch packs to control differential action. The
mounting distance of the differential side gear is controlled by plates on each side, friction and steel. Also
included is a steel selective shim to control the position of the differential side gear, and a spring which
provides initial preload to the clutch pack. The steel clutch plates are splined to the axle shafts. The friction
plates are contained in the case by matching slots, thus providing continuous engagement of the differential
clutch packs. The Torsen® front differential case houses the parallel axis planetary helical side gears to
which the axle shafts are splined. The engine angle is built into the engine mounts. If the engine angle is out
of specification, the engine mounts must be inspected for damage.
Vehicle Certification (VC) Label Example
The Vehicle Certification (VC) label is located in the driver door jamb. The first 2 digits of the axle code
indicate the rear axle and the third digit refers to the front axle, if equipped. For information on the VC label,
refer to Section 100-01 .
Front Axle Identification Tag
Item Description
1 Plant code
2 Axle ratio
3 Ring gear diameter (inch)
4 Build year
5 Build month
6 Build day
Rear Axle Identification Tag
Item Description
1 Plant code
2 Axle ratio
3 Differential type
C= Open/conventional
L= Limited slip
E= Electronic Locking Differential (ELD)

4 Ring gear diameter (inch)
5 Build year
6 Axle serial number
7 Lubricant type
NOTE: The axle identification tag is the official service identifier. Do not damage the tag.
The axle identification tag identifies a particular axle design, a specific ratio, and if it is a conventional or
limited slip type. In addition, the plant code will not change as long as that particular axle assembly never
undergoes an external design change. If, however, an internal design change takes place during the
production life of the axle and that internal change affects the interchangeability of the components, a dash
and numerical suffix is added to the plant code. This means that, as an assembly, both axles are
interchangeable; however, internally they are different. Therefore, each requires different internal
components at the time of repair.
Driveline System
Special Tool(s)
Clamp Plate, Driveshaft
205-320 (T92L-4851-C)
Dial Indicator Gauge with Holding

Fixture
100-002 (TOOL-4201-C) or
equivalent

Fixture
100-D002 (D78P-4201-B) or
equivalent
Gauge, Differential (Traction-Lok)

205-385 (T97T-4205-B)
Runout Gauge, Drive Pinion

Flange
205-319 (T92L-4851-B)
Material
Item Specification
Threadlock and Sealer WSK-M2G351-A5
TA-25
The driveline system enables the power generated by the engine and transferred through the transmission
and, if applicable, transfer case, to place the vehicle in motion. Rotational torque received from the
transmission or transfer case is delivered to the front and rear drive axles by way of the driveshafts. The U-
joints or CV joints at the ends of the shafts allow the shafts to rotate smoothly in an allowable angle plane.
The rotational torque is introduced into the axle drive pinion which drives the differential ring gear. The ring
gear is bolted to the differential case flange on the differential. The differential divides the torque between
the right and left halfshaft while permitting the halfshafts to turn at different speeds when required, such as
when cornering.
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical damage.

Mechanical
z U-joints
z CV joints
z Center bearings
z Driveshaft tubes
z Mounting brackets
z Flanges
z Housing and cover damage
z Differential bearings
z Differential gear sets
z Pinion bearings
4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Driveline or GO to
Symptom Chart - NVH .
Symptom Chart — Driveline
Symptom Chart — Driveline

z Traction-Lok does z Differential z CARRY OUT the Traction-Lok
not work in snow, Differential Operation Check in
mud or on ice this section. REPAIR as
necessary. REFER to Section
205-02A or Section 205-02B .
z Torsen® differential z Differential z CARRY OUT the Torsen
does not work in Differential Operation Check in
snow, mud or on ice this section. REPAIR as
205-03 .
z Lubricant leaking z Vent z CLEAN the axle housing vent.
from the pinion seal, z Damage in the seal z INSTALL a new pinion flange
axle shaft oil seals contact area or dust and the pinion seal if damage
or support arm to the slinger on the pinion is found.
housing flange dust shield
z The vehicle does not z Mode switch z REFER to Section 308-07A .
shift between the z Wiring/relays
different modes z Shift motor
correctly z Transfer case
z Generic Electronic
Module (GEM) or
4x4 control module
z Front axle will not z Switches z REFER to Section 308-07A .
engage z Wiring
z GEM or 4x4 control
module
z Shift motor
z Integrated Wheel
End (IWE)
z Front axle will not z Switches z REFER to Section 308-07A .
disengage z Wiring
z GEM or 4x4 control
module
z Shift motor
z IWE
z Electronic Locking z Mode switch z REFER to Section 308-07A .
Differential (ELD) z Differential
does not engage in z Transfer Case
snow, mud or on ice Control Module
(TCCM)
z Wiring
z Differential side z Insufficient z INSTALL new gears. FILL the
gears/pinion gears lubrication axle to specification. REFER
are scored to Section 205-02A , Section
205-02B or Section 205-03 .
z Incorrect or z INSTALL new gears. CLEAN
contaminated and REFILL the axle to
lubricant type specification. REFER to
Section 205-02A , Section
205-02B or Section 205-03 .
z Axle overheating z Lubricant level too z CHECK the lubricant level.
low FILL the axle to specification.
REFER to Section 205-02A ,
Section 205-02B or Section
205-03 .
z Incorrect or z INSPECT the axle for
contaminated damage. REPAIR as
lubrication type necessary. CLEAN and
REFILL the axle to
specification. REFER to
205-02B or Section 205-03 .
z Bearing preload z CHECK the ring and pinion for
adjusted too tight damage. INSPECT the ring
and pinion wear pattern.
ADJUST the preload as
necessary.
z Excessive gear wear z INSPECT all the axle gears for
wear or damaged. INSTALL
new components as
necessary.
z Incorrect ring gear z INSPECT the ring gear for
backlash scoring. INSPECT the ring
and pinion wear pattern.
ADJUST the ring gear
backlash as necessary.
z Broken gear teeth z Overloading the z INSTALL a new ring and
on the ring gear or vehicle pinion. REFER to Section 205-
pinion 02A , Section 205-02B or
Section 205-03 .
z Halfshaft broken z Overloading the z INSTALL a new axle halfshaft.
vehicle REFER to Section 205-04 .
z Misaligned axle z INSPECT the axle for
halfshaft damage. CHECK axle
halfshaft alignment. INSTALL
a new axle halfshaft. REFER
to Section 205-04 .
z Axle howling or whine — z Axle lubricant low z CHECK the lubricant level.
front or rear axle FILL the axle to
205-02B or Section 205-
03 .
z Axle housing z INSPECT the axle housing
damage for damage. REPAIR or
INSTALL a new axle as
necessary. REFER to
03 .
z Damaged or worn z CHECK for abnormal
wheel hub wheel hub bearing play or
bearings roughness. REFER to
02 .
z Damaged or worn z INSPECT and INSTALL a

differential ring new differential ring and
and pinion pinion as necessary.
REFER to Section 205-
02A , Section 205-02B or
Section 205-03 .
z Damaged or worn z INSPECT and INSTALL
differential side or new differential side or
pinion bearings pinion bearings as
necessary. REFER to
03 .
z Driveline clunk — loud z Incorrect axle z CHECK the lubricant level.
clunk when shifting from lubricant level FILL the axle to
REVERSE to DRIVE specification. REFER to
03 .
z Excessive z CHECK the axle backlash.
backlash in the REPAIR as necessary.
axle REFER to Section 205-
Section 205-03 .
z Damaged or worn z REPAIR or INSTALL new
pinion bearings pinion bearings as
necessary. REFER to
03 .
z Damaged or worn z INSPECT the U-joints for
U-joints wear or damage. INSTALL
new U-joints or driveshaft
Section 205-01 .
z Loose or missing z CHECK all driveline
fasteners fasteners for proper
torque. REFER to Section
205-01 , Section 205-02A ,
Section 205-02B or
Section 205-03 .
z Driveline clunk — occurs z Worn driveshaft z INSPECT the CV joint and
as the vehicle starts to CV joint or U- U-joints for a worn
move forward following a joints with condition. INSTALL a new
stop excessive play driveshaft or U-joints as
necessary. REFER to
Section 205-01 .
z Loose axle mount z CHECK the axle for loose
bolts. TIGHTEN to
03 .

205-01 , Section 205-02A ,
Section 205-02B or
Section 205-03 .
z Driveline clunk — occurs z Damaged or worn z INSPECT the CV joint and
during acceleration or from CV joint boot. INSTALL a new CV
cruise to joint as necessary. REFER
coast/deceleration to Section 205-04 .
205-01 , Section 205-02A ,
Section 205-02B or
Section 205-03 .
z Clicking, popping or z Inadequate or z CHECK the CV boots and
grinding — occurs while contaminated joints for wear or damage.
the vehicle is turning lubrication in the INSTALL new components
CV joints as necessary. REFER to
Section 205-04 .
z Another z CHECK the halfshafts and
component the area around the
contacting the halfshafts. REPAIR as
halfshaft necessary.
z High pitched chattering — z Incorrect or z CHECK the vehicle by
noise from the axle when contaminated driving in tight circles (5
the vehicle is turning lubricant clockwise, 5
counterclockwise). CLEAN
and REFILL the axle to
03 .
z Damaged or worn z REPAIR or INSTALL new
differential differential side gears or
(differential side pinion gears as necessary.
gears and pinion REFER to Section 205-
gears) 02A , Section 205-02B or
Section 205-03 .
z Buzz — buzzing noise is z Incorrect driveline z CHECK for correct
the same at cruise or angles driveline angles. REPAIR
coast/deceleration as necessary. REFER to
Driveline Angle
Measurement in this
section.
z Rumble or boom — noise z Driveshaft is out- z CHECK the driveshaft for
occurs at of-balance damage, missing balance
coast/deceleration, usually weights or undercoating.
driveshaft speed-related REFER to Driveshaft
and noticeable over a wide Runout and Balancing in
range of speeds this section.
z U-joints are z ROTATE the driveshaft
binding or seized and CHECK for rough
operation or seized U-
joints. INSTALL new U-
joints or driveshaft as
necessary. REFER to
Section 205-01 .
z Misalignment of z REINSTALL driveshaft
yellow dot on with yellow dots aligned
driveshaft-to- plus or minus 1 bolt hole.
yellow dot on REFER to Section 205-
pinion flange plus 01 .
or minus 1 bolt
hole
z Worn or damaged z CHECK the insulator for
driveshaft center damage or wear. ROTATE
bearing support the driveshaft and CHECK
for rough operation.
INSTALL a new driveshaft
Section 205-01 .
z Grunting — normally z Driveshaft CV z CLEAN the CV joint and
associated with a shudder joint binding INSTALL a new driveshaft
experienced during as necessary. REFER to
acceleration from a Section 205-01 .
complete stop
z Loose axle mount z INSPECT the rear
bolts or suspension and axle.
suspension TIGHTEN the fasteners to
fasteners specification. REFER to
03 .
z Howl — can occur at z Incorrect ring and z INSPECT and REPAIR as
various speeds and driving pinion contact, necessary. REFER to
conditions. Affected by incorrect bearing Section 205-02A , Section
acceleration and preload or gear 205-02B or Section 205-
deceleration damage 03 .
z Chuckle — heard at z Incorrect ring and z INSPECT and REPAIR as
coast/deceleration. Also pinion contact or necessary. REFER to
described as a knock damaged teeth on Section 205-02A , Section
the coast side of 205-02B or Section 205-
the ring and 03 .
pinion
z Knock — noise occurs at z Gear tooth z INSTALL a new ring and
various speeds. Not damage to the pinion. REFER to Section
affected by acceleration or drive side of the 205-02A , Section 205-
deceleration ring and pinion 02B or Section 205-03 .
z Scraping noise — a z Worn or damaged z INSPECT and REPAIR or
continuous low pitched pinion bearings INSTALL new pinion
noise starting at low bearings. REFER to
speeds Section 205-02A , Section
03 .
z Driveline shudder — z Drive axle z CHECK the axle mounts
occurs during acceleration assembly and the rear suspension
from a slow speed or stop mispositioned for damage or wear.
(vehicle unloaded) REPAIR as necessary.
Section 205-03 .
z Loose axle bolts z CHECK the axle for loose
bolts. TIGHTEN the bolts
to specification. REFER to
03 .
205-01 , Section 205-02A ,
Section 205-02B or
Section 205-03 .
z Driveline angles z MEASURE and ADJUST
out of the driveline angles as
specification necessary. REFER to
Driveline Angle
Measurement , Driveline
Angle Adjustment .
z U-joints binding or z ROTATE the driveshaft
seized and CHECK for rough
operation or seized U-
joints. INSTALL new U-
joints or driveshaft as
necessary. REFER to
Section 205-01 .
z Binding or z INSPECT the driveshaft
damaged CV joint and coupling shaft
driveshaft CV joint for wear or damage.
as necessary. REPAIR as
necessary. REFER to
Section 205-01 .
z Transfer case z REFER to Section 308-
07A .
z Driveline shudder — z Driveline angle z MEASURE and ADJUST
occurs during acceleration out of the driveline angles as
from a slow speed or stop specification due necessary. REFER to
(vehicle loaded) to loaded Driveline Angle
condition Measurement , Driveline
Angle Adjustment .
z Take-off shudder — with 1- z Driveline angle z MEASURE and ADJUST
piece driveshaft (loaded or out of the driveline angles as
unloaded) specification necessary. REFER to
Driveline Angle
Measurement , Driveline
Angle Adjustment .
z If concern is still present
lower axle pinion using 1
degree shim with thick end
forward. REFER to,
Driveline Angle
Adjustment .
z Take-off shudder — with 1- z Driveline angle z Lower axle pinion
piece driveshaft (loaded or out of replacing 1 degree shim
unloaded) after driveline specification with a 2 degree shim with

angle adjustment using 1 thick end forward. REFER
degree shim to, Driveline Angle
Adjustment .
z Driveline vibration or moan z Driveline angle z MEASURE and ADJUST
— occurs on deceleration out of the driveline angles as
(coast down) above 45 specification necessary. REFER to
mph with 1-piece Driveline Angle
driveshaft (loaded or Measurement , Driveline
unloaded) Angle Adjustment .
raise axle pinion using 1
rearward. REFER to,
Driveline Angle
Adjustment .
z Driveline vibration or moan z Driveline angle z Raise axle pinion replacing
— occurs on deceleration out of 1 degree shim with a 2
(coast down) above 45 specification degree shim with thick end
mph with 1-piece rearward. REFER to,
driveshaft (loaded or Driveline Angle
unloaded) after driveline Adjustment .
angle adjustment using 1
degree shim
z Shudder on acceleration z Driveline angle z MEASURE and ADJUST
from 10-25 mph under out of the driveline angles as
medium to heavy throttle specification necessary. REFER to
— with 2-piece driveshaft Driveline Angle
(loaded or unloaded) Measurement , Driveline
Angle Adjustment .
lower axle pinion using 1
forward. REFER to,
Driveline Angle
Adjustment .
z Shudder on acceleration z Driveline angle z Lower axle pinion
from 10-25 mph under out of replacing 1 degree shim
medium to heavy throttle specification with a 2 degree shim with
— with 2-piece driveshaft thick end forward. REFER
(loaded or unloaded) after to, Driveline Angle
driveline angle adjustment Adjustment .
using 1 degree shim
z Driveline vibration or moan z Driveline angle z Lower the center bearing.
— occurs on deceleration out of Driveline Angle
above 45 mph with 2-piece specification Adjustment .
driveshaft (loaded or
unloaded), after driveline
angle adjustment using 1
degree shim is installed
with the thick end forward
z Driveline vibration or moan z Driveline angle z MEASURE and ADJUST
— occurs on deceleration out of the driveline angles as
above 45 mph with 2-piece specification necessary. REFER to
driveshaft (loaded or Driveline Angle
unloaded) Measurement , Driveline
Angle Adjustment .
raise axle pinion using 1
rearward. REFER to,
Driveline Angle
Adjustment .
z Driveline vibration or moan z Driveline angle z Raise axle pinion replacing
— occurs on deceleration out of 1 degree shim with a 2
above 45 mph with 2-piece specification degree shim with thick end
driveshaft (unloaded), after rearward. REFER to,
driveline angle adjustment Driveline Angle
using 1 degree shim is Adjustment .
installed with the thick end
rearward
z Shudder on acceleration z Driveline angle z Lower the center bearing.
from 10-25 mph under out of Driveline Angle
medium to heavy throttle specification Adjustment .
— after driveline angle
adjustment using 1 degree
shim is installed with the
thick end rearward — with
2-piece driveshaft
(unloaded)
z Driveline vibration — z Worn U-joints z CHECK for wear or
occurs at cruising speeds incorrect seating. INSTALL
new U-joints or driveshaft
Section 205-01 .
z Misalignment of z REINSTALL driveshaft
yellow dot on with yellow dots aligned
driveshaft-to- plus or minus 1 bolt hole.
yellow dot on REFER to Section 205-
pinion flange plus 01 .
or minus 1 bolt
hole
z Worn or damaged z CHECK the insulator for
driveshaft center damage or wear. ROTATE
bearing support the driveshaft and CHECK
for rough operation.
Section 205-01 .
z Loose driveshaft- z INSPECT the axle pinion
to-axle pinion or flange. TIGHTEN the
transmission pinion flange bolts to
flange bolts specification. REFER to
Section 205-01 .
z Excessive axle z CARRY OUT a runout
pinion flange check. REPAIR as
runout necessary. REFER to
Component Test in this
section.
z Driveshaft is out- z CHECK the driveshaft for
of-balance damage, missing balance
weights or undercoating.
CHECK the driveshaft
balance. CARRY OUT a
driveline vibration test.
REFER to Driveshaft
Runout and Balancing in
this section.
z Binding or z INSPECT the driveshaft
damaged CV joint for wear or
driveshaft CV joint damage. INSTALL a new
driveshaft as necessary.
01 .
z Excessive z CARRY OUT a runout
driveshaft runout check. REFER to
Driveshaft Runout and
Balancing in this section.
z Driveline angles z CHECK for correct
out of driveline angles. REPAIR
specification as necessary. REFER to
Driveline Angle
Measurement in this
section.
z Incorrectly seated z CHECK the outer CV joint
CV joint in the for correct seating into the
wheel hub hub. REPAIR as
necessary. REFER to
Section 205-04 .
z Damage or z INSTALL a new driveshaft
missing driveshaft as necessary. REFER to
slip yoke damper Section 205-01 .
(163 in wheelbase
and 133 in
wheelbase 4.6L
4x2 do not get
dampers)
Analysis of Leakage
Clean the leaking area enough to identify the exact source.
A plugged axle housing vent can cause excessive pinion seal lip wear due to internal pressure buildup.
Verify the lubricant level is at least 3-5 mm (1/8-3/16 in) below the bottom of the fill hole.
Axle Vent
A plugged vent will cause excessive seal lip wear due to internal pressure buildup. If a leak occurs, check
the vent. If the vent cannot be cleared, install a new vent.
Drive Pinion Seal
Leaks at the drive pinion seal originate from the following causes:
z Damaged seal
z Worn seal journal surface
Any damage to the seal bore (dings, dents, gouges or other imperfections) distorts the seal casing and
allows leakage past the outer edge of the drive pinion seal.
The drive pinion seal can be torn, cut or gouged if it is not installed correctly. The spring that holds the drive
pinion seal against the pinion flange may be knocked out and allow fluid to pass the lip.
Metal chips trapped at the sealing lip can cause oil leaks. These can cause a wear groove on the drive
pinion flange and result in pinion seal wear.
When a seal leak occurs, install a new drive pinion seal and check the vent to make sure it is clean and free
of foreign material.
A new drive pinion flange must be installed if any of these conditions exist.
Drive Pinion Nut
NOTICE: Install the drive pinion nut to the correct torque specifications or damage to the differential
components may occur.
On some high-mileage vehicles, oil may leak through the threads of the drive pinion nut. This condition can
be corrected by installing a new nut and applying threadlock and sealer on the threads and nut face.
Component Tests
Traction-Lok Differential Operation Check
A Traction-Lok differential can be checked for correct operation without removing it from the rear axle
housing.
Raise and remove only one rear wheel. Install the Differential Gauge (Traction-Lok) on the wheel bolts.
Use a torque wrench with the capacity of at least 271 Nm (200 lb-ft) to rotate the axle shaft. Make sure that
the transmission is in NEUTRAL, and that one rear wheel is on the floor while the other rear wheel is raised
off the floor. The breakaway torque required to start rotation must be at least 27 Nm (20 lb-ft). The initial
breakaway torque may be higher than the continuous turning torque.
The axle shaft must turn with even pressure throughout the check without slipping or binding. If the torque
reading is less than specified, check the differential case for incorrect assembly.
Traction-Lok Differential Check Road Test
1. Place one wheel on a dry surface and the other wheel on ice, mud or snow.
2. Gradually open the throttle to obtain maximum traction prior to break away. The ability to move the
vehicle demonstrates correct performance of a Traction-Lok rear axle assembly.
3. When starting with one wheel on an excessively slippery surface, a slight application of the parking
brake may be necessary to help energize the Traction-Lok feature of the differential. Release the
brake when traction is established. Use light throttle on starting to provide maximum traction.
4. If, with unequal traction, both wheels slip, the limited slip rear axle has done all it can possibly do.
5. In extreme cases of differences in traction, the wheel with the least traction may spin after the
Traction-Lok has transferred as much torque as possible to the non-slipping wheel.
Torsen® Differential Check Road Test
1. Place one wheel on a dry surface and the other wheel on ice, mud or snow.
2. Gradually open the throttle to obtain maximum traction prior to break away. The ability to move the
vehicle demonstrates correct performance of a Torsen® front axle assembly.
3. When starting with one wheel on an excessively slippery surface, a slight application of the parking
brake may be necessary to help energize the Torsen® feature of the differential. Release the brake
when traction is established. Use light throttle on starting to provide maximum traction.
4. If, with unequal traction, both wheels slip, the limited slip front axle has done all it can possibly do.
5. In extreme cases of differences in traction, the wheel with the least traction may spin after the
Torsen® has transferred as much torque as possible to the non-slipping wheel.
Pinion Flange Runout Check — Circular
NOTICE: Pinion bearing preload must be reset if the pinion nut has been loosened or removed for
pinion flange reindexing or replacement or damage to the component may occur.
1. Raise the vehicle on a twin-post hoist that supports the rear axle.
2. Remove the driveshaft. Refer to Section 205-01 .
3. Check the pinion flange for damage.
4. Position the Driveshaft Clamp Plate and Drive Pinion Flange Runout Gauge on the pinion flange.

1 — Pilot (part of 205-319) (T92L-4851-B)
2 354845 Pinion nut
3 205-319 Gauge, Drive Pinion Flange Runout (T92L-4851-B)
4 — Bolts (2 required) (part of 205-320) (T92L-4851-C)
5 205-320 Plate, Driveshaft Clamp (T92L-4851-C)
6 4851 Pinion flange
5. Position the Driveshaft Clamp Plate and Drive Pinion Flange Runout Gauge onto the pinion flange.
6. Align the holes on the clamp plate with the holes in the pinion flange and install the bolts. Snug the
bolts evenly.
7. Position the Dial Indicator Gauge with Holding Fixture as shown. Turn the Dial Indicator Gauge, and
locate and mark the high spot on the pinion flange with yellow paint.
If the flange runout exceeds 0.25 mm (0.010 in), remove the pinion flange, reindex the flange one-half turn
on the pinion, and reinstall it. Refer to Section 205-02A , Section 205-02B or Section 205-03 for the flange
removal and installation procedures.
8. Check the runout again. If necessary, rotate the flange until an acceptable runout is obtained. If the
flange runout is still more than 0.25 mm (0.010 in), install a new pinion flange.
9. If excessive runout is still evident after replacement of the pinion flange, install a new ring and pinion.
Repeat the above checks until the runout is within specifications.
10. Install the driveshaft. Refer to Section 205-01 .
Tooth Contact Pattern Check — Gearset
1. To check the gear tooth contact, paint the gear teeth with a suitable marking compound. A mixture
that is too wet will run and smear; a mixture that is too dry cannot be pressed out from between the
teeth.
2. Use a box wrench on the ring gear bolts as a lever to rotate the ring gear several complete
revolutions in both directions or until a clear tooth contact pattern is obtained.
3. Certain types of gear tooth contact patterns on the ring gear indicate incorrect adjustment. Incorrect
adjustment can be corrected by readjusting the ring gear or the pinion.
Contact Pattern Location
In general, desirable ring gear tooth patterns must have the following characteristics:
z Drive pattern on the drive side ring gear well centered on the tooth.
z Coast pattern on the coast side ring gear well centered on the tooth.
z Clearance between the pattern and the top of the tooth.
z No hard lines where the pressure is high.
Acceptable ring gear tooth patterns for all axles.
Correct backlash with a thinner pinion position shim required.
Correct backlash with a thicker pinion position shim required.
Correct pinion position shim that requires a decrease in backlash.
Correct pinion position shim that requires an increase in backlash.
Driveline Angle Adjustment
NOTE: Some vehicles may exhibit a drive-away shudder or vibration under moderate to heavy acceleration
from a stop, especially when heavily loaded or when towing a trailer. It is important to confirm how the
vehicle is driven the majority of the time (loaded or unloaded), as adjusting the driveline angle in one
condition (loaded or unloaded) may result in a shudder or vibration with the vehicle in the opposite condition
(loaded or unloaded).
NOTE: Verify suspension is not modified from the original configuration. Aftermarket leveling kits and rear
leaf spring shackle kits change ride height, which affects pinion angle and other critical driveline related
operating angles. Vehicle must be at Original Equipment Manufacturer (OEM) specifications before accurate
evaluation and diagnosis can be performed.
NOTE: The driveline angle must be measured with the vehicle in the same condition as the concern (loaded
or unloaded) to determine the amount of adjustment necessary to correct the condition.
1. Measure the driveline angle. For additional information, refer to Driveline Angle Measurement in this
section.
z If the driveline does not have an optimum 3.5 degree operating range, proceed to the following
adjustment steps using the parts listed in the table below.
Part Number Part Name

5A313 1 degree pinion angle shim
5A313 2 degree pinion angle shim
00812 Upper u-bolt center plate bolt (4 required)
5705 U-bolt (4 required)
W520215 U-bolt nut (8 required)
W713078 Center bearing support bolt
W713649 Center bearing support nut
4A209 Center bearing support shim
506545 Shock absorber lower bolt
W520214 Shock absorber lower nut
NOTE: The driveline angle on these vehicles can be changed by adding 1 degree or 2 degree pinion angle
shims.
2. Remove and discard the shock absorber lower nut and bolt.
3. NOTE: To change the pinion angle.
Using a suitable jack to support the rear axle, remove and discard the 8 u-bolt nuts and the 4 u-bolts.
For additional information, refer to Section 204-02 .
4. NOTE: Replace one bolt at time.
Replace the upper u-bolt center plate bolts. For additional information, refer to Section 204-02 .
z Install the new bolts and tighten to 102 Nm (75 lb-ft).
5. NOTE: Never use more then 1 shim on a side at a time.
Install desired shim on the axle spring seat, or on top of the 4x4 spacer block.
z Lower the axle pinion using the thick edge of the shim forward, to decrease pinion angle.
z Raise the axle pinion using the thick edge of the shim rearward, to increase pinion angle.
6. Install 4 new u-bolts and 8 new u-bolt nuts. With the suspension at curb height, tighten the new u-bolt
nuts evenly in a cross-type pattern in 4 stages. For additional information, refer to Section 204-02 .
7. Install a new shock absorber lower nut and bolt. For additional information, refer to Section 204-02 .
z Tighten the new nut and bolt to 90 Nm (66 lb-ft).
8. NOTE: If adjusting axle pinion angle to reduce/eliminate driveline vibration or moan causes an issue
with shudder on acceleration, then the pinion angle must be adjusted to optimize the balance
between perceived vibration/moan and perceived shudder.
NOTE: Shims can be used to lower the center bearing support and minimize this condition. Up to 3
shims may be installed. The center bearing support bolts must be replaced using the part listed in the
table or new grade 10.9 bolts. The bolts should be long enough to extend at least 3 threads past the
nuts.
Measure the driveline angle again. For additional information, refer to Driveline Angle Measurement
in this section.
z If necessary, remove and discard the 2 center bearing support bolts and install shims in 1/4
inch increments to lower the center bearing support.
z Install 2 new bolts and tighten to 48 Nm (35 lb-ft).
Driveline Angle Measurement
Special Tool(s)
Anglemaster II Driveline
Inclinometer/Protractor
NOTE: This procedure does not apply to CV joints, flex couplers or double cardan joints that are used in
some driveshafts. This check is for single-cross and roller-style joints found in the driveshafts.
NOTE: Prior to checking driveline angularity, inspect the U-joints for correct operation.
NOTE: An incorrect driveline angle can cause a vibration or shudder. For additional information, refer to
Section 100-04 .
NOTE: Driveline angularity is the angular relationship between the engine crankshaft, the driveshaft and the
rear axle pinion. Factors determining driveline angularity include ride height, rear spring and engine mounts.
All vehicles
1. Carry out the following preliminary setup steps:

z Inspect the U-joints for correct operation.
z Park the vehicle on a level surface such as a drive-on hoist, or back onto a front end alignment
rack.
z Verify the curb position ride height is within specifications with the vehicle unloaded and all of
the tires are inflated to their normal operating pressures.
z Calibrate the Anglemaster II Driveline Inclinometer/Protractor by placing it on a clean, flat level
section of the frame rail and press the ALT-ZERO button.
Vehicles with flat-flanged, split-pin or slip-flanged U-joints
2. NOTE: If equipped, remove the snap ring to allow access to the base of the U-joint cup. Make sure
the Anglemaster II Driveline Inclinometer/Protractor is seated against the U-joint cup.
NOTE: Rotate the driveshaft until the flange U-joint cup is parallel with the floor. This will simplify
taking measurements.
To check the U-joint operating angle, install the Anglemaster II Driveline Inclinometer/Protractor.
Check and record the flange angle as angle A.
3. Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the connecting
component. Record the measurement of the component angle as angle B.
Multiple piece driveshafts
4. NOTE: Repeat this step for each center support bearing on the driveshaft.
NOTE: It is not necessary to remove the U-joint snap ring, if equipped, for these measurements.
Using the Anglemaster II Driveline Inclinometer/Protractor, measure the slope of the components in
front and behind the center support bearing U-joint in the area indicated. Record the front component
as angle A and the rear component as angle B.
All vehicles
5. NOTE: When 2 connected components slope in the same direction, subtract the smallest number
from the larger number to find the U-joint operating angle. When 2 connected components slope in
the opposite direction, add the measurements to find the U-joint operating angle.
Calculate the difference in the slope of the components to determine the U-joint operating angle.
z The U-joint operating angle is the angle formed by 2 yokes connected by a cross and bearing
kit. Ideally, the operating angles on each connection of the driveshaft must:
be equal or within one degree of each other.
have a 3 degree maximum operating angle.
have at least one-half of one degree continuous operating angle.
6. If the angle is not within specifications, repair or adjust to obtain the correct angle. Inspect the engine
mounts, transmission mounts, center support bearing mounting, rear suspension, rear axle, rear axle
mounting or the frame for wear or damage.
Driveshaft Runout and Balancing
Special Tool(s)
Fixture
100-002 (TOOL-4201-C) or
equivalent
Mastertech® Series MTS 4000

Driveline Balance and NVH
Analyzer (Vetronix)
Driveshaft Inspection
NOTE: Driveline vibration exhibits a higher frequency and lower amplitude than high-speed shake. Driveline
vibration is directly related to the speed of the vehicle and is noticed at various speeds. Driveline vibration
can be perceived as a tremor in the floorpan or heard as a rumble, hum or boom.
NOTE: Refer to Specifications in this section for all runout specifications.
1. NOTE: Do not make any adjustments before carrying out a road test. Do not change the tire pressure
or the vehicle load.
Carry out a visual inspection of the vehicle. Operate the vehicle and verify the condition by
reproducing it during the road test.
z The concern should be directly related to vehicle road speed, not affected by acceleration or
deceleration or could not be reduced by coasting in NEUTRAL.
02 .
z The driveshaft should be kept at an angle equal to or close to the curb-weighted position. Use
a twin-post hoist or a frame hoist with jackstands.
3. Inspect the driveshaft for damage, undercoating or incorrectly seated U-joints. Rotate the driveshaft
slowly by hand and feel for binding or end play in the U-joint trunnions. Remove the driveshaft. For
additional information, refer to Section 205-01 . Inspect the slip yoke splines for any galling, dirt, rust
or incorrect lubrication. Clean the driveshaft or install new U-joints as necessary. Install a new
driveshaft if damaged. After any corrections or new components are installed, recheck for the
vibration at the road test speed.
z If the vibration is gone, test drive the vehicle.
z If the vibration persists or the driveshaft passes visual inspection, measure the driveshaft
runout.
Driveshaft Runout
1. Install the Dial Indicator Gauge with Holding Fixture. Rotate the driveshaft by turning the axle and
measure the runout at the front, the center and the rear of the driveshaft.
z If the runout exceeds 1 mm (0.040 in) at the front or center, install a new driveshaft.
z If the front and center is within 1 mm (0.040 in), but the rear runout is not, index-mark the rear
runout high point and proceed to Step 2.
z If the runout is within 1 mm (0.040 in) at all points, recheck for vibration at road test speed. If
the vibration persists, balance the driveshaft. For additional information, refer to Driveshaft
Balancing in this procedure.
2. NOTE: Circular pinion flanges can be turned in 90 degree or one-fourth increments. Half-round pinion
flanges are limited to 2 positions.
Index-mark the driveshaft to the pinion flange. Disconnect the driveshaft and rotate it 180 degrees.
Reconnect the driveshaft. Recheck the runout at the rear of the driveshaft.
z If the runout is still over specification, mark the high point and proceed to Step 3.
z If the runout is within specification, check for the vibration at the road test speed. If the
vibration is still present, balance the driveshaft. For additional information, refer to Driveshaft
Balancing in this procedure.
3. Excessive driveshaft runout can originate in the driveshaft itself or from the pinion flange. To find the
source, compare the 2 high points previously determined.
z If the index marks are close together, within 25 mm (1 in), the driveshaft is eccentric. Install a
new driveshaft.
z If the marks are on opposite sides of the driveshaft, 180 degrees apart, the slip yoke or pinion
flange is responsible. Check the pinion flange runout. If the pinion flange runout exceeds
specifications, a bent pinion is indicated.
z If the pinion flange and pinion runouts are within specifications, road test and check for the
vibration at the road test speed. If the vibration persists, balance the driveshaft. For additional
information, refer to Driveshaft Balancing in this procedure.
Driveshaft Balancing — Using the Mastertech® Series MTS 4000 Driveline Balance and NVH
Analyzer (Vetronix)
All vehicles
1. Install the Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix) to the
vehicle.
2. Working under the vehicle, install an accelerometer. The accelerometer can be attached and
mounted near either the transmission or differential end of the driveshaft.
3. Clean an area of the driveshaft and install the reflective tape, then install the photo-tachometer
sensor. The sensor should be placed at approximately a 20-degree angle from perpendicular to the
surface of the reflective tape. Make sure the sensor does not get moved during the balance
procedure.
1. Reflective tape.
2. Photo-tachometer sensor.
4. Using the Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a
driveshaft balance test with the driveshaft unmodified.
Vehicles with tapped pinion flanges
5. Label the tapped holes in the pinion flange numerically, starting at the top hole as 1. Mark the
remaining holes 2, 3 and 4. Label in the direction of rotation.
second test with the 12 mm (0.47 in) test weight set screw in the No. 1 hole, previously marked on the
pinion flange.
7. Remove the test weight, then install the weight combination directed by the Mastertech® Series MTS
4000 Driveline Balance and NVH Analyzer (Vetronix).
Vehicles without tapped pinion flanges
second test with a test weight. Using a metal band, secure the test weight to the end of the driveshaft.
The weight should be placed at the end of the driveshaft tube, as close to the tube-to-yoke weld seam
as possible. Mark the location of the test weight on the driveshaft, as shown in the figure below.
1. Test weight.
2. Tube-to-yoke weld seam.
3. Driveshaft pinion flange.
z Select the test weight based on driveshaft size. Larger driveshafts use 10 g (0.353 oz). Smaller
driveshafts use 5 g (0.176 oz).
9. Remove the test weight, then install the recommended weight at the position directed by the
Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix). Using a metal band
and epoxy, secure the test weight to the driveshaft, as shown in the figure below.
1. Test weight.
2. Measure in this direction.
3. Driveshaft diameter.
4. Directional rotation.
5. Balance weight relative to test weight centerline.
z The results are displayed with respect to the location to where the test weight was placed.
All vehicles
10. Using the Mastertech® Series MTS 4000 Driveline Balance and NVH Analyzer (Vetronix), run a third
test to verify the repair.
Driveshaft Balancing — Hose Clamp Method
1. Install 1 or 2 hose clamps on the driveshaft, near the rear. Position of the hose clamp head(s) can be
determined through trial and error.
2. Mark the rear of the driveshaft into 4 approximately equal sectors and number the marks 1 through 4.
Install a hose clamp on the driveshaft with its head at position No. 1, as shown in the figure below.
Check for vibration at road speed. Recheck with the clamp at each of the other positions to find the
position that shows minimum vibration. If 2 adjacent positions show equal improvement, position the
clamp head between them.
3. If the vibration persists, add a second clamp at the same position and recheck for vibration.
4. If no improvement is noted, rotate the clamps in opposite directions, equal distances from the best
position determined in Step 2. Separate the clamp heads about 13 mm (1/2 in) and recheck for
vibration at the road speed.
5. Repeat the process with increasing separation until the best combination is found or the vibration is
reduced to an acceptable level.
SECTION 205-01: Driveshaft 2014 F-150 Workshop Manual

Material
Item Specification Fill Capacity
Threadlock and Sealer WSK-M2G351-A5 —
TA-25
Rear driveshaft center bearing bolts 48 35
Rear driveshaft flange bolts 103 76
Front driveshaft flange-to-pinion flange bolts 55 41
Front driveshaft flange-to-transfer case flange bolts 55 41
Skid plate bolts (SVT Raptor vehicles) 48 35
Stabilizer bar bracket nuts 55 41

Driveshaft

Driveshaft Universal Joint — Snap Ring Type
Special Tool(s)
Screw
205-086 (T74P-4635-C)

1 4841 Driveshaft slip yoke
2 4635 U-joint assembly
3 — Snap rings (part of 4635)
4 4602 Driveshaft assembly
5 4782 Driveshaft flange
Disassembly
1. Remove the driveshaft. Refer to Driveshaft — Front , Driveshaft — Rear, One-Piece or Driveshaft —
Rear, Two-Piece in this section.
2. NOTICE: Do not, under any circumstance, clamp the driveshaft assembly in the jaws of a vise
or similar holding fixture. Denting or localized fracturing may result, causing driveshaft failure
during vehicle operation.
Place the driveshaft on a suitable workbench. Do not damage the tube.
3. NOTE: If the components are not marked and therefore installed incorrectly, driveshaft imbalance can
occur.
Index-mark the driveshaft components.
4. Remove and discard all 4 of the snap rings.
5. Place the C-Frame and Screw Remover/Installer in a vise.
6. NOTE: If necessary, use a pair of pliers to remove a bearing cup that fails to press out all the way.
Remove the bearing cups and the driveshaft slip yoke.

1. Position the driveshaft slip yoke in the C-Frame and Screw Remover/Installer.
2. Press out a bearing cup.
3. Rotate the driveshaft slip yoke 180 degrees.
4. Press on the U-joint spider to remove the remaining bearing cup.
5. Remove the driveshaft slip yoke.
7. Repeat steps to remove the remaining bearing cups and the U-joint spider from the driveshaft yoke.
8. NOTE: Inspect the bearing cup bores and retaining ring grooves. Remove any rust or other surface
irregularities.
Inspect the bearing cup bores of the driveshaft slip yoke and driveshaft yoke. Make sure that the
bearing cup bores are clean and smooth.
Assembly
1. NOTE: Install the U-Joint Kits as complete assemblies only. Do not mix components from other U-
Joint Kits.
NOTE: Lubricate the driveshaft slip yoke and driveshaft yoke bearing cup bores with grease from part
kit # KT9L3P-M1C111-AA before installing the bearing cups.
Install a new U-joint spider and bearing cup.

1. Start a new bearing cup in the driveshaft yoke.
Check the needle bearings for correct positioning.
2. Position the new U-joint spider in the driveshaft yoke.
3. Press the bearing cup to just below the snap ring groove using the C-Frame and Screw
Remover/Installer.
2. NOTE: Never mix yellow and black snap rings on opposing sides.
Remove the shaft from the C-Frame and Screw Remover/Installer and install a new yellow snap ring.
3. Repeat steps to install the new bearing cup and snap ring on the opposite side of the driveshaft yoke.
z If the yellow snap ring will not seat in the snap ring groove, install the black snap rings.
4. Install the driveshaft slip yoke and new bearing cup.

1. Align the index marks made during disassembly and install the driveshaft slip yoke on the U-
joint spider.
2. Start a new bearing cup in the driveshaft slip yoke.
Check the needle bearings for correct positioning.
3. Position the assembly in the C-Frame and Screw Remover/Installer.
4. Press the bearing cup to just below the snap ring groove using the C-Frame and Screw
Remover/Installer.
5. Remove the driveshaft from the C-Frame and Screw Remover/Installer and install a new yellow snap
ring.
6. NOTE: Never mix yellow and black snap rings on opposing sides.
Repeat steps to install the new bearing cup and snap ring on the opposite side of the driveshaft slip
yoke.
z If the yellow snap ring will not seat in the snap ring groove, install the black snap rings.
7. A sharp rap on the driveshaft yoke with a brass or plastic hammer will seat the bearing cups.
8. Rotate the driveshaft yoke to make sure the U-joints are free to rotate easily, without binding, before
installing the driveshaft.
9. Install the driveshaft. Refer to Driveshaft — Front , Driveshaft — Rear, One-Piece or Driveshaft —
Rear, Two-Piece in this section.

Driveshaft
NOTE: All driveshafts are balanced. If undercoating the vehicle, protect the driveshaft and U-joints to
prevent overspray of any undercoating material.
Vehicles have the following types of driveshafts:
z Front driveshaft with CV joints at the front and rear ends of the driveshaft. The only serviceable part
of the front driveshaft is the mounting hardware. The front driveshaft can be balanced by methods
described in the General Driveline section. Refer to Section 205-00 .
z One-piece rear driveshafts with a rear U-joint flange and a slip yoke
z Two-piece rear driveshafts with a front flanged U-joint or slip yoke, center bearing with a slip joint and
a flanged U-joint at the rear
Driveshafts are used to transfer movement from the transmission or transfer case to the front or rear axle.
The driveshaft is composed of the U-joints, CV joints, connecting shafts and the attaching yokes. Some
vehicles are equipped with a center support bearing. The center support bearing is prelubricated and sealed
for the life of the bearing.
Driveshafts differ in length, diameter and type of yoke to accommodate various wheelbase and powertrain
combinations.

Universal Joints
U-joints have the following features:
z Lubed-for-life design and require no lubrication

z Equipped with nylon thrust washers (located at each base of the bearing cup) which control end play,
position the needle bearing and improve grease movement
z Held in place by snap rings
The U-joints allow the speeding up and slowing down of the driveshafts as the angularity of the driveshaft
changes.

1 4635 U-joint
2 — Grease seal (part of 4635)
3 — Needle rollers (part of 4635)
4 — Thrust washer (part of 4635)
5 — Bearing cup (part of 4635)

Driveshaft — Front
Removal
1. With the vehicle in NEUTRAL, position the vehicle on a hoist. Refer to Section 100-02 .
2. If equipped.
3.
4.
5. NOTE: If new bolts are not available, the old bolts and washers can be reused if they are not
damaged. When reusing old bolts, the threads need to be cleaned and loctite has to be used on the
threads of each bolt.
6. NOTE: If new bolts are not available, the old bolts and washers can be reused if they are not
damaged. When reusing old bolts, the threads need to be cleaned and loctite has to be used on the
threads of each bolt.
7.
8.
Installation

Driveshaft — Rear, One-Piece
Material
Item Specification
TA-25

2 N800594 Driveshaft flange-to-pinion bolts (4 required)
3 4782 Rear driveshaft flange
5 4602 Driveshaft assembly
NOTE: For automatic transmissions, when installing a new driveshaft, match the yellow dots on the
driveshaft to the yellow dots on the pinion flange and the output shaft to maintain balance during installation.
02 .
2. Index-mark the driveshaft flange to the pinion flange and the driveshaft flange to the transmission
flange to maintain alignment during installation.
3. Remove and discard the 4 driveshaft flange bolts.

z To install, tighten the 4 new bolts to 103 Nm (76 lb-ft).
4. NOTICE: The driveshaft flange fits tightly on the flange pilot. Never hammer on the driveshaft
or any of its components to disconnect the driveshaft flange from the flange pilot. Pry only in
the area shown with a suitable tool to disconnect the driveshaft flange from the flange pilot or
damage to the driveshaft flange can occur.
Using a suitable tool as shown, disconnect the driveshaft flange from the flange pilot and remove the
driveshaft.
5. NOTICE: The driveshaft flange fits tightly on the pinion flange pilots. To make sure that the
driveshaft flanges seat squarely on the pinion flange pilots, tighten the driveshaft flange bolts
evenly in a cross pattern or damage to the flanges can occur.
NOTE: If new bolts are not available, coat the threads of the original driveshaft flange bolts with
threadlock and sealer.
NOTE: Align the index marks made during removal.
To install, reverse the removal procedure.

Driveshaft — Rear, Two-Piece
Material
Item Specification
Motorcraft® Threadlock and WSK-M2G351-
Sealer A5
TA-25
NOTE: Front slip yoke shown, front fixed flange similar.
Part
1 7A309 Transmission extension housing
2 4A209 Center bearing shim (if equipped)
4 4782 Driveshaft flange
5 N800594 Driveshaft flange-to-pinion bolts (4 required) (front
fixed flange [8 required])
6 4R602 Driveshaft assembly
7 W713078 Driveshaft center bearing bolts (2 required)
NOTE: For automatic transmissions, when installing a new driveshaft, match the yellow dots on the
driveshaft to the yellow dots on the pinion flange and the output shaft to maintain balance during installation.
02 .
2. Index-mark the driveshaft flange to the pinion flange to maintain alignment during installation.
3. Index-mark the driveshaft to the extension housing to maintain alignment during installation.
4. Remove and discard the 4 driveshaft flange bolts.

5. NOTICE: The driveshaft flange fits tightly on the flange pilot. Never hammer on the driveshaft
or any of its components to disconnect the driveshaft flange from the flange pilot. Pry only in
the area shown with a suitable tool, to disconnect the driveshaft flange from the flange pilot or
damage to the driveshaft flange can occur.
Using a suitable tool as shown, disconnect the driveshaft flange from the flange pilot.
6. Remove the driveshaft in the following sequence.

1. Remove the 2 driveshaft center bearing bolts.
2. Lower the driveshaft and slide the driveshaft slip yoke rearward off of the output shaft.
To install, tighten to 48 Nm (35 lb-ft).
7. Plug the extension housing to prevent fluid loss.
8. NOTICE: The driveshaft flange fits tightly on the pinion flange pilots. To make sure that the
driveshaft flanges seat squarely on the pinion flange pilots, tighten the driveshaft flange bolts
evenly in a cross pattern or damage to the driveshaft flange can occur.
NOTE: Align the index marks made during removal.
NOTE: Clean any residual lubricant from the component.

Driveshaft Slip Yoke Boot
Part
1 4R602 Driveshaft assembly
2 3B478 Driveshaft slip-yoke boot clamps (2 required)( large
clamp also part of kit M1C111)
3 4421 Driveshaft slip-yoke boot
4 4A335 Slip yoke
Removal
1. NOTICE: The driveshaft and slip yoke have to be reassembled in the same phase as it was
before disassembly. If the driveshaft and slip yoke isn't assembled in the same phase, a
vibration can result.
Mark a straight line down the slip yoke and driveshaft, to help align for reassembly.
2. Remove the driveshaft. Refer to Driveshaft — Front or Driveshaft — Rear, Two-Piece in this section.
3. NOTICE: Do not, under any circumstance, clamp the driveshaft in the jaws of a vise or similar
holding fixture. Denting or localizing fracture can result, causing driveshaft failure during
vehicle operation.
Place the driveshaft on a suitable workbench. Do not damage the tubes.
4. Remove the driveshaft slip yoke from the driveshaft in the following sequence.
1. Remove and discard the front driveshaft slip-yoke boot clamp.
2. Remove the driveshaft slip yoke from the driveshaft.
5. Remove the slip-yoke boot from the driveshaft.

z Inspect the boot for damage. Replace the boot as necessary.
6. Inspect the lubricant on the driveshaft splines and in the driveshaft slip yoke for contamination. If
contaminated, inspect the driveshaft splines and the driveshaft slip yoke for wear. Install new
components as necessary.
Installation
1. Using a clean, dry lint free shop towel, thoroughly clean old grease from slip yoke splines.
2. Position the new small driveshaft slip-yoke boot clamp on the driveshaft stub shaft.
3. Slide the small opening end of the slip-yoke boot on the driveshaft stub shaft, as far as it will travel.
4. Using boot clamp pliers, crimp the driveshaft slip-yoke boot clamp.
5. NOTICE: The driveshaft and slip yoke have to be reassembled in the same phase as before
disassembly. If the driveshaft and slip yoke aren't assembled in the same phase, a vibration
can result.
Install the driveshaft slip-yoke on the driveshaft.
1. Lubricate the driveshaft splines with long-life grease supplied in part # KT9L3P-M1C111-AA.
2. Pull the slip-yoke boot toward the driveshaft.
3. Position the new large slip-yoke boot clamp supplied in part # KT9L3P-M1C111-AA.
4. Align the marks from disassembly, and install the driveshaft slip yoke on the driveshaft.
6. Set the driveshaft assembled length to specification.

1. Remove any excess grease from the slip-yoke boot and driveshaft slip-yoke surfaces.
2. Position the slip-yoke boot in the slip-yoke boot groove.
3. Set the driveshaft assembled length to specification.
Measure from the stub shaft weld to the U-joint centerline.
4. Bleed the air from the slip-yoke boot.
7. Using boot clamp pliers, crimp the large driveshaft slip-yoke boot clamp.
8. Install the driveshaft. Refer to Driveshaft — Front or Driveshaft — Rear, Two-Piece in this section.
SECTION 205-02A: Rear Drive Axle/Differential — Ford 8.8-Inch Ring Gear 2014 F-150 Workshop Manual
Material
Additive Friction EST-M2C118-A —
Modifier
XL-3 (US); CXL-3
(Canada)
Motorcraft® High — —
Contrast Hypoid Gear
Marking Compound
XG-14
Motorcraft® SAE 75W- WSL-M2C192-A 2.84L (6.0 pt) (to
140 Synthetic Rear Axle and GL-5 the bottom of the
Lubricant filler hole)
XY-75W140-QL (US);
CXY-75W140-1L
(Canada)
Premium Long-Life ESA-M1C75-B —
Grease
XG-1-C or XG-1-K (US);
CXG-1-C (Canada)
Silicone Gasket and WSE-M4G323- —
Sealant A4
TA-30
TA-25 A5
Item Specification
Available drive pinion bearing adjustment shim in steps of 0.25 mm 0.254-0.965 mm (0.010-0.038
(0.010 in) in)
Backlash between ring gear teeth and pinion teeth 0.203-0.304 mm (0.008-0.012
in)
Differential case maximum runout 0.076 mm (0.003 in)
Pinion bearing rotational preload 1.5-3.0 Nm (13-26 lb-in)
Ring gear maximum variation between teeth backlash 0.102 mm (0.004 in)
Maximum axle shaft flange runout 0.279 mm (0.011 in)
Rear Axle Backlash Shim Adjustment Table

Backlash Change Required Thickness Change Required
mm in mm in
0.025 0.001 0.050 0.002

0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Axle vent 18 — 159
Brake hose bracket bolts 30 22 —
Brake tube/parking brake cable bracket bolt 25 18 —
RH parking brake cable bracket bolt 30 22 —
Differential bearing cap bolt 112 83 —
Differential housing cover bolts 45 33 —
Differential pinion shaft lock bolt 30 22 —
Differential ring gear bolts a — — —
Filler plug 52 38 —
Handle Adapter 2.2 — 20
Lower shock absorber nuts 90 66 —
Tool 205-135 nut 7 — 62
U-bolt nut a — — —
Wheel speed sensor bolts 15 — 133
Rear Drive Axle and Differential
The rear axle assembly consists of the following:
z Integral-type housing hypoid gear design (center of the pinion set below the centerline of the ring
gear)
z Hypoid differential ring gear and pinion consists of an 8.8-inch ring gear and an overhung drive pinion
that is supported by 2 opposed tapered roller bearings
z Axle housing assembly that consists of a cast center section with 2 steel tube assemblies and a
stamped differential housing cover
z Differential pinion shaft is retained by a threaded differential pinion shaft lock bolt attached to the
differential case
z Differential case is mounted in the rear axle housing between 2 opposing differential bearings that are
retained in the rear axle housing by 2 removable bearing caps
The rear drive axle receives rotational torque from the driveshaft. The direction of the rotation determines
movement of the vehicle. The rotation enters the rear drive axle through the drive pinion flange, turning the
drive pinion and rotating the ring gear. The ring gear is bolted to the differential case. The differential case
houses the pinion shaft upon which the differential pinion gears ride. The pinion gears are in mesh with the
differential side gears to which the axle shafts are splined. It is the unique arrangement of the differential that
allows the axle shafts to be driven at different speed when needed, such as when driving around corners. A
Traction-Lok differential is also available that introduces a series of clutch plates and discs behind the
differential side gears to deliver as much torque as possible to each axle shaft when the traction at the rear
wheels is not equal. The Traction-Lok differential requires a friction modifier that must be installed with the
axle lubricant for the plates and discs to be functional.
Ring Gear Backlash Adjustment
Special Tool(s)
Dial Indicator Gauge With Holding
Fixture
100-002 (TOOL-4201-C)
Installer, Differential Shim

205-220 (T85L-4067-AH)
Material
Item Specification
Motorcraft® High Contrast Hypoid —
Gear Marking Compound
XG-14
1. Remove the differential housing cover. For additional information, refer to Differential Housing Cover
in this section.
2. Install the Dial Indicator Gauge with Holding Fixture and measure the ring gear backlash.
z If a zero backlash condition occurs or the backlash is not within specification, proceed to Step
3.
z If the backlash is within specification, proceed to Step 14.
3. Remove the axle shafts. For additional information, refer to Axle Shaft in this section.
4. NOTE: Index-mark the position of the differential bearing caps, as arrows may not be visible. The
differential bearing caps must be installed in their original locations and positions.
Remove the 4 bearing cap bolts and 2 caps.
5. If a zero backlash condition has occurred, add 0.50 mm (0.020 in) to the RH side shim and subtract
0.50 mm (0.020 in) from the LH side shim to allow a backlash indication. Install the 2 bearing caps
and 4 bolts.
z Go back to Step 2.
6. To correct for high or low backlash, increase the thickness of one differential bearing shim and
decrease the thickness of the other differential bearing shim by the same amount. Refer to the
following tables when adjusting the backlash.

mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart 4067

Dimension A
Stripes and Color Code mm Inch
2 — C-COAL 7.7978-7.8105 0.3070-0.3075

1 — C-COAL 7.7470-7.7597 0.3050-0.3055
5 — BLU 7.6962-7.7089 0.3030-0.3035
4 — BLU 7.6454-7.6581 0.3010-0.3015
3 — BLU 7.5946-7.6073 0.2990-0.2995
2 — BLU 7.5458-7.5565 0.2970-0.2975
5 — PINK 7.4422-7.4549 0.2930-0.2935
4 — PINK 7.3914-7.4041 0.2910-0.2915
3 — PINK 7.3406-7.3533 0.2890-0.2895
2 — PINK 7.2898-7.3025 0.2870-0.2875
1 — PINK 7.2390-7.2517 0.2850-0.2855
5 — GRN 7.1882-7.2009 0.2830-0.2835
4 — GRN 7.1374-7.1501 0.2810-0.2815
3 — GRN 7.0866-7.0993 0.2790-0.2795
2 — GRN 7.0358-7.0485 0.2770-0.2775
1 — GRN 6.9850-7.0485 0.2750-0.2755
5 — WH 6.9342-6.9469 0.2730-0.2735
4 — WH 6.8834-6.8961 0.2710-0.2715
3 — WH 6.8326-6.8453 0.2690-0.2695
2 — WH 6.7818-6.7945 0.2670-0.2675
1 — WH 6.7310-6.7437 0.2650-0.2655
5 — YEL 6.6802-6.6929 0.2630-0.2635
4 — YEL 6.6294-6.6421 0.2610-0.2615
3 — YEL 6.5786-6.5913 0.2590-0.2595
2 — YEL 6.5278-6.5405 0.2570-0.2575
1 — YEL 6.4770-6.4897 0.2550-0.2555
5 — ORNG 6.4262-6.4389 0.2530-0.2535
4 — ORNG 6.3754-6.3881 0.2510-0.2515
3 — ORNG 6.3246-6.3373 0.2490-0.2495
2 — ORNG 6.2738-6.2865 0.2470-0.2475
1 — ORNG 6.2223-6.2357 0.2450-0.2455
2 — RED 6.1722-6.1849 0.2430-0.2435
1 — RED 6.1214-6.1341 0.2410-0.2415
7. Install the 2 bearing caps and 4 bolts.

8. Using the Dial Indicator Gauge with Holding Fixture, recheck the ring gear backlash.
z If backlash is now within specification, proceed to Step 9.
z If backlash is not within specification, go back to Step 4.
9. Remove the 4 bearing cap bolts and 2 bearing caps.
10. To establish differential bearing preload, increase both LH and RH differential bearing shim size by
the thickness shown.
11. Using the Differential Shim Installer, fully seat the differential bearing shims. Make sure the assembly
rotates freely.

13. Using the Dial Indicator Gauge with Holding Fixture, do a final check of the ring gear backlash.
14. Apply marking compound and rotate the differential assembly 5 complete revolutions.
15. Verify an acceptable pattern check. For additional information, refer to Tooth Contact Pattern Check
in Section 205-00 .
16. Install the axle shafts. For additional information, refer to Axle Shaft in this section.
17. Install the differential housing cover. For additional information, refer to Differential Housing Cover in
this section.
Differential Case and Ring Gear — Conventional
Special Tool(s)
Fixture
100-002 (TOOL-4201-C)
Gauge, Differential Clutch

205-022 (T66L-4204-A)
Gauge, Differential (Traction

Lock)
205-386 (T97T-4205-D)
Installer, Differential Side Bearing

205-010 (T57L-4221-A2)
Remover, Differential Bearing

205-116 (T77F-4220-B1)
Step Plate
205-D016 (D80L-630-5) or
equivalent
Material
Item Specification
Motorcraft® SAE 75W-140 WSL-M2C192-A
Synthetic Rear Axle Lubricant and GL-5
XY-75W140-QL (US); CXY-

75W140-1L (Canada)
Premium Long-Life Grease ESA-M1C75-B
XG-1-C or XG-1-K (US); CXG-
1-C (Canada)
TA-25

1 4236 Differential side gears
2 4228 Differential side gear thrust washers
3 — Differential side gear wave washers
4 4215 Differential pinion gear (2 required)
5 4230 Differential pinion thrust washer (2 required)
6 4N237 Axle shaft U-washer (2 required)
7 4209 Differential ring gear
8 4241 Differential pinion shaft lock bolt
9 4211 Differential pinion shaft
10 4204 Differential case
11 4216 Differential ring gear bolt (10 required)
12 4221 Differential bearings
13 4222 Differential bearing cups
Initial disassembly
NOTE: If the differential ring gear backlash between teeth is greater than specification, remove the ring gear
to check the differential case flange runout. Do not disassemble the differential carrier assembly.
1. Remove the differential carrier. Tag the differential shims and bearing cups for location. For additional
information, refer to Differential Carrier in this section.
2. Remove and discard the 10 differential ring gear bolts.
3. NOTICE: Care should be taken not to damage the differential ring gear bolt hole threads.
Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.
4. If checking differential case flange runout, install the bearing cups in their original location and install
the differential assembly.
1. Install the bearing caps and differential shims.
Rotate the differential assembly to verify the bearings have seated.
2. Install the Dial Indicator Gauge With Holding Fixture and record the differential case runout.
Final disassembly
5. Using the Differential Bearing Remover and Step Plate, remove the differential bearings.
6. Remove the differential pinion shaft lock bolt.
7. Remove the differential pinion shaft.
8. Install the Differential Gauge in a suitable vise.
9. Install the differential case on the Differential Gauge.
10. NOTE: Apply a small amount of grease to the centering hole of the Differential Gauge.
Install the Differential Gauge step plate in the bottom differential side gear.
11. Install the Differential Gauge nut in the upper differential side gear. Hold the nut in position while
installing the Differential Gauge hex screw. Tighten the hex-head screw until contact is made with the
Step Plate.
12. Rotate and remove the differential pinion gears and differential pinion gear thrust washers.
13. Remove the differential side gears, the differential side gear washers and the differential side gear
wave washers.
Assembly
1. NOTE: Lubricate the differential side gear thrust washers, wave washers and the side gear journals
with axle lubricant.
Position the differential side gear thrust washers and wave washers on the differential side gears.
2. Install the differential side gears.
3. NOTE: Apply a small amount of grease to the Step Plate bore.
NOTE: If necessary, insert the Differential Gauge dowel bar in the nut bore to keep the nut from
turning as the hex screw is tightened.
Assembly the Differential Gauge to the differential case.

1. Position the Differential Gauge step plate in the bottom differential side gear.
2. Position the Differential Gauge hex screw plate in the top differential side gear and hold it in
place.
3. Install the Differential Gauge hex screw and tighten it 2 turns after it contacts the bottom Step
Plate.
4. Use axle lubricant to lubricate the differential pinion gear thrust washers and the differential pinion
gears.
5. Install the differential pinion gears and differential pinion gear thrust washers opposite the differential
side gears.
6. Rotate the differential pinion gears to align with the differential pinion shaft bore.
7. Install the differential pinion shaft.

z Align the hole in the differential pinion shaft with the hole in the differential case.
8. NOTE: If a new pinion shaft lock bolt is unavailable, coat the threads with threadlock and sealer prior
to installation.
Install a new differential pinion shaft lock bolt and tighten finger-tight.
9. Using the Differential Side Bearing Installer, install the new differential bearings on the differential
case.
10. Position the differential ring gear on the differential case. Align the bolt holes by starting 2 bolts
through the holes in the differential case and into the differential ring gear.
11. Using a shop press, press the ring gear on the differential case.
12. Install the 10 new differential ring gear bolts. Tighten in 2 stages.
z Stage 1: Tighten to 60 Nm (44 lb-ft).
z Stage 2: Tighten an additional 90 degrees.
13. Install the differential carrier. For additional information, refer to Differential Carrier in this section.
Differential Case and Ring Gear — Traction-Lok
Special Tool(s)
Fixture
100-002 (TOOL-4201-C)

205-135 (T80P-4946-A)

205-022 (T66L-4204-A)

(Mandrel for 205-135 [T80P-4946-
A])
205-270 (T87T-4946A)
Gauge, Differential (Traction-

Lock)
205-386 (T97T-4205-D)

205-010 (T57L-4221-A2)
Remover, Differential Bearing

205-116 (T77F-4220-B1)
Rotator, Differential
205-378 (T97T-4205-C)
Step Plate
205-D016 (D80L-630-5) or
equivalent
Material
Item Specification
Additive Friction Modifier EST-M2C118-A
XL-3 (US); CXL-3 (Canada)
75W140-1L (Canada)
1-C (Canada)
TA-25

3 4236 Differential side gear
4 — Retainer clip (part of 4880)
5 4230 Differential pinion thrust washer
6 4215 Differential pinion gear
7 — Plate preload spacer (part of 4880)
8 — Clutch disc (part of 4880)
9 — Clutch plate (part of 4880)
11 — Selective shim (part of 4880)
Initial disassembly
NOTE: If the Diagnostic Chart directed the servicing of the Traction-Lok clutch packs, it is not necessary to
remove the differential carrier assembly from the axle housing. Proceed to Step 7.
NOTE: If the differential ring gear backlash between teeth is greater than specification, remove the ring gear
to check the differential case flange runout. Do not disassemble the differential carrier assembly.
Final disassembly
5. Using the Differential Bearing Remover and Step Plate, remove the differential bearings.
6. Remove the differential pinion shaft lock bolt and remove the differential pinion shaft.
10. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw.
Tighten the hex-head screw until contact is made with the Differential Gauge step plate.
11. NOTE: The dowel bar is used to keep the nut from turning when the forcing screw is tightened.
Insert a suitable dowel bar in the hole of the nut. Tighten the forcing screw to force the differential
side gears away from the differential pinion gears.
12. NOTE: Differential pinion gear thrust washers cannot be removed independently of the differential
pinion gears.
Insert the Differential Rotator in the pinion shaft bore, and turn the differential case to "walk" the
differential pinion gears and differential case windows.
13. Remove the differential pinion gears and differential pinion gear thrust washers.
14. Remove the differential side gears and differential clutch packs with the selective shim and Belleville
spring, tag them RH and LH.
15. NOTICE: Do not use acids or solvents when cleaning the differential clutch pack or damage to
the components can result. Wipe components with a clean, lint-free cloth only.
NOTE: When separating the clutch plates and clutch disc, note the sequence in which they are
disassembled. They must be reassembled in the same sequence.
Separate the differential clutch disc and clutch plates for cleaning and inspection.
Assembly
1. NOTE: Use 118 ml (4 oz) of the specified friction modifier in the axle.
Pre-lubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15
minutes.
2. NOTE: Do not mix the differential clutch packs or selective shims from one side with the other.
NOTE: The Belleville spring is a dished plate.
Assemble the differential clutch packs (without the selective shims and Belleville spring) on the
respective differential side gears.
3. NOTE: Make sure the correct mandrel is used with the Differential Clutch Gauge.
Place the base portion of the Differential Clutch Gauge in a vise. Install the differential clutch pack
and differential side gear (without the selective shim or Belleville spring) on the gauge.
4. Position the Differential Clutch Gauge hand-tight on top of the differential clutch pack.
5. Install the Differential Clutch Gauge over the disc and differential clutch pack.
6. Install the nut of the gauge over the top and base stud.
7. NOTE: Selective shims shown are available as part of the Clutch Pack Replacement Kit.
Use the feeler gauge and select the thickest blade that will enter between the tool and the differential
clutch pack. Refer to the chart to determine which shim to use.
Selective Shims
Feeler Gauge Part Number Description
0.096-0.104 E0AZ-4A324-G 0.025 in
0.105-0.109 E0AZ-4A324-H 0.030 in
0.110-0.114 E0AZ-4A324-C 0.035 in
0.115-0.190 E0AZ-4A324-D 0.040 in
0.120-0.125 E0AZ-4A324-F 0.045 in
8. Remove the Differential Clutch Gauge from the clutch pack and differential side gear assembly.
9. Place the selective shim and Belleville spring on the differential clutch pack.
z The dished or concave side of the Belleville spring must face up against the thrust face of the
differential case.
10. Install the differential side gears with the differential clutch packs, selective shims and Belleville spring
into the differential case.
z Hold the differential side gear assembly in place to prevent it from falling out of the differential
case.
11. NOTE: Apply a small amount of grease to the step plate bore.
NOTE: If necessary, insert the dowel bar in the nut bore to keep the nut from turning as the hex
screw is tightened.
Assemble the Differential Gauge to the differential case.

2. Position the Differential Gauge in the top differential side gear and hold it in place.
3. Install the Differential Gauge and tighten it 2 turns after it contacts the bottom step plate.
12. NOTE: Lubricate both sides of the differential pinion gear thrust washers with axle lubricant.
NOTE: Make sure the differential pinion gears are 180 degrees apart so they will align correctly with
the pinion shaft bore.
Position the differential pinion gears and differential pinion gear thrust washers in the window of the
differential case so they mesh with the differential side gear teeth.
13. NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential
pinion gears and differential side gears to rotate.
Inspect the Differential Rotator into the pinion shaft bore, and turn the differential case. This will cause
the differential pinion gears to engage the differential side gear and "walk" into the differential case.
Rotate the differential case until the pinion shaft mating holes are lined up exactly with the holes in
the differential pinion gears.
14. Remove the special tools.
15. NOTE: If a new differential pinion shaft lock bolt is unavailable, coat the threads of the original
differential pinion shaft lock bolt with threadlock prior to installation.
Install the differential pinion shaft, then a new differential pinion shaft lock bolt finger-tight.
16. Check the torque required to rotate one differential side gear.
z Mount the differential assembly and Differential Clutch Gauge in a vise.
z The initial minimum break-away torque, if original clutch plates are used, must be within
specification. The minimum rotating torque required to keep the differential side gear turning
with new clutch plates may vary.
17. Using the Differential Side Bearing Installer, install the 2 differential bearings on the differential case.
18. Position the differential ring gear and the differential case. Align the bolt holes by hand-starting 2 new
bolts through the holes in the differential case and into the differential ring gear.
19. Hand-start the 8 remaining new differential ring gear bolts. Tighten the 10 bolts in 2 stages.
IN-VEHICLE REPAIR Procedure revision date: 10/25/2013
Axle Shaft
Material
Item Specification
XG-1-C or XG-1-K (US); CXG-1-C
(Canada)
Threadlock and Sealer WSK-M2G351-
TA-25 A5
02 .
2. Remove the rear wheel and tire. For additional information, refer to Section 204-04 .
3. Remove the rear brake disc. For additional information, refer to Section 206-04 .
4.
5. Remove the differential housing cover and drain the lubricant. For additional information, refer to
Differential Housing Cover in this section.
6. Discard the specified component. Follow local disposal regulations.

7.
8.

z Inspect and lubricate the lip of the wheel bearing oil seal with grease.
Differential Bearings
Special Tool(s)
2 Jaw Puller
205-D072 (D79L-4221-A1) or
equivalent
Adapter for 205-S127

205-105 (T76P-4020-A3)

205-109 (T76P-4020-A9)

205-110 (T76P-4020-A10)

205-111 (T76P-4020-A11)

205-129 (T79P-4020-A18)

205-130 (T79P-4020-A19)

205-010 (T57L-4221-A2)
Installer, Drive Pinion Bearing

Cup
205-024 (T67P-4616-A)
Installer, Shaft Bearing Cone

308-169 (T88T-7025-B)
Plate, Bearing Oil Seal

205-090 (T75L-1165-B)
Protector, Drive Pinion Thread

Puller, Bearing
205-D064 (D84L-1123-A) or
equivalent
Step Plate
205-D016 (D80L-630-5) or
equivalent
Part
1 4346 Differential housing cover bolt (10 required)
2 4033 Differential housing cover
3 46108 Differential bearing cap bolts (part of 4010) (4
required)
4 — Differential bearing caps (part of 4010) (2 required)
5 4067 Differential bearing shims (2 required)
6 4222 Differential bearing cups (2 required)
7 4221 Differential bearings (2 required)
8 4216 Ring gear bolt (10 required)
9 4204 Differential assembly

10 4209 Ring gear
10 4209 Drive pinion
11 4663 Pinion bearing alignment shim
12 — Inner pinion bearing cup (part of 4625)
13 4625 Inner pinion bearing
14 4662 Collapsible spacer (part of 4320)
15 — Outer pinion bearing cup (part of 4621)
16 4621 Outer pinion bearing
17 4670 Oil slinger
18 4676 Drive pinion oil seal
19 4851 Drive pinion flange
20 4C121 Drive pinion nut (part of 4320)
Removal
1. Remove the drive pinion seal. For additional information, refer to Drive Pinion Flange and Drive
Pinion Seal in this section.
2. Remove the differential carrier. For additional information, refer to Differential Carrier in this section.
3. Remove the axle drive pinion shaft oil slinger.
4. Using the Drive Pinion Thread Protector and a soft-faced hammer, drive the pinion assembly out of
the outer pinion bearing and remove it through the rear of the differential housing.
5. Remove the outer pinion bearing.
6. Remove the drive pinion collapsible spacer and discard it.
7. Using the Bearing Puller and a suitable press, remove the inner pinion bearing.
8. Using a brass drift, remove the pinion bearing cups by tapping alternately on opposite sides of the
bearing cups.
9. Using the 2 Jaw Puller and Step Plate, remove the 2 differential bearings.
Installation
1. Position the Drive Pinion Bearing Cup Installer and the inner and outer bearing cups in their
respective bores.
1. After placing the inner and outer bearing cups in their respective bores, place the Drive Pinion
Bearing Cup Installer on the inner bearing cup.
2. Place the Drive Pinion Bearing Cup Installer on the outer bearing cup.
3. Install the Drive Pinion Bearing Cup Installer.
2. Tighten the Drive Pinion Bearing Cup Installer to seat the pinion bearing cups in their bores.
3. NOTE: If a feeler gauge of the specification shown can be inserted between a cup and the bottom of
its bore at any point around the cup, the cup is not correctly seated.
Make sure the differential pinion bearing cups are correctly seated.
4. NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil
provides adequate lubricant without upsetting the drive pinion bearing preload settings.
Assemble and position the Adapters.
Part
1 205-105 Adapter for 205-S127 (1.612 in OD) (T76P-4020-A3)
2 205-111 Adapter for 205-S127 (T76P-4020-A11)
3 4621 Drive pinion bearing (outer)
4 205-109 Adapter for 205-S127 (T76P-4020-A9)
5 4630 Drive pinion bearing (inner)
6 205-129 Adapter for 105-S127 (1.1884 in thick) (T79P-4020-
A18)
7 205-110 Adapter for 205-S127 (1.7 in thick) (T76P-4020-A10)
5. NOTE: This step duplicates final drive pinion bearing preload.
Tighten the Adapter.

z Tighten to 2.2 Nm (20 lb-in) rotational torque.
6. NOTE: The Adapter must be offset to obtain an accurate reading.
Rotate the Adapter several half turns to make sure of correct seating of the drive pinion bearings and
position the Adapter.
7. Install the Adapter.

1. Position the gauge tube.
2. Install the 2 differential bearing caps.
3. Install the 4 differential bearing cap bolts.
Tighten to 112 Nm (83 lb-ft).
8. NOTE: Drive pinion bearing adjustment shims must be flat and clean.
NOTE: A slight drag should be felt for correct drive pinion bearing adjustment shim selection. Do not
attempt to force the drive pinion bearing adjustment shim between Adapter and gauge tube. This will
minimize selection of a drive pinion bearing adjustment shim thicker than required, which results in a
deep tooth contact in final assembly of integral axle assemblies.
Use a drive pinion bearing adjustment shim as a gauge for drive pinion bearing adjustment shim
selection.
z After the correct drive pinion bearing adjustment shim thickness has been determined, remove
all of the Adapters.
9. Using the Shaft Bearing Cone Installer and Bearing Oil Seal Plate and a shop press, drive the inner
drive pinion bearing and drive pinion bearing adjustment shim until they are firmly seated on the
pinion shaft.
10. Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.
11. Install the drive pinion assembly into the axle housing.
12. Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
13. Install the drive pinion seal and flange. For additional information, refer to Drive Pinion Flange and
Drive Pinion Seal in this section.
14. Using the Differential Side Bearing Installer, install the 2 new differential bearings.
Differential Housing Cover
Material
Item Specification
75W140-1L (Canada)
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30

Removal
02 .
2. Remove the differential housing cover.

1. Remove the 10 differential housing cover bolts and drain the lubricant from the axle housing.
Installation
1. NOTE: The machined surfaces on the differential housing and the differential housing cover must be
clean and free of oil before applying the silicone sealant. Cover the inside of the rear axle prior to
cleaning the machined surface to prevent contamination.
Clean the gasket mating surfaces.
2. Apply a new continuous bead of sealant to the differential housing cover.
3. NOTE: The differential housing cover must be installed within 15 minutes of application of the silicone
sealant, or new sealant must be applied. If possible, allow one hour before filling the axle housing
with axle lubricant to make sure the silicone sealant has correctly cured.
Install the differential housing cover and the 10 differential housing cover bolts.
4. NOTE: When filling a Traction-Lok axle with new lubricant, first fill the axle with 118 ml (4 oz) of
friction modifier.
Remove the filler plug, fill the axle with 2.8L (6.0 pt) of axle lubricant and install the filler plug.
Differential Ring And Pinion
Special Tool(s)
2 Jaw Puller
205-D072 (D79L-4221-A1) or
equivalent

205-105 (T76P-4020-A3)

205-109 (T76P-4020-A9)

205-110 (T76P-4020-A10)

205-111 (T76P-4020-A11)

205-129 (T79P-4020-A18)

205-130 (T79P-4020-A19)

205-010 (T57L-4221-A2)

Cup
205-024 (T67P-4616-A)
Installer, Shaft Bearing Cone

308-169 (T88T-7025-B)
Plate, Bearing Oil Seal

205–090 (T75L-1165–B)

Step Plate
205-D016 (D80L-630-5) or
equivalent
Part
required)
5 4067 Differential bearing shims (2 required)

10 4209 Ring gear
11 4663 Pinion bearing alignment shim
17 4670 Oil slinger
Removal
1. Remove the drive pinion flange seal. For additional information, refer to Drive Pinion Flange and
2. Remove the differential carrier assembly. For additional information, refer to Differential Carrier in this
section.
4. NOTE: Care should be taken not to damage the differential ring gear bolt hole threads.
5. Using the 2 Jaw Puller and Step Plate, remove the differential bearings.
6. Remove the drive pinion shaft oil slinger and the outer drive pinion bearing.
7. Install the Drive Pinion Thread Protector. Using a soft-faced hammer, drive the pinion assembly out of
the axle housing.
8. Remove and discard the drive pinion collapsible spacer.
9. Using a brass drift, remove the drive pinion bearing cups by tapping alternately on opposite sides of
the drive pinion bearing cups.
Installation
1. Position the Drive Pinion Bearing Cup Installer and the inner and outer drive pinion bearing cups in
their respective bores.
1. After placing the inner and outer drive pinion bearing cups in their bores, place the Drive Pinion
Bearing Cup Installer (inner) on the inner drive pinion bearing cup.
2. Place the Drive Pinion Bearing Cup Installer (outer) on the outer drive pinion bearing cup.
2. Tighten the Drive Pinion Bearing Cup Installer to seat the drive pinion bearing cups into their bores.
3. NOTE: If a feeler gauge can be inserted between a drive pinion bearing cup and the bottom of its
bore at any point around the drive pinion bearing cup, the drive pinion bearing cup is not correctly
seated.
Make sure the drive pinion bearing cups are correctly seated in their bores.
4. NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil
Part
1 205-105 Adapter for 205-S127 (1.612 in OD) (T76P-4020-A3)
2 205-111 Adapter for 205-S127 (T76P-4020-A11)
4 205-109 Adapter for 205-S127 (T76P-4020-A9)
6 205-129 Adapter for 105-S127 (1.1884 in thick) (T79P-4020-
A18)
7 205-110 Adapter for 205-S127 (1.7 in thick) (T76P-4020-A10)
z Tighten to 2.2 Nm (20 lb-in) rotational torque.
Rotate the Adapter several half-turns to make sure of correct seating of the drive pinion bearings and
7. Install the Adapter.

1. Position the Adapter.
attempt to force the drive pinion bearing adjustment shim between the Adapter and the gauge tube.
This will minimize selection of a drive pinion bearing adjustment shim thicker than required, which
results in a deep tooth contact in final assembly of integral axle assemblies.
selection.
all of the special tools.
9. Using the Shaft Bearing Cone Installer and Bearing Oil Seal Plate and a shop press, drive the inner
drive pinion bearing and the selected drive pinion bearing adjustment shim until they are firmly seated
on the pinion shaft.
10. Install a new drive pinion collapsible spacer on the pinion shaft against the pinion shaft shoulder.
11. Install the drive pinion assembly into the axle housing.
12. Install the outer drive pinion bearing and the drive pinion shaft oil slinger.
13. Using the Differential Side Bearing Installer, install the 2 new differential bearings.
14. Using 2 ring gear bolts as a guide, press the ring gear on the differential assembly.
15. Install the 10 new differential ring gear bolts. Tighten in 2 stages.
Drive Pinion Flange and Drive Pinion Seal
Special Tool(s)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent
Holding Fixture, Drive Pinion

Flange
205-126 (T78P-4851-A)
Installer, Drive Pinion Flange

205-002 (TOOL-4858-E)
Installer, Drive Pinion Oil Seal

205-208 (T83T-4676-A)
Material
Item Specification
75W140-1L (Canada)
1-C (Canada)

1 389546 Drive pinion nut
Removal
NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the same
color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion
bearing preload reduction, install the nut supplied with the new spacer or damage to the component
may occur.
02 .
2. Remove the brake disc. For additional information, refer to Section 206-04 .
3. Remove the driveshaft. For additional information, refer to Section 205-01 .
4. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of
the pinion gear through several revolutions.
5. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove and discard the
pinion nut.
6. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment
during installation.
7. Using the 2 Jaw Puller, remove the pinion flange.
8. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer
until the drive pinion seal is removed.
Installation
1. Lubricate the new drive pinion seal with grease.
2. NOTE: If the new drive pinion seal becomes misaligned during installation, remove the drive pinion
seal and install a new drive pinion seal.
Using the Drive Pinion Oil Seal Installer, install a new drive pinion seal.
3. Lubricate the pinion flange splines with axle lubricant.
4. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
Align the pinion flange with the drive pinion shaft.
5. Using the Drive Pinion Flange Installer, install the pinion flange.
6. NOTICE: Install a new pinion nut with the same color as the original if not replacing the
collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit or damage
to the component may occur.
Position the new pinion nut.
8.8-In Drive Pinion Nut

Part Number Color Description Application
389546-S100 Orange Axles built before 7/16/07
4320 Purple Axles built after 7/16/07
4C121 Purple Kit with spacer for all 223.52 mm (8.8 in) axles
7. NOTICE: Under no circumstances is the pinion nut to be backed off to reduce drive pinion
bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion
collapsible spacer and pinion nut must be installed or damage to the component may occur.
NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the
same color new drive pinion nut for installation. If a new collapsible spacer must be installed
for pinion bearing preload reduction, install the nut supplied with the new spacer or damage to
the component may occur.
NOTE: Remove the Drive Pinion Flange Holding Fixture while taking drive pinion bearing preload
readings with the Nm (lb-in) torque wrench.
Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the pinion nut.
z Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating
correctly.
z Install a Nm (lb-in) torque wrench on the pinion nut.
z Rotating the drive pinion through several revolutions, take frequent drive pinion bearing
preload readings until the original recorded drive pinion bearing preload reading is obtained.
z If the original recorded drive pinion bearing preload is lower than specifications, tighten to the
appropriate specifications for used drive pinion bearings. If the drive pinion bearing preload is
higher than specification, tighten the pinion nut to the original reading as recorded. For
additional information, refer to Specifications in this section.
8. Install the driveshaft. For additional information, refer to Section 205-01 .
9. Install the brake disc. For additional information, refer to Section 206-04 .
Rear Wheel Bearing and Axle Shaft Seal
Special Tool(s)
Adapter For 303-224 (Handle)
205-153 (T80T-4000-W)
Installer, Axle Bearing

205-194 (T83T-1225-B)
Installer, Axle Oil Seal

205-381 (T97T-1177-A)
Remover, Axle Bearing

205-193 (T83T-1225-A)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
75W140-1L (Canada)
1-C (Canada)

1 1177 Axle shaft oil seal
2 1225 Axle shaft bearing
Removal
1. Remove the axle shaft. For additional information, refer to Axle Shaft in this section.
2. NOTE: If the axle shaft oil seal is leaking, the axle housing vent may be plugged with foreign material.
NOTE: Use care to avoid damaging the axle shaft oil seal bore.
Using a suitable seal remover, remove and discard the axle shaft oil seal.
3. Inspect the rear wheel bearing and axle shaft for wear or damage.
4. If necessary, using the Axle Bearing Remover and Slide Hammer, remove the rear wheel bearing.
Installation
1. If removed, lubricate the new rear wheel bearing with axle lubricant.
2. If removed, use the Axle Bearing Installer and Handle to install the rear wheel bearing.
3. Lubricate the lip of the new axle shaft oil seal with grease.
4. Using the Axle Oil Seal Installer and Handle, install the new axle shaft oil seal.
5. Install the axle shaft. For additional information, refer to Axle Shaft in this section.
Axle Assembly

1 W705518 U-bolt nuts (8 required)
2 5798 U-bolt plates (2 required)
3 W520214 Lower shock absorber nuts (2 required)
4 W506545 Lower shock absorber bolts (2 required)
5 57632 Brake tube/parking brake cable bracket bolt
6 4022 Axle vent
7 W712215 Brake hose bracket bolt
NOTICE: Suspension fasteners are critical components because they affect performance of vital
components and systems and their failure can result in major service expense. Install new
components with the same component number or an equivalent component if installation is
necessary. Do not use an installation component of lesser quality or substitute design. Torque
values must be used as specified during reassembly to make sure of correct retention of these
components.
3. Release the parking brake cable tension. For additional information, refer to Section 206-05 .
4. Disconnect the parking brake cables.
5. Disconnect the wheel speed sensor harness retainers from the axle.
NOTE: If the vent hose is disconnected from the vehicle body, a new retainer must be installed.
6. Disconnect the vent hose and remove the axle vent.

7. Remove the RH parking brake cable bracket bolt.

8. Remove the brake tube/parking brake cable bracket bolt.

9. Disconnect the brake tube from the brake tube retaining clip.
10. Remove the 2 brake hose bracket bolts.

11. Support the axle with a suitable transmission jack.
12.
absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this
Remove and discard the 2 lower shock absorber nuts and 2 bolts.
z To install, tighten the new nuts to 90 Nm (66 lb-ft).
13. NOTICE: Final tightening of the U-bolt nuts must be done with the suspension at curb height
or incorrect clamp load may occur.
Remove and discard the 8 U-bolt nuts and the 4 U-bolts.

z To install, with the suspension at curb height, tighten the new nuts evenly in a cross-type
pattern in 4 stages.
Stage 1: Tighten to 35 Nm (26 lb-ft).
Stage 4: Tighten to 133Nm (98 lb-ft).
14.
service jack. Avoid obstructions while lowering and raising the jack. Improperly secured
assemblies or contact with obstructions may cause the assembly to fall off the jack, which
could result in serious personal injury.
Lower and remove the axle assembly.
15. To install the original assembly, reverse the removal procedure.
16. Check the rear axle fluid level after installation.
Differential Carrier
Special Tool(s)
Shim Driver
205-220 (T85L-4067-AH)
Part
1 — Differential bearing cap bolts (part of 4010) (4
required)
3 4067 Differential carrier bearing shims (2 required)
Removal
Remove the 4 differential bearing cap bolts and the 2 differential bearing caps.
3. NOTICE: Place a wood block between the pry bar and the axle housing to protect the
machined surface from damage.
NOTE: Index-mark the position of the differential bearing shims. The differential bearing shims must
be installed in their original locations and positions.
Using pry bars and wood blocks, remove the differential carrier assembly from the axle housing.
Installation
1. Position the differential assembly in the axle housing.
2. Install the originally removed differential bearing shim on the LH side.
3. NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.
Install the LH differential bearing cap and loosely install the 2 differential bearing cap bolts.
4. Install the original differential bearing shim on the RH side.
5. Using the Shim Driver, fully seat the differential bearing shims.
6. Install the RH side differential bearing cap and tighten the 4 LH side and RH side differential bearing
cap bolts.
7. Rotate the differential assembly to make sure it rotates freely.
8. Adjust the ring and pinion backlash. For additional information, refer to Ring Gear Backlash
SECTION 205-02B: Rear Drive Axle/Differential — Ford 9.75-Inch Ring Gear 2014 F-150 Workshop Manual
Material
Additive Friction EST-M2C118- 118 ml (4 oz) to be
Modifier A installed before axle
XL-3 (US); CXL-3 lubricant — Not to be
(Canada) used with Electronic
Locking Differentials
(ELD)
Maximum — —
Strength Retaining
Compound
Loctite® 638™
Motorcraft® High — —
Contrast Hypoid
Gear Marking
Compound
XG-14
Motorcraft® SAE WSL-M2C192- 2.84L (6.0 pt) — ELD
75W-140 A and GL-5 only
Synthetic Rear 2.60L (5.5 pt) — Non
Axle Lubricant Traction-Lok equipped
XY-75W140-QL 2.48L (5.25 pt) —
(US); CXY- Traction-Lok equipped
75W140-1L
(Canada)
Premium Long- ESA-M1C75-B —
Life Grease
XG-1-C or XG-1-K
(US); CXG-1-C
(Canada)
Silicone Gasket WSE-M4G323- —
and Sealant A4
TA-30
Threadlock and WSK-M2G351- —
Sealer A5
TA-25
Rear Axle Backlash Shim Adjustment Table

mm In mm In
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006

0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Item Specification
Available drive pinion shims in steps of 0.25 mm (0.010 in) 0.254 mm (0.010 in) —
0.965 mm (0.038 in)

Electronic Locking Differential (ELD) side gear backlash 0.100-1.000 mm (0.004-0.040 in)
Maximum differential case flange ring gear runout 0.076 mm (0.003 in)
Maximum variation between ring gear teeth 0.102 mm (0.004 in)
Pinion bearing preload 1.8-3.3 Nm (16-29 lb-in)
Ring gear backlash 0.203-0.304 mm (0.008-0.012 in)
Maximum axle shaft flange runout 0.279 mm (0.011 in)
Axle vent 18 — 159
Brake hose bracket bolts 30 22 —
Brake tube/parking brake cable bracket bolt 25 18 —
RH parking brake cable bracket bolt 30 22 —
Differential bearing cap bolts 105 77 —
Differential housing cover bolts 45 33 —
Differential pinion shaft lock bolt 30 22 —
a — — —
Differential ring gear bolts
Driveshaft flange bolts 103 76 —
Electronic Locking Differential (ELD) coil screws 5 — 44
ELD electrical connector bolt 7 — 62
Fill plug 30 22 —
Handle Adapter 2.2 — 20
Lower shock absorber nuts 90 66 —
Tool 205-135 nut 7 — 62
U-bolt nut a — — —
Wheel speed sensor bolts 15 — 133
The rear axle assembly consists of the following:
z Integral-type housing hypoid gear design (center of the pinion set below the centerline of the ring
gear)
z Hypoid differential ring gear and pinion consisting of a 9.75-inch ring gear and an overhung drive
pinion that is supported by 2 opposed tapered roller bearings
z Pinion bearing preload that is maintained by a drive pinion collapsible spacer on the differential pinion
shaft and adjusted by the pinion nut
z Cast center section with 2 steel tube assemblies and a stamped differential housing cover
z Differential housing cover using silicone sealant as a gasket
z Differential pinion shaft that is retained by a threaded differential pinion shaft lock bolt attached to the
differential case
z Differential case that is mounted in the rear axle housing between 2 opposing differential bearings
that are retained in the rear axle housing by 2 removable bearing caps
z Differential bearing preload and ring gear backlash which are adjusted by differential bearing shims
that are located between the differential bearing cups and the rear axle housing
The rear drive axle receives rotational torque from the driveshaft. The direction of the rotation determines
movement of the vehicle. The rotation enters the rear drive axle through the drive pinion flange, turning the
drive pinion and rotating the ring gear. The ring gear is bolted to the differential case. The differential case
houses the pinion shaft upon which the differential pinion gears ride. The pinion gears are in mesh with the
differential side gears to which the axle shafts are splined. It is the unique arrangement of the differential that
allows the axle shafts to be driven at different speed when needed, such as when driving around corners. A
Traction-Lok differential is available that introduces a series of clutch plates and discs behind the differential
side gears to deliver as much torque as possible to each axle shaft when the traction at the rear wheels is
not equal. The Traction-Lok differential requires a friction modifier that must be installed with the axle
lubricant for the plates and discs to be functional. An Electronic Locking Differential (ELD) is also available
which electronically locks the differential side gears to the differential case which will allow maximum torque
to both rear wheels. The operator controls the differential with a dash mounted switch.
The ELD system consists of the following components:
z ELD coil, located at the rear differential

z Rear differential
z Mode Select Switch (MSS) (unique for ELD equipped vehicles), located on instrument panel
The ELD system, which is optional on Electronic Shift-On-The-Fly (ESOF) equipped vehicles, allows the
operator to lock the rear differential side gears when in 4H or 4L mode. ELD operation is requested by
pulling out on the MSS when in 4H or 4L mode.
The operator can switch between 4H mode without ELD or 4H mode with ELD at speeds up to 30 km/h (19
mph). In 4H, the ELD will disengage at speeds above 40 km/h (25 mph) and will automatically reengage at
speeds below 30 km/h (19 mph).
To engage or disengage the ELD while in 4L range, the vehicle speed must be less than 90 km/h (56 mph).
Ring Gear Backlash Adjustment
Special Tool(s)
Fixture
100-002 (TOOL-4201-C)
Installer, Differential Shim

205-220 (T85L-4067-AH)
Material
Item Specification
XG-14
1. Remove the differential housing cover. For additional information, refer to Differential Housing Cover
in this section.
2. Install the Dial Indicator Gauge with Holding Fixture and measure the ring gear backlash.
z If a zero backlash condition occurs or the backlash is not within specification, proceed to Step
3.
z If the backlash is within specification, proceed to Step 14.
Remove the 4 bearing cap bolts and 2 caps.
5. If a zero backlash condition had occurred, add 0.50 mm (0.020 in) to the RH side shim and subtract
0.50 mm (0.020 in) from the LH side shim to allow a backlash indication. Install the 2 bearing caps
and 4 bolts.
z Go back to Step 2.

mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart 4067

Dimension A
Stripes and Color Code mm Inch
2 — C-COAL 7.7978-7.8105 0.3070-0.3075

1 — C-COAL 7.7470-7.7597 0.3050-0.3055
5 — BLU 7.6962-7.7089 0.3030-0.3035
4 — BLU 7.6454-7.6581 0.3010-0.3015
3 — BLU 7.5946-7.6073 0.2990-0.2995
2 — BLU 7.5458-7.5565 0.2970-0.2975
5 — PINK 7.4422-7.4549 0.2930-0.2935
4 — PINK 7.3914-7.4041 0.2910-0.2915
3 — PINK 7.3406-7.3533 0.2890-0.2895
2 — PINK 7.2898-7.3025 0.2870-0.2875
1 — PINK 7.2390-7.2517 0.2850-0.2855
5 — GRN 7.1882-7.2009 0.2830-0.2835
4 — GRN 7.1374-7.1501 0.2810-0.2815
3 — GRN 7.0866-7.0993 0.2790-0.2795
2 — GRN 7.0358-7.0485 0.2770-0.2775
1 — GRN 6.9850-7.0485 0.2750-0.2755
5 — WH 6.9342-6.9469 0.2730-0.2735
4 — WH 6.8834-6.8961 0.2710-0.2715
3 — WH 6.8326-6.8453 0.2690-0.2695
2 — WH 6.7818-6.7945 0.2670-0.2675
1 — WH 6.7310-6.7437 0.2650-0.2655
5 — YEL 6.6802-6.6929 0.2630-0.2635
4 — YEL 6.6294-6.6421 0.2610-0.2615
3 — YEL 6.5786-6.5913 0.2590-0.2595
2 — YEL 6.5278-6.5405 0.2570-0.2575
1 — YEL 6.4770-6.4897 0.2550-0.2555
5 — ORNG 6.4262-6.4389 0.2530-0.2535
4 — ORNG 6.3754-6.3881 0.2510-0.2515
3 — ORNG 6.3246-6.3373 0.2490-0.2495
2 — ORNG 6.2738-6.2865 0.2470-0.2475
1 — ORNG 6.2223-6.2357 0.2450-0.2455
2 — RED 6.1722-6.1849 0.2430-0.2435
1 — RED 6.1214-6.1341 0.2410-0.2415

z If backlash is now within specification, proceed to Step 9.
z If backlash is not within specification, go back to Step 4.
9. Remove the 4 bearing cap bolts and 2 bearing caps.
10. To establish differential bearing preload, increase both LH and RH differential bearing shim size by
the thickness shown.
11. Using the Differential Shim Installer, fully seat the differential bearing shims. Make sure the assembly
rotates freely.

13. Using the Dial Indicator Gauge with Holding Fixture, do a final check of the ring gear backlash.
15. Verify an acceptable pattern check. For additional information, refer to Tooth Contact Pattern Check
in Section 205-00 .
17. Install the differential housing cover. For additional information, refer to Differential Housing Cover in
this section.
Differential Case and Ring Gear — Conventional
Special Tool(s)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent

Fixture
100-002 (TOOL-4201-C)

Lock)
205-384 (T97T-4205-A)

Lock)
205-386 (T97T-4205-D)
Installer, Differential Carrier

Bearing
205-D044 (D81T-4221-A) or
equivalent
Step Plate
205-D061 (D80L-630-8) or
equivalent
Material
Item Specification
Maximum Strength Retaining —
Compound
Loctite® 638™
75W140-1L (Canada)

1 — Differential side gears (part of 4215)
2 4228 Differential side gear thrust washers
3 4214 Differential side gear wave washers
4 4215 Differential pinion gear
5 4230 Differential pinion thrust washer (also part of 4215)
6 4N237 Axle shaft U-washer
8 4241 Differential pinion shaft lock bolt (also part of 4215)
11 4216 Differential ring gear bolts (12 required)
12 4220 Differential bearings
13 — Differential bearing cups (part of 4220)
Disassembly
5. If necessary, remove the differential bearings with the 2 Jaw Puller and Step Plate.
6. Remove the differential pinion shaft lock bolt and the differential pinion shaft.
9. NOTE: Apply a small amount of grease to the centering hole of the Differential Gauge step plate.
10. Install the Differential Gauge nut in the upper differential side gear. Hold the nut in position while
installing the Differential Gauge hex screw. Tighten the hex-head screw until contact is made with the
Step Plate.
13. Remove the differential side gears, the differential side gear thrust washers and the differential side
gear wave washers.
Assembly
All vehicles
1. NOTE: Lubricate the differential side gear thrust washers, wave washers and the side gear journals
with axle lubricant.
Position the differential side gear thrust washers and wave washers on the differential side gears.
2. Position the differential side gears.
screw is tightened.

2. Position the Differential Gauge hex screw plate in the top differential side gear and hold it in
place.
3. Install the Differential Gauge hex screw and tighten it 2 turns after it contacts the bottom step
plate.
5. Engage the differential pinion gears opposite the differential side gears.
6. Rotate the differential pinion gears to align the differential pinion shaft bore.
7. Remove the Differential Gauges after verifying the differential pinion shaft bore alignment.
8. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.
9. If removed, use the Differential Carrier Bearing Installer to install the differential bearings.
Electronic Locking Differential (ELD) equipped vehicles and all vehicles equipped with 3.55, 3.73,
and 4.10 ratio gear sets
10. NOTE: The differential flange and ring gear flange must be free of any old retaining compound
material. Make sure both surfaces are clean and free of oil, dust and debris. Failure to clean the
surfaces can result in ring gear runout concerns.
Clean all traces of the old retaining compound material from the differential flange.
z Use solvent and Scotch-Brite® pads to remove.
11. Apply a one-eighth inch bead of maximum strength retaining compound on the rear face of the ring
gear in the pattern shown.
All vehicles
12. Install the ring gear.

1. Place the ring gear on the differential assembly.
2. Hand-start 3 new ring gear bolts to align the holes in the ring gear and the differential case.
3. Using a suitable press, position the ring gear.
4. Press the ring gear into place.
13. Hand-start the remaining 9 new differential ring gear bolts. Tighten the 12 bolts in 2 stages.
Differential Case and Ring Gear — Electronic Locking Differential (ELD)
Special Tool(s)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent

Fixture
100-002 (TOOL-4201-C)

Bearing
205-D044 (D81T-4221-A) or
equivalent
Puller, Bearing
205-D064 (D84L-1123-A)
Step Plate
205-D061 (D80L-630-8) or
equivalent
Material
Item Specification
Compound
Loctite® 638™
75W140-1L (Canada)

1 — Differential side gears (part of kit 4215)
2 — Differential side gear thrust washers (part of kit 4215)
3 — Differential pinion gears (part of kit 4215)
4 — Differential pinion thrust washers (part of kit 4215)
5 — Differential pinion spring (part of kit 4215)
11 4220 Differential bearing
12 — Cam-ring (part of kit 4880)
13 — Plunger (part of kit 4880)
14 — Coil (part of kit 4880)
15 — Coil bolt (part of kit 4880) (6 required)
16 — Stopper (part of kit 4880) (3 required)
Disassembly
3. Insert a punch in the differential ring gear bolt holes and drive the differential ring gear off.
4. Using the Bearing Puller plate, Step Plate and a suitable press, remove the LH differential bearing.
5. Using the 2 Jaw Puller and Step Plate, remove the RH differential bearing.
6. Remove and discard the 6 screws and 3 stoppers that hold the Electronic Locking Differential (ELD)
coil in place and remove the coil.
7. Remove the plunger assembly.
8. Remove the differential pinion shaft lock bolt and the differential pinion shaft.
10. Remove the differential side gears, the differential side gear thrust washers and spring.
11. Remove the cam-ring.
Assembly
All vehicles
1. Install the cam-ring.
2. NOTE: Start by using the thickest thrust washers. If the gears do not assemble using the thickest
thrust washers, back down in thickness until the gears will assemble.
Position the 2 LH differential side gear thrust washers and spring on the lower differential side gear
and install the gear.
z Lubricate the differential side gear thrust washers and the differential side gear journals with
axle lubricant.
3. NOTE: Start by using the thickest thrust washer. If the gears do not assemble using the thickest
thrust washers, back down in thickness until the gears will assemble.
Position the differential side gear thickest thrust washer on the RH differential side gear and install the
gear.
z Lubricate the differential side gear thrust washers and the differential side gear journals with
axle lubricant.
4. Assemble the differential pinion gear thrust washers and the differential pinion gears.
z Lubricate the washers and gears with rear axle lubricant.
5. Engage the differential pinion gears opposite the differential side gears.
6. Rotate the differential pinion gears to align the differential pinion shaft bore.
7. Insert the differential pinion shaft, and install a new differential pinion shaft lock bolt finger-tight.
8. Install the Dial Indicator Gauge With Holding Fixture.

z While pulling up on the RH differential gear, measure the backlash of the LH differential gear.
z Backlash should be 0.001-1.000 mm (0.004-0.040 in).
z If backlash is incorrect, install a thicker LH thrust washer to reduce backlash, or a thinner
washer to increase backlash.
Part Number Thickness (mm) Thickness (in) Quantity

Part of kit 4880 1.4 0.05 2
Part of kit 4880 1.6 0.06 2
Part of kit 4880 1.8 0.07 2
9. Turn the differential over and reposition the Dial Indicator Gauge With Holding Fixture.
z While pulling up on the LH differential gear, measure the backlash of the RH differential gear.
z Backlash should be 0.001-1.000 mm (0.004-0.040 in).
z If backlash is incorrect, install a thicker RH thrust washer to reduce backlash, or a thinner
washer to increase backlash.
Part Number Thickness (mm) Thickness (in) Quantity

Part of kit 4880 1.1 0.04 1
Part of kit 4880 1.3 0.05 1
Part of kit 4880 1.5 0.06 1
10. Tighten the differential pinion shaft lock bolt to 30 Nm (22 lb-ft).
11. Install the plunger assembly.
12. Install the ELD coil, 3 new stoppers and 6 new screws that hold the coil in place.
13. Use the Differential Carrier Bearing Installer to install the 2 differential bearings.
All vehicles
16. Install the ring gear and the 12 new differential ring gear bolts. Tighten in 2 stages.
17. NOTE: Install the differential with the tabs on the ELD coil up against the differential bearing cap
mounting surface.
Install the differential carrier in the axle housing. For additional information, refer to Differential Carrier
in this section.
Differential Case and Ring Gear — Traction-Lok
Special Tool(s)
15-101 Gauge, Differential Clutch
(Excluding Mandrel)
205-135 (T80P-4946-A)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent

Fixture
100-002 (TOOL-4201-C)

Lock)
205-384 (T97T-4205-A)
Gauge, Differential (Traction

Lock)
205-386 (T97T-4205-D)

Lock) (Mandrel for 205-135
[T80P-4946-A])
205-389 (T97T-4946-A)

Bearing
205-D044 (D81T-4221-A) or
equivalent
Rotator, Differential
205-378 (T97T-4205-C)
Step Plate
205-D061 (D80L-630-8) or
equivalent
Material
Item Specification
Compound
Loctite® 638™
75W140-1L (Canada)
1-C (Canada)
TA-25
Traction-Lok Differential Assembly

2 4241 Differential pinion shaft lock bolt (part of 4215)
3 — Differential side gear (part of 4215)
4 — Retainer clip (part of 4947)
5 4230 Differential pinion thrust washer (part of 4215)
6 — Differential pinion gear (part of 4215)
7 — Plate preload spacer (part of 4947)
8 — Clutch disc (part of 4947)
9 — Clutch plate (part of 4947)
Disassembly
Insert a punch in the differential ring gear bolt holes. Drive off the differential ring gear.
5. NOTE: The differential bearings need not be removed to overhaul the Ford limited slip differential.
If necessary, use the 2 Jaw Puller and Step Plate to remove the differential bearings.
Install the Differential Gauge in the bottom differential side gear.
9. Install the nut in the upper differential side gear. Hold the nut in position while installing the hex screw.
Tighten the hex-head screw until contact is made with the Step Plate.
11. NOTE: Differential pinion gear thrust washers cannot be removed independently of the differential
pinion gears.
Insert the Differential Rotator in the pinion shaft bore, and turn the differential case to "walk" the
differential pinion gears and differential pinion gear thrust washers out to the differential case
windows.
12. Remove the differential pinion gears and differential pinion gear thrust washers.
13. Remove the differential side gears and differential clutch packs with the selective shim and Belleville
spring, tag them RH and LH.
14. NOTE: When separating the clutch plates and clutch discs, note the sequence in which they are
disassembled. They must be reassembled in the same sequence.
NOTE: Do not use acids or solvents when cleaning the differential clutch pack. Wipe components
with a clean, lint-free cloth only.
Separate the differential clutch discs and clutch plates for cleaning and inspection.
Assembly
All vehicles
1. Lubricate each steel clutch plate and soak all friction plates with friction modifier for at least 15
minutes.
2. NOTE: Do not mix the differential clutch packs or selective shims from one side with the other.
NOTE: The Belleville spring is a dished plate.
Assemble the differential clutch packs (without the selective shims and Belleville springs) on their
respective differential side gears.
3. Clamp the bolt head of the Differential Gauge in a vise. Install the differential clutch pack and the
differential side gear (without the selective shim or the Belleville spring) on the Differential Gauge.
4. Position the Differential Clutch Gauge on top of the differential clutch pack.
5. Install the Differential Gauge over the disc and differential clutch pack.
6. Install the nut over the top and base stud.

7. NOTE: Selective shims shown are available as part of the Clutch Pack Replacement Kit.
Use the feeler gauge and select the thickest blade that will enter between the tool and the differential
clutch pack. Subtract 0.0075" from the reading, Then select the closest thinner thickness selective
shim, that will be the new selective shim that should be used.
8. Place the selective shim and Belleville spring on the differential clutch pack.
z The dished or concave side of the Belleville spring must face up against the thrust face of the
differential case.
9. Install the differential side gears with the differential clutch packs, selective shims and Belleville spring
into the differential case.
z Hold the differential side gear assembly in place to prevent it from falling out of the differential
case.
screw is tightened.

1. Position the Differential Gauge in the bottom differential side gear.
2. Position the Differential Gauge in the top differential side gear and hold it in place.
3. Install the Differential Gauge and tighten it 2 turns after it contacts the bottom step plate.
12. NOTE: It will probably be necessary to loosen or tighten the forcing screw to allow the differential
pinion gears and differential side gears to rotate.
Insert the Differential Rotator into the pinion shaft bore, and turn the differential case. This will cause
the differential pinion gears to engage the differential side gears and "walk" into the differential case.
Rotate the differential case until the pinion shaft mating holes are lined up exactly with the holes in
the differential pinion gears.
13. Remove the Differential Gauge.
14. Install the 2 new differential bearings using the Differential Carrier Bearing Installer.
15. Check the torque required to rotate one differential side gear.
z Install the Differential Gauge with the 1/2-inch drive hole as shown.
z The initial break-away torque, if original clutch plates are used, must be at least the minimum
specification. The rotating torque required to keep the differential side gear turning with new
clutch plates may vary.
All vehicles
18. Using a suitable press, install the differential ring gear.
19. Install the new 12 differential ring gear bolts.

Axle Shaft
Material
Item Specification
(Canada)
TA-25 A5

3 4241 Differential pinion shaft locking bolt
5 4N237 Axle shaft C-washer
6 4234 Axle shaft
Removal
02 .
2. Remove the differential housing cover. For additional information, refer to Differential Housing Cover .
4. Remove the bolt and position aside the wheel speed sensor.

1. Remove and discard the differential pinion shaft lock bolt.
6. Remove the U-washer.

1. Push in on the axle shaft.
2. Remove the U-washer.
7. Remove the axle shaft.
Installation
1. Lubricate the lip of the axle shaft oil seal with grease.
2. Install the axle shaft.
3. NOTE: Do not damage the rubber O-rings in the U-washer grooves.
Install the U-washer.

1. Position the U-washer on the button end of the axle shaft.
2. Pull the axle shaft outward.
4. NOTE: If a new differential pinion shaft lock bolt is unavailable coat the threads of the original
differential pinion shaft lock bolt with threadlock prior to installation.
Install the differential pinion shaft.

1. Align the hole in the differential pinion shaft with the differential case lock bolt hole.
2. Install a new differential pinion shaft lock bolt.
5. Install the wheel speed sensor and the bolt.

6. Install the rear brake disc. For additional information, refer to Section 206-04 .
7. Install the differential housing cover. For additional information, refer to Differential Housing Cover .
Special Tool(s)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent

205-111 (T76P-4020-A11)

205-159 (T80T-4020-F42)

205-160 (T80T-4020-F43)
Depth Gauge/Aligner, Drive

Pinion
205-226 (T85T-4020-AH1)

Pinion
205-383 (T97T-4020-B)
Gauge Tube, Drive Pinion

205-377 (T97T-4020-A)

Bearing
205-D044 (D81T-4221-A) or
equivalent

Cone
205-488

Cup
205-024 (T67P-4616-A)
Installer, Input Shaft Bearing Cup

308-391
Installer, Rear Axle Pinion Bearing

Cup
205-852
Plate, Bearing/Oil Seal

205-090 (T75L-1165-B)

205-229 (T85T-4209-AH)
Puller, Bearing
205-D064 (D84L-1123-A)
Step Plate
205-D061 (D83T-4205-C2) or
equivalent
Material
Item Specification
Motorcraft® Premium Long-Life ESA-M1C75-
Grease B
XG-1-C (US); CXG-1-C (Canada)
Part
4 4670 Pinion oil slinger
8 4662 Collapsible spacer

10 4663 Pinion bearing adjustment shim
13 4220 Differential carrier bearings (2 required)
14 — Differential carrier bearing cups (Part of 4220) (2
required)
16 — Differential bearing cap (part of 4010) (2 required)
required)
Removal
All vehicles
1. Remove the drive pinion seal. Refer to Drive Pinion Flange and Drive Pinion Seal in this section.
2. Remove the differential carrier assembly. Refer to Differential Carrier in this section.
3. Remove the drive pinion shaft oil slinger.
4. Install the Drive Pinion Thread Protector, then use a soft-faced hammer to drive the pinion gear out of
the outer drive pinion bearing and remove the pinion gear.
6. Using a brass drift, remove the 2 drive pinion bearing cups by tapping alternately on opposite sides of
the 2 drive pinion bearing cups.
Electronic Locking Differential (ELD) equipped vehicles
Non- ELD equipped vehicles
9. Remove the 2 differential bearings with the 2 Jaw Puller and Step Plate.
Installation
1. Place the Rear Axle Pinion Bearing Cup Installer on the outer drive pinion bearing cup.
2. Place the Rear Axle Pinion Bearing Cup Installer on the inner drive pinion bearing cup.
2. Tighten the Drive Pinion Bearing Cup Installer to fully seat the 2 differential drive pinion bearing cups.
4. NOTICE: Use the same drive pinion bearings and the drive pinion bearing adjustment shim
from the drive pinion bearing adjustment shim selection procedure for final assembly or
damage to the component may occur.
NOTE: Install new drive pinion bearings without any additional lubricant since the anti-rust oil
Install the new drive pinion bearings and Adapters as shown.

2 205-160 Adapter for 205-S127
4 205-383 Depth Gauge/Aligner, Drive Pinion
5 205-159 Adapter for 205-S127
6 205-377 Drive Pinion Gauge Tube

8 4010 Rear axle housing outer (front) pinion bearing
9 205-111 Adapter for 205-S127

z Tighten to 2.2 Nm (20 lb-in).
Rotate the Adapter several half-turns to make sure of correct seating of the drive pinion bearings.
7. Install the Drive Pinion Gauge Tube.

1. Position the Drive Pinion Gauge Tube.
attempt to force the drive pinion bearing adjustment shim between the gauge block and the gauge
tube. This will minimize selection of a drive pinion bearing adjustment shim thicker than required,
which results in a deep tooth contact in the final assembly of integral axle assemblies.
selection.
the Adapters.
9. Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Cone Installer, press the drive pinion
bearing and selected drive pinion bearing adjustment shim until they are firmly seated on the pinion
gear.
10. Place a new drive pinion collapsible spacer on the pinion gear against the pinion gear shoulder.
11. Install the outer drive pinion bearing and drive pinion shaft oil slinger.
12. Lubricate the pinion flange splines with grease.
13. Install the pinion gear in the pinion gear bore from inside the axle housing.
14. Using the Differential Carrier Bearing Installer, press the LH and RH differential bearing on the
differential assembly.
15. Install the differential carrier. Refer to Differential Carrier in this section.
16. Install the drive pinion seal and flange. Refer to Drive Pinion Flange and Drive Pinion Seal in this
section.
Differential Housing Cover
Material
Item Specification
75W140-1L (Canada)
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
02 .
2. Separate the 3 brake tube fasteners from the differential housing cover stud bolts.

1. Remove the 9 differential housing cover bolts and the 3 differential housing cover stud bolts,
and drain the lubricant from the axle housing.
Installation
1. NOTE: Remove all of the silicone gasket and make sure the surfaces are free of oil before applying
the new silicone gasket.
Clean the gasket mating surface of the axle and the differential housing cover.
2. Apply a new, continuous bead of sealant to the differential housing cover as shown.
3. NOTE: The differential housing cover must be installed within 15 minutes of application of the
silicone, or new sealant must be applied. If possible, allow one hour before filling with lubricant to
make sure the silicone sealant has correctly cured.
Install the differential housing cover and the 9 differential housing cover bolts and the 3 differential
housing cover stud bolts.
4. Remove the fill plug.
5. NOTE: If equipped with Traction-Lok axles, first fill the axle with 118 ml (4 oz) of friction modifier. No
friction modifier is used on Electronic Locking Differential (ELD) axles.
Fill the axle with the specified amount of axle lubricant and install the fill plug.
Special Tool(s)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent

205-111 (T76P-4020-A11)

205-159 (T80T-4020-F42)

205-160 (T80T-4020-F43)

Pinion
205-937 (TKIT-2009C-F)

Pinion
205-383 (T97T-4020-B)

205-377 (T97T-4020-A)

Bearing
205-D044 (D81T-4221-A) or
equivalent

Cone
205-488

Cup
205-024 (T67P-4616-A)
Installer, Input Shaft Bearing Cup

308-391
Installer, Rear Axle Pinion Bearing

Cup
205-852
Plate, Bearing/Oil Seal

205-090 (T75L-1165-B)

205-229 (T85T-4209-AH)
Puller, Bearing
205-D064 (D84L-1123-A)
Step Plate
205-D061 (D83T-4205-C2) or
equivalent
Material
Item Specification
Compound
Loctite® 638™
Motorcraft® Premium Long-Life ESA-M1C75-
Grease B
XG-1-C (US); CXG-1-C (Canada)
Part
4 4670 Pinion oil slinger

10 4663 Pinion bearing adjustment shim
11 4209 Drive pinion and ring gear
14 4220 Differential carrier bearings (2 required)
15 — Differential carrier bearing cups (part of 4220)
17 — Differential bearing cap (part of 4010) (2 required)
required)
Removal
All vehicles
1. Remove the drive pinion flange seal. For additional information, refer to Drive Pinion Flange and
2. Remove the differential carrier assembly. For additional information, refer to Differential Carrier in this
section.
3. Remove and discard the 12 ring gear bolts.
4. NOTE: Do not damage the ring gear bolt hole threads.
Insert a punch in the ring gear bolt holes and drive the differential ring gear off.
Non- ELD equipped vehicles
7. Remove the 2 differential bearings with the 2 Jaw Puller and Step Plate.
All Vehicles
8. Remove the drive pinion shaft oil slinger.
9. Install the Drive Pinion Thread Protector, then use a soft-faced hammer to drive the pinion gear out of
the outer drive pinion bearing and remove the pinion gear.
11. Using a brass drift, remove the 2 drive pinion bearing cups by tapping alternately on opposite sides of
the 2 drive pinion bearing cups.
Installation
All vehicles
1. Place the Rear Axle Pinion Bearing Cup Installer on the outer drive pinion bearing cup.
2. Place the Rear Axle Pinion Bearing Cup Installer on the inner drive pinion bearing cup.
2. Tighten the Drive Pinion Bearing Cup Installer to fully seat the 2 differential drive pinion bearing cups.
Install the new drive pinion bearings and Adapters as shown.

2 205-160 Adapter for 205-S127
5 205-159 Adapter for 205-S127
6 205-377 Drive Pinion Gauge Tube
8 4010 Rear axle housing outer (front) pinion bearing
9 205-111 Adapter for 205-S127
5. Tighten the Adapter to the specified rotational torque.

Rotate the Adapter several half-turns to make sure of correct seating of the drive pinion bearings.

which results in a deep tooth contact in the final assembly of integral axle assemblies.
selection.
the Adapters.
9. Using the Bearing/Oil Seal Plate and Drive Pinion Bearing Cone Installer, press the drive pinion
bearing and selected drive pinion bearing adjustment shim until they are firmly seated on the pinion
gear.
10. Place a new drive pinion collapsible spacer on the pinion gear against the pinion gear shoulder.
11. Install the outer drive pinion bearing and drive pinion shaft oil slinger.
12. Lubricate the pinion flange splines with grease.
13. Install the pinion gear in the pinion gear bore from inside the axle housing.
15. Using the Differential Carrier Bearing Installer, press the LH and RH differential bearing on the
All vehicles
18. NOTE: If removed, press the speed sensor ring on with the differential ring gear.
Install the differential ring gear.

1. Place the differential ring gear on the differential assembly.
2. Hand-start 3 new ring gear bolts to align the holes in the differential ring gear and the
3. Place the differential assembly and differential ring gear onto the press bed blocks with the
differential ring gear teeth facing downward.
4. Press the differential ring gear into place.
19. Install the remaining 9 new differential ring gear bolts.

Drive Pinion Flange and Drive Pinion Seal
Special Tool(s)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent

Flange
205-126 (T78P-4851-A)

205-233 (T85T-4851-AH)

205-208 (T83T-4676-A)
Material
Item Specification
75W140-1L (Canada)
Motorcraft® Premium Long-Life ESA-M1C75-B
Grease
1-C (Canada)

4 4010 Differential housing
Removal
color new drive pinion nut for installation. If a new collapsible spacer must be installed for pinion
bearing preload reduction, install the nut supplied with the new spacer or damage to the component
may occur.
02 .
3. Index-mark the driveshaft flange and pinion flange for correct alignment during installation.
4. Remove the 4 driveshaft flange bolts.
5. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. Never hammer on
the driveshaft or any of its components to disconnect the driveshaft centering socket yoke from the
pinion flange. Pry only in the area shown with a suitable tool to disconnect the driveshaft centering
socket yoke from the pinion flange.
Using a suitable tool as shown, disconnect the driveshaft centering socket yoke from the pinion
flange.
z Using mechanic's wire, position the driveshaft aside.
6. Using a Nm (lb-in) torque wrench on the pinion nut, record the torque required to maintain rotation of
the pinion gear through several revolutions.
7. Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove and discard the
pinion nut.
8. Index-mark the pinion flange in relation to the drive pinion stem to make sure of correct alignment
during installation.
10. Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer
until the drive pinion seal is removed.
Installation
1. Lubricate the new drive pinion seal with grease.
2. Using the Drive Pinion Oil Seal Installer, install a new drive pinion seal.
3. Lubricate the pinion flange splines with axle lubricant.
4. NOTE: Disregard the scribe marks if a new pinion flange is being installed.
Align the pinion flange with the drive pinion shaft.
collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit, as
indicated in the chart below, or damage to the component may occur.
Position the new pinion nut.
9.75 Inch Drive Pinion Nut

Part Number Color Description Application
19G405 Green Axles built before 7/16/07
4320 White Axles built after 7/16/07
4C121 White Kit with spacer for all 9.75-in axles
7. NOTICE: Under no circumstances is the pinion nut to be backed off to reduce drive pinion
bearing preload. If reduced drive pinion bearing preload is required, a new drive pinion
collapsible spacer and pinion nut must be installed or damage to the component may occur.
NOTE: Remove the Drive Pinion Flange Holding Fixture while taking drive pinion bearing preload
readings with the Nm (lb-in) torque wrench.
Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the pinion nut.
z Rotate the drive pinion occasionally to make sure the drive pinion bearings are seating
correctly.
z Install a Nm (lb-in) torque wrench on the pinion nut.
z Rotating the drive pinion through several revolutions, take frequent drive pinion bearing
preload readings until the original recorded drive pinion bearing preload reading is obtained.
z If the original recorded drive pinion bearing preload is lower than specification, tighten to the
appropriate specification for used drive pinion bearings. If the drive pinion bearing preload is
higher than specification, tighten the pinion nut to the original reading as recorded. For
additional information, refer to the Specification portion of this section.
8. Position the driveshaft and align the index mark on the pinion flange.
9. NOTE: The driveshaft centering socket yoke fits tightly on the pinion flange pilot. To make sure that
the driveshaft centering socket yoke seats squarely on the pinion flange, tighten the driveshaft flange
bolts evenly in a cross pattern.
Install the 4 new driveshaft flange bolts.

Electronic Locking Differential (ELD) Field Coil
Special Tool(s)
Bearing
205-D044 9D81T-4221-A) or
equivalent
Puller, Bearing
205-D064 (D84L-1123-A)
Step Plate
205-D061 (D83T-4205-C2) or
equivalent
Part

1 — Differential side gears (part of kit 4880)
2 — Differential side gear thrust washers (part of kit 4880)
3 — Differential pinion gears (part of kit 4880)
4 — Differential pinion thrust washers (part of kit 4880)
5 — Differential pinion spring (part of kit 4880)
7 — Differential pinion shaft lock bolt (part of kit 4880)
11 4221 Differential bearing
12 — Cam-ring (part of kit 4880)
13 — Plunger (part of kit 4880)
14 — Electronic Locking Differential (ELD) coil (part of kit
4880)
15 — ELD coil screw (part of kit 4880) (6 required)
16 — Stopper (part of kit 4880) (3 required)
Removal
3. Remove and discard the 6 screws and 3 stoppers that hold the Electronic Locking Differential (ELD)
coil in place and remove the coil.
4. Remove and discard the plunger assembly.
Installation
1. Install a new plunger assembly.
2. Install the new ELD coil, 3 stoppers and 6 screws that hold the coil in place.
3. Use the Differential Carrier Bearing Installer to install the LH differential bearing.
Rear Wheel Bearing and Axle Shaft Seal
Special Tool(s)
Adapter For 303-224 (Handle)
205-153 (T80T-4000-W)
Installer, Axle Bearing

205-382 (T97T-1225-A)
Installer, Axle Oil Seal

205-381 (T97T-1177-A)
Remover, Axle Bearing

205-224 (T85T-1225-AH)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
75W140-1L (Canada)
1-C (Canada)

1 1177 Axle shaft oil seal
2 1225 Axle shaft bearing
Removal
1. Remove the axle shaft. For additional information, refer to Axle Shaft in this section.
2. NOTE: If only a new axle shaft oil seal needs to be installed, use care to avoid damaging the axle
shaft oil seal bore.
Using a suitable seal remover, remove and discard the axle shaft oil seal.
3. Inspect the rear wheel bearing and axle shaft for wear or damage.
4. Using the Axle Bearing Remover and Slide Hammer, remove the rear wheel bearing.
Installation
1. Lubricate the new rear wheel bearing with axle lubricant.
2. Using the Axle Bearing Installer and Handle, install the rear wheel bearing.
3. Lubricate the lip of the new axle shaft oil seal with grease.
4. Using the Axle Oil Seal Installer and Handle, install the new axle shaft oil seal.
5. Install the axle shaft. For additional information, refer to Axle Shaft in this section.
Axle Assembly

1 W705518 U-bolt nuts (8 required)
2 5798 U-bolt plates (2 required)
3 W520214 Lower shock absorber nuts (2 required)
4 W506545 Lower shock absorber bolts (2 required)
5 57632 Brake tube/ parking brake cable bracket bolt
6 4022 Axle vent
7 W712215 Brake hose bracket bolt (2 required)
All vehicles
NOTICE: Suspension fasteners are critical components because they affect performance of vital
components and systems and their failure can result in major service expense. Install new
components with the same component number or an equivalent component if installation is
necessary. Do not use an installation component of lesser quality or substitute design. Torque
values must be used as specified during reassembly to make sure of correct retention of these
components.
3. Release the parking brake cable tension. For additional information, refer to Section 206-05 .
4. Disconnect the parking brake cables.
5. Disconnect the wheel speed sensor harness retainers from the axle.
Vehicles with Electronic Locking Differential (ELD)
6. Disconnect the ELD electrical connector.
All vehicles
7. NOTE: If the vent hose is disconnected from the vehicle body, a new retainer must be installed.
Disconnect the vent hose and remove the axle vent.

8. Remove the RH parking brake cable bracket bolt.

9. Remove the brake tube/parking brake cable bracket bolt.

10. Disconnect the brake tube from the brake tube retaining clip.
11. Remove the 2 brake hose bracket bolts.

12. Support the axle with a suitable transmission jack.
13.
absorber and strut tube are gas pressurized and could explode if heated. Failure to follow this
Remove and discard the 2 lower shock absorber nuts and 2 bolts.
z To install, tighten the new nuts to 90 Nm (66 lb-ft).
14. NOTICE: Final tightening of the U-bolt nuts must be done with the suspension at curb height
or incorrect clamp load may occur.
Remove and discard the 8 U-bolt nuts and the 4 U-bolts.

z To install, with the suspension at curb height, tighten the new nuts evenly in a cross-type
pattern in 4 stages.
15.
Lower and remove the axle assembly.
16. To install the original assembly, reverse the removal procedure.
17. Check the rear axle fluid level after installation.
Special Tool(s)
Shim Driver
205-228 (T85T-4067-AH)
Part
required)
Removal
All vehicles
Remove the 4 differential bearing cap bolts and the 2 differential bearing caps.
3. Disconnect the Electronic Locking Differential (ELD) electrical connector and remove the bolt that
holds the connector adapter to the housing.
4. Pull the connector adapter out and disconnect the ELD coil electrical connector from the connector
adapter. Discard the adapter.
All vehicles
5. NOTICE: Place a wood block between the pry bar and the axle housing to protect the
machined surface from damage.
Using pry bars and wood blocks, remove the differential carrier assembly from the axle housing.
Installation
All vehicles
1. Position the differential assembly in the axle housing.
2. Install the original differential bearing shim on the LH side.
ELD equipped vehicles
3. Install the differential with the tabs on the ELD coil up against the differential bearing cap mounting
surface.
4. Push the ELD coil electrical connector through the differential case and connect the connector to the
new adapter.
5. Seat the connector adapter into the differential housing and install the bolt. Connect the electrical
connector.
All vehicles
6. NOTE: Apply pressure toward the LH side to make sure the LH differential bearing cap is seated.
Install the LH differential bearing cap and loosely install the 2 differential bearing cap bolts.
7. Install the original differential bearing shim on the RH side.
8. Using the Shim Driver, fully seat the differential bearing shims.
9. Install the RH side differential bearing cap and tighten the 2 LH side and 2 RH side differential
bearing cap bolts.
10. Rotate the differential assembly to make sure it rotates freely.
11. Adjust the ring and pinion backlash. For additional information, refer to Ring Gear Backlash
SECTION 205-03: Front Drive Axle/Differential 2014 F-150 Workshop Manual

Material
Capacity
Motorcraft® SAE 80W-90 WSP-M2C197- 1.66L
Premium Rear Axle Lubricant A (3.5 pt)
80W90-1L (Canada)
Additive Friction Modifier EST-M2C118-A 4.0 oz
Premium Long-Life Grease ESA-M1C75-B —
XG-1-C or XG-1-K (US); CXG-1-
C (Canada)
Silicone Gasket and Sealant WSE-M4G323- —
TA-30 A4
TA-25 A5
Item Specification
Backlash Specifications
Ring gear backlash 0.204-0.305 mm (0.008-0.012 in)
Ring gear maximum backlash between teeth 0.101mm (0.004 in)
Clearance Specifications
Differential case maximum runout 0.076 mm (0.003 in)
Housing spreader adapter thread 12.5 mm (0.500 in)
engagement
Maximum differential housing spread 0.762 mm (0.030 in)
Lubricant Fill Level Checks
Front axle
Lubricant level 9.56 mm (0.38 in) below bottom of differential housing fill
hole
Rotational Torque Ranges
Pinion bearing torque preload 1.8-3.3 Nm (16-29 lb-in)
Axle housing tube bolts 73 54
Axle housing tube bushing bolt 175 129
Crossmember bolts and nuts 90 66

Differential bearing cap bolts 105 77
Differential housing cover bolts 32 24
Differential pinion shaft lock bolt 30 22
Fill plug 25 18
Front axle housing bushing bolt 175 129
Rear axle housing bushing bolt 175 129
Ring gear bolts a — —
Lower steering column shaft-to-steering gear bolt 30 22

Front Drive Axle and Differential
The front drive axle consists of:
z a cast-aluminum center section, a removable cast-aluminum axle housing tube and a differential
housing cover. Both the axle housing tube and the differential housing cover use silicone sealant as a
gasket.
z a hypoid-design gearset of an 8.8-inch ring gear and a pinion gear. Two opposed tapered roller
bearings support the drive pinion in the axle housing.
z a drive pinion collapsible spacer, located on the pinion shaft, maintains pinion bearing preload. The
pinion nut adjusts the preload.
z differential bearing shims, located between the differential bearing cups and the axle housing, adjust
the differential bearing preload and the ring gear backlash.
z a differential case, a 1-piece design with 2 openings to allow for assembly of the internal components
and lubricant flow. Two opposed tapered roller bearings (differential bearings) support the differential
case in the axle housing. Removable differential bearing caps retain the differential assembly in the
axle housing.
z inside the differential case, the differential pinion shaft supports 2 differential pinion gears. The pinion
gear speed is synchronized by a differential clutch spring. The pinion gears engage the differential
side gears, to which the left axle shaft and the right axle shaft are splined. The differential pinion shaft
bolt retains the differential pinion shaft in the differential case.
z The bar code tag located on the differential cover contains the axle information.
The front drive axle receives input from the transfer case by way of the front driveshaft. Rotational torque is
transferred through the drive pinion to the ring gear, which in turn drives the differential case. Inside the
differential case are the pinion gears which rotate on the stationary pinion shaft and the side gears which are
splined to the axle shafts. The differential assembly is a gear arrangement that allows the drive wheels to be
driven at different speeds and divides the input torque of the pinion gear between the axle halfshafts. The
front axle transmits torque only and carries no vehicle load. CV joints located at each end of the halfshafts
allow the axle to remain stationary in relationship to front wheels, yet articulate at the knuckle. These CV
joints permit the wheels to be driven and turned at the same time. Lack of lubrication is among the most
common causes of CV joint concerns. It is essential that all CV boots and clamps be inspected for damage
or signs of leakage. Refer to Section 205-04 .
The Torsen® front differential case houses the parallel axis planetary helical side gears to which the axle
halfshafts are splined. It is the unique arrangement of the differential that allows the continuous,
uninterrupted torque output and allows the axle halfshafts to be driven at different speed when needed, such
as when driving around corners. There are no clutch plates or discs in this axle design. The Torsen®
differential requires 4.0 oz of friction modifier to be added with the axle lubricant. The axle shafts are
retained in this differential with the circlips.

Front Drive Axle

Differential Case Runout Check
Special Tool(s)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent

Fixture
100-002 (TOOL-4201-C)

205-010 (T57L-4221-A2)
Spreader, Differential Carrier

205-001 (TOOL-4000-E)
Step Plate
205-D061 (D83T-4205-C2)
2. NOTE: Use a drift punch to separate the ring gear from the differential case.
Remove and discard the 10 bolts. Remove the ring gear.
3. NOTE: Visually inspect the differential bearing cups and cones for discoloration indicating bearing
overheating or failure.
NOTE: It may be necessary to use the Differential Carrier Spreader to carry out this step.
Install the differential case with the bearing cups and all the shims in the housing.
1. Position the differential case with the bearing cups and shims in their original location.
2. Install the 2 bearing caps.
3. Install the 4 bolts.
4. Rotate the differential case to make sure the bearings have seated correctly.
4. Install the Dial Indicator Gauge with Holding Fixture.
5. Rotate the differential case and check the differential case runout using the Dial Indicator Gauge with
Holding Fixture.
z If the runout does not exceed the specification, install a new ring gear and pinion.
z If runout exceeds the specification, the ring gear is true and the condition is due to differential
case/differential bearing damage.
Inspect the differential bearings and the differential case. Always install new differential
bearings when installing a new differential case, or if a bearing condition is
questionable.
6. Remove the bearing caps and the differential case with the bearing cups and shims from the housing.
7. If necessary, using the 2 Jaw Puller and Step Plate, remove the differential bearings.
8. NOTICE: Press against the differential bearing inner cone only or damage to the component
may occur.
Install the new differential bearings.

1. Position the appropriate differential bearing (RH or LH).
2. Using a suitable press and the Differential Side Bearing Installer, install the differential bearing.
Repeat the steps for the other differential bearing.
9. NOTE: It may be necessary to use the Differential Carrier Spreader to carry out this step.
NOTE: Recheck the flange runout.
Install the differential case with the bearing cups and the shims in the housing.
1. Position the differential case with the bearing cups and shims in their original locations.
2. Install the 2 bearing caps.
4. Rotate the differential case to make sure the bearings have seated correctly.
11. NOTE: If the runout is still excessive, install a new differential case.
Using the Dial Indicator Gauge with Holding Fixture, check the runout with the new differential
bearings. If the runout does not exceed the specification, use the new differential bearings for
assembly.
12. Remove the 4 bolts.
13. Remove the differential case with the bearing cups and the shims from the housing.
1. Remove the 2 bearing caps.
2. Remove the differential case with the bearing cups and the shims from the housing.
14. Install the differential ring gear.

3. Place the differential carrier and differential ring gear onto the press bed blocks with the
15. Install the 10 new ring gear bolts.


Axle
Special Tool(s)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent

205-105 (T76P-4020-A3)

205-109 (T76P-4020-A9)

205-110 (T76P-4020-A10)

205-111 (T76P-4020-A11)

205-129 (T79P-4020-A18)
Adapter for Differential Housing

Spreader
205-368 (T96T-4000-A)

Fixture
100-002 (TOOL-4201-C)
Gauge, Clutch Housing

308-021 (T75L-4201-A)

205-336 (T93P-4020-A)

Flange
205-126 (T78P-4851-A)
Holding Fixture, Transmission

307-003 (T57L-500-B)

Bearings
205-D044 (D81T-4221-A) or
equivalent

205-010 (T57L-4221-A2)

Cone
205-005 (T53T-4621-C)

Cup
205-024 (T67P-4616-A)

205-002 (TOOL-4858-E)

205-208 (T83P-4676-A)

205-460
Remover, Bearing
205-055 (T71P-4621-B)
Remover, Bearing Cup

308-047 (T77F-1102-A)
Remover, Transmission Fluid

Pump
307-397
Slide Hammer
100-001 (T50T-100-A)

205-001 (TOOL-4000-E) or
equivalent
Spreader, Differential Housing

(Plate)
205-335 (T93P-4000-A) (RH)
Step Plate
205-D061 (D83T-4205-C2)
Material
Item Specification
XG-14
Motorcraft® SAE 80W-90 Premium WSP-M2C197-
Rear Axle Lubricant A
XY-80W90-QL (US); CXY-80W90-
1L (Canada)
(Canada)
Silicone Gasket and Sealant WSE-M4G323-
TA-30 A4
Front Axle Assembly — Disassembled View

1 3C202 Differential carrier assembly
2 4338 Axle housing vent
3 4B422 Circlips
4 3N136 Differential housing cover
6 3A380 Intermediate shaft
7 3B210 Axle housing tube
8 4B413 Axle shaft bearing assembly (outer)
9 4B416 Axle shaft dust seal
10 5638 Front axle support mounting bushings (3 required)
11 N808703 Axle housing tube bolt (4 required)
12 4121 Axle identification tag
13 373098 Fill plug
14 4369 O-ring
Disassembly
1. Remove the axle assembly. For additional information, refer to Axle Assembly in this section.
2. Remove the 10 bolts and the differential housing cover.

z Drain the fluid.
z Remove the bolts.
z Remove the differential housing cover.
3. NOTICE: The fixture mounting bolts must have the minimum specified thread engagement in
the carrier or damage to the component may occur.
Install the Transmission Holding Fixture.
4. Using the Transmission Fluid Pump Remover and Slide Hammer, remove the intermediate shaft.
5. Remove the 4 bolts and the axle housing tube.
6. NOTICE: The housing spreader adapter bolts must have the minimum specified thread
engagement in the carrier or damage to the component may occur.
Install the Differential Housing Spreader Plate and Adapter for Differential Housing Spreader.
7. Position the Differential Carrier Spreader on the spreader adapters.
8. Install the Dial Indicator Gauge with Holding Fixture and Clutch Holding Gauge.
z Position the adapter tip in the spreader adapter hole.
9. NOTICE: Overspreading may damage the axle housing.
Spread the axle housing to the specification.

1. Adjust the Dial Indicator Gauge to zero.
2. Tighten the housing spreader screw to spread the axle housing to the specification.
3. Remove the Dial Indicator Gauge with Holding Fixture.
10. NOTE: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before removing
them. Always install the bearing caps in their original place and position.
Mark and remove the 2 differential bearing caps.

1. Remove the bolts.
2. Remove the differential bearing caps.
11. NOTICE: Use wood blocks to avoid axle housing damage.
Remove the differential assembly from the axle housing.

1. Position the wood blocks.
2. Position and push down on the 2 pry bars.
3. Remove the differential assembly.
4. Remove the Differential Carrier Spreader.
12. Index-mark the axle U-joint flange to the pinion stem.
13. Install the Drive Pinion Flange Holding Fixture and loosen, but do not remove, the pinion nut.
14. With the pinion nut still engaged by a few threads, use the 2 Jaw Puller to separate the axle U-joint
flange from the pinion gear.
15. Remove the nut and the flange.
16. Using the Drive Pinion Thread Protector and a soft hammer, remove the pinion gear.
17. Discard the drive pinion collapsible spacer.
18. NOTICE: Do not damage the carrier housing while removing the pinion seal.
Remove the pinion seal and slinger.

z Pry up on the seal flange. Install gripping pliers, and strike with a hammer to remove the seal.
20. Using the Bearing Cup Remover and Slide Hammer, remove the inner pinion bearing cup.
21. NOTE: The pinion bearing oil baffle aids in bearing lubrication. Normally, it is not necessary to
remove the baffle.
If necessary, remove the pinion bearing oil baffle.
22. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from
cocking.
23. Using the Bearing Remover and a suitable press, remove the pinion bearing.
24. NOTE: A drive pinion bearing adjustment shim sits under the pinion bearing. Use a micrometer to
measure the shim thickness. Record the measurement for comparison to the shim gauge reading
taken prior to installing the pinion bearing.
Remove and measure the drive pinion bearing adjustment shim.
25. NOTE: Use a drift punch to separate the ring gear from the differential case.
Remove and discard the 10 bolts and remove the ring gear.
26. Using the 2 Jaw Puller and Step Plate, remove the differential bearings.
Assembly
1. NOTICE: Do not omit the pinion bearing oil baffle; bearing failure may result.
If removed, position the baffle on the Drive Carrier Bearings Installer.
2. Using the Drive Carrier Bearings Installer, install the baffle.
3. NOTE: Always install new pinion bearings when installing new pinion bearing cups.
Lightly oil the new pinion bearing cups and pinion bearings with front axle lubricant.
4. Using the Drive Pinion Bearing Cup Installer, install the bearing cups.
5. NOTE: The pinion bearings assembled in this procedure step must be used at final assembly.
Assemble and position the Adapters and the pinion bearings in the carrier housing.
1. Position the screw adapter.
2. Position the aligning adapter.
3. Position the pinion bearing.
4. Position the gauge disc adapter.
5. Position the gauge block adapter.
6. Position the pinion bearing.
7. Thread on the handle adapter.
6. NOTE: This step duplicates final pinion bearing preload.
Tighten the Adapter to simulate bearing preload.

7. NOTE: Offset the gauge block adapter to obtain an accurate reading.
Rotate the gauge block Adapter several half-turns to make sure the pinion bearings seat correctly and
position the gauge block adapter.

9. NOTE: Use only flat, clean drive pinion bearing adjustment shims.
NOTE: Do not attempt to force the shim between the gauge block adapter and the gauge tube
adapter. A slight drag indicates correct shim selection.
Use a drive pinion bearing adjustment shim as a gauge for shim selection.
z Check the adjustment shim thickness between the gauge block adapter and the gauge tube
adapter.
z After determining the correct shim thickness, remove the Drive Pinion Gauge Tube.
10. NOTE: The same pinion bearings from the previous steps must be used.
Install the pinion bearing.

z Place the drive pinion bearing adjustment shim on the pinion gear.
z Using a suitable press and the Drive Pinion Bearing Cone Installer, press the pinion bearing
until it is firmly seated on the pinion gear.
11. Place a new drive pinion collapsible spacer on the pinion stem.
12. Install the outer pinion bearing.
13. Install the slinger.
14. NOTE: Coat the lips of the pinion seal with front axle lubricant.
Place the pinion seal on the Drive Pinion Oil Seal Installer.
15. Place the Drive Pinion Oil Seal Installer and seal in the pinion seal bore and drive the seal into place.
16. Lightly lubricate the pinion gear splines with front axle lubricant.
17. Position the drive pinion in the housing.
18. NOTICE: Never install the drive pinion U-joint flange with a hammer or power tools.
NOTE: Disregard the scribe marks if installing a new flange.
Align the index marks and position the U-joint flange on the drive pinion.
19. Using the Drive Pinion Flange Installer, install the drive pinion U-joint flange.
20. Apply a small amount of lubricant to the washer side of the new pinion nut, and install the nut.
21. NOTICE: Do not loosen the pinion nut to reduce preload under any circumstance. If it is
necessary to reduce preload, install a new drive pinion collapsible spacer and pinion nut or
Install the Drive Pinion Flange Holding Fixture and tighten the pinion nut. Refer to the torque
specifications in the Specifications portion of this section.

z Rotate the pinion gear occasionally to make sure the pinion bearings are seating correctly.
Take frequent pinion bearing torque preload readings by rotating the pinion gear with a Nm (lb-
in) torque wrench.
22. Use a fine flat file to remove any burrs or nicks from the ring gear mounting surface.

2. Hand-start 3 ring gear bolts to align the holes in the differential ring gear and the differential
assembly.
differential gear teeth facing downward.
24. Install the remaining new bolts.

25. NOTE: Press against the bearing inner core only.
Using a suitable press and the Differential Side Bearing Installer, install the differential bearings.
1. Position the appropriate differential bearing (RH or LH).
2. Using a suitable press and the Differential Side Bearing Installer, install the differential bearing.
z Repeat the procedure for the other differential bearing.
26. Install the differential carrier.

1. Position the differential bearing cups on the differential bearings.
2. Lower the differential carrier in place.
27. Install a differential bearing shim of the thickness shown on the LH side of the differential bearing.
28. NOTE: Apply pressure to the left side to make sure the left bearing cup is seated.
Install the left bearing cap and loosely install the 2 bearing cap bolts.
29. Install progressively thicker differential bearing shims on the right side until the thickest differential
bearing shim can be inserted by hand.
30. Install the right bearing cap and 2 bolts.
31. Tighten the 4 differential bearing cap bolts.

32. Rotate the differential carrier to make sure it turns freely.
34. Using the Dial Indicator Gauge with Holding Fixture and the Clutch Housing Gauge, measure the ring
gear backlash at 4 places to obtain a consistent reading.
35. NOTE: If the backlash is not within the specifications, correct it by increasing the thickness of one
differential bearing shim and decreasing the thickness on the other differential bearing shim by the
same amount.
To increase the backlash, install a thicker differential bearing shim and a thinner differential bearing
shim as shown.
36. To decrease the backlash, install a thicker differential bearing shim and a thinner differential bearing
shim as shown.
37. Select the appropriate shim by the thickness or the stripe color.

mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart

Stripes/Color mm Inch
2 — C-COAL 7.7978-7.8105 0.3070-0.3075
1 — C-COAL
7.7470-7.7597 0.3050-0.3055
5 — BLU
4 — BLU 7.6962-7.7089 0.3030-0.3035
3 — BLU
7.6454-7.6581 0.3010-0.3015
2 — BLU
1 — BLU 7.5946-7.6073 0.2990-0.2995
5 — PINK
7.5458-7.5565 0.2970-0.2975
4 — PINK
3 — PINK 7.4930-7.5050 0.2950-0.2955
2 — PINK
7.4422-7.4549 0.2930-0.2935
1 — PINK
5 — GRN 7.3914-7.4041 0.2910-0.2915
4 — GRN
7.3406-7.3533 0.2890-0.2895
3 — GRN
2 — GRN 7.2898-7.3025 0.2870-0.2875
1 — GRN
7.2390-7.2517 0.2850-0.2855
5 — WH
4 — WH 7.1882-7.2009 0.2830-0.2835
3 — WH
7.1374-7.1501 0.2810-0.2815
2 — WH
1 — WH 7.0866-7.0993 0.2790-0.2795
5 — YEL
7.0358-7.0485 0.2770-0.2775
4 — YEL
3 — YEL 6.9850-6.9977 0.2750-0.2755
2 — YEL
6.9342-6.9469 0.2730-0.2735
1 — YEL
5 — ORNG 6.8834-6.8961 0.2710-0.2715
4 — ORNG
6.8326-6.8453 0.2690-0.2695
3 — ORNG
2 — ORNG 6.7818-6.7945 0.2670-0.2675
1 — ORNG
6.7310-6.7437 0.2650-0.2655
2 — RED
1 — RED 6.6802-6.6929 0.2630-0.2635
6.6294-6.6421 0.2610-0.2615
6.5786-6.5913 0.2590-0.2595
6.5278-6.5405 0.2570-0.2575
6.4770-6.4897 0.2550-0.2555
6.4262-6.4389 0.2530-0.2535
6.3754-6.3881 0.2510-0.2515
6.3246-6.3373 0.2490-0.2495
6.2738-6.2865 0.2470-0.2475
6.2223-6.2357 0.2450-0.2455
6.1722-6.1849 0.2430-0.2335
6.1214-6.1341 0.2410-0.2415
38. Remove the 4 differential bearing cap bolts.

z Remove the differential carrier.
39. Measure the thickness of the selected right and left bearing shims.
40. To establish differential bearing preload, increase both the left and right differential bearing shim
thickness by 0.203 mm (0.008 in).
41. Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier
Spreader.
42. NOTICE: Overspreading may damage the differential housing.
NOTE: Tighten and loosen the differential carrier spreader adapters to normalize the housing
adapters prior to taking the final Dial Indicator reading.
Spread the differential housing to the specification.

2. Tighten the screw until spreading the differential housing to the specifications.
3. Remove the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
43. NOTICE: To avoid galling the case, insert the shims with a light coating of grease before
installing the differential carrier.
Place the differential bearing shims in the differential housing.

1. Position the 2 differential bearing cups on the differential bearings.
2. Lower the differential carrier in place between the differential bearing shims.
45. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the Differential Carrier
Spreader.
Install the 2 differential bearing caps and 4 bolts in their original location.
46. Loosen and remove the Differential Carrier Spreader.
47. Install the Dial Indicator Gauge with Holding Fixture at the 12 o'clock position.
48. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, recheck the ring gear
backlash.
50. Verify an acceptable pattern check. For additional information, refer to Diagnosis and Testing in this
section.
51. Assemble the axle housing tube.

z Align the bolt holes and position the axle tube.
z Position the axle identification tag.
z Install the 4 bolts.
52. Install a new stub shaft seal. For additional information, refer to Stub Shaft Pilot Bearing and Seal in
this section.
53. Install a new circlip on the intermediate shaft end.
54. Insert the intermediate shaft and engage the circlip with the side gears.
55. Remove the axle assembly from the Holding Fixture and place it on the bench.
NOTE: The differential housing cover must be installed within 15 minutes of application of the
Apply a continuous bead of sealant, of the specified thickness, to the differential housing cover
mounting surface as shown in the illustration.
z Use silicone gasket and sealant.
57. Install the differential housing cover and the 10 cover bolts.
58. Install the axle assembly. For additional information, refer to Axle Assembly in this section.
59. Remove the fill plug and fill the axle assembly with the specified type and amount of lubricant.
z Tighten the fill plug to 25 Nm (18 lb-ft).

Differential Case
Material
Item Specification
Motorcraft® SAE 80W-90 WSP-M2C197-
Premium Rear Axle Lubricant A
XY-80W90-QL (US); CXY-80W90-
1L (Canada)
TA-25 A5
Disassembly
NOTE: The Torsen® differential should be replaced as a unit only. Do not attempt to rebuild.
1. Remove the differential carrier. Refer to Differential Carrier .
2.
3.
4.
5.
6.
7.
8. General Equipment: Hydraulic Press

General Equipment: Bearing Puller
Assembly
1. General Equipment: Hydraulic Press
2.
3.
4.
5. NOTE: If a new pinion shaft bolt is unavailable, coat the threads with sealer.
6. NOTE: Loosely install 3 bolts to align the ring gear and carrier bolt holes.
General Equipment: Hydraulic press
7.
8. Install the differential carrier. Refer to Differential Carrier .

Drive Pinion Flange and Seal
Special Tool(s)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent

Flange
205-126 (T78P-4851-A)

205-002 (TOOL-4858-E)

205-208 (T83P-4676-A)
Material
Item Specification
XY-80W90-QL (US); CXY-80W90-
1L (Canada)

1 389546 Pinion nut and washer
3 3N134 Drive pinion oil seal
4 3C202 Axle housing
Removal
color new drive pinion nut for installation as the original. If a new collapsible spacer must be
installed for pinion bearing preload reduction, install the nut supplied with the new spacer or
NOTICE: This operation disturbs the pinion bearing preload. Carefully reset the pinion bearing
preload during assembly.
2. Remove the front brake pads. Refer to Section 206-03 .
3. Remove the front driveshaft. Refer to Section 205-01 .
4. Measure and record the pinion bearing preload.

z Using a Nm (lb-in) torque wrench, rotate the pinion gear. Measure the torque required to
maintain pinion gear rotation.
5. Index-mark the pinion flange and the drive pinion gear.
collapsible spacer. If a new collapsible spacer is installed, install the nut in the kit or damage
to the component may occur.
Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, remove and discard the
pinion nut and washer.
8. Inspect the pinion flange for burrs and damage. Inspect the end of the pinion flange that contacts the
pinion bearing cone, pinion nut counterbore and drive pinion seal surface for nicks. Discard the pinion
flange if damaged.
9. NOTICE: Do not damage the axle housing.
Force up on the metal flange of the drive pinion seal. Install gripping pliers and strike with a hammer
to remove the drive pinion seal.
10. Verify the splines on the drive pinion gear are free of burrs. If burrs are evident, remove them with a
fine crocus cloth.
11. Clean the drive pinion seal bore.
Installation
1. NOTE: Lubricate the drive pinion seal lips with axle lubricant.
NOTE: Drive pinion seal must be fully seated all the way around or drive pinion seal damage will
occur.
Using the Drive Pinion Oil Seal Installer, install the drive pinion seal.
2. NOTICE: Never use a hammer or install the pinion flange with power tools.
NOTE: Lubricate the pinion flange splines with axle lubricant.
Align the index marks made during removal and, using the Drive Pinion Flange Installer, install the
pinion flange.
3. NOTICE: The color on the rear face of the drive pinion nut is critical to this repair. Use the
same color new drive pinion nut for installation as the original. If a new collapsible spacer
must be installed for pinion bearing preload reduction, install the nut supplied with the new
spacer or damage to the component may occur.
Select the correct pinion nut for installation.
8.8 In. Drive Pinion Nut

Part Number Color Description Part Description
389546-S100 Orange Pinion nut
4320 Purple Pinion nut
4C121 Purple Kit with spacer for all 223.52 mm (8.8 in) axles
collapsible spacer or damage to the component may occur.
Install the new washer and pinion nut. Only hand-tighten the pinion nut at this time.
5. NOTICE: Do not loosen the pinion nut to reduce drive pinion bearing preload. Install a new
drive pinion collapsible spacer and pinion nut if drive pinion bearing preload reduction is
necessary. If a new collapsible spacer must be installed for pinion bearing preload reduction,
install the nut supplied with the new spacer or damage to the component may occur.
Using the Drive Pinion Flange Holding Fixture to hold the pinion flange, tighten the pinion nut to set
the drive pinion bearing preload.
z Tighten the pinion nut, rotating the pinion occasionally to make sure the drive pinion bearings
are seating correctly. Take frequent drive pinion bearing preload readings by rotating the drive
pinion gear with a Nm (lb-in) torque wrench. The final reading must be 0.56 Nm (5 lb-in) more
than the initial reading taken during removal.
6. Install the front driveshaft. Refer to Section 205-01 .
7. Install the disc brake pads. Refer to Section 206-03 .

Stub Shaft Pilot Bearing and Seal
Special Tool(s)
Handle
205-D055 (D81L-4000-A)
Installer, Axle Shaft Oil Seal

205-123 (T78P-1177-A)
Installer, Wheel Speed Sensor

Ring
206-034 (T88P-20202-B)

308-047 (T77F-1102-A)

Pump
307-397
Slide Hammer
100-001 (T50T-100-A)

1 3A380 Intermediate shaft
2 3B112 Stub shaft seal
3 4B413 Stub shaft bearing
4 3B210 Axle housing tube
Removal
NOTE: Install a new stub shaft seal whenever a halfshaft is removed.
1. Remove the halfshafts. For additional information, refer to Section 205-03 .
3. Remove and discard the intermediate shaft circlip.
4. Using a suitable seal remover, remove and discard the stub shaft pilot bearing oil seal.
5. Using the Bearing Cup Remover and Slide Hammer, remove and discard the stub shaft pilot bearing.
Installation
1. Position the stub shaft pilot bearing in the axle tube or differential housing bore and using the Axle
Shaft Oil Seal Installer, install the bearing.
2. Carefully align the stub shaft pilot bearing oil seal with the housing bore and install the stub shaft
bearing oil seal flush in the housing using the Wheel Speed Sensor Ring Installer and Handle.
4. Insert the intermediate shaft and engage the circlip with the differential side gear.
5. Install the halfshafts. For additional information, refer to Section 205-04 .

Axle Assembly

1 W712724 Axle tube bushing bolt
2 W712723 Axle tube bushing flagnut
3 W712724 Rear axle housing bushing bolt
4 N808684 Steering column coupler bolt
5 W712743 Front axle housing bushing support bolt

6 636893 Crossmember nuts (4 required)
2. Remove the halfshafts. Refer to Section 205-04 .
3. Remove the 4 crossmember nuts and bolts and the crossmember.

4. Use a high-lift jack to support the axle assembly.
5. Remove the axle tube bushing bolt and flagnut.

6. Remove the front axle housing bushing bolt.

7. NOTE: Use a steering wheel holding device (such as a Hunter® 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
8. NOTICE: Do not allow the steering column to rotate while the steering column shaft is
disconnected or damage to the clockspring may result. If there is evidence that the steering
column has rotated, the clockspring must be removed and recentered. Refer to Section 501-
20B .
Remove and discard the steering column shaft-to-steering gear bolt and disconnect the shaft from the
steering gear.
z To install, tighten the new bolt to 30 Nm (22 lb-ft).
9. Remove the rear axle housing bushing bolt.

10. Carefully lower the front drive axle assembly.
11. Disconnect the vent hose from the axle vent barbed fitting.
12. NOTE: Make sure the axle vent hose is connected.

Axle Carrier Bushing
Special Tool(s)
Installer, Front Axle Mounting
Bushing Drawbolt
205-374 (T96T-5638-H)
Installer, Front Differential

Mounting Bushing
204-187 (T95T-5638-AH)
Installer, Wheel Hub Dust Seal

205-289 (T89P-1249-A)
Remover, Front Axle Mounting

Bushing Cup
205-371 (T96T-5638-E)
Remover, Front Axle Mounting

Bushing
205-376 (T96T-5638-K)
Remover, Front Differential

Housing Bushing
204-186 (T95T-5638-AH)
Remover/Installer, Front
Differential Housing Bushing
205-527/1

1 W712724 Axle bushing bolts (2 required)
2 5638 Axle bushings (3 required)
3 W712723 Axle bushing flagnut
4 W712743 Axle bushing bolt
Removal
All bushings
1. NOTE: It is not necessary to remove the axle assembly from the jack.
Remove the axle assembly. For additional information, refer to Axle Assembly in this section.
2. Measure and record the width of the gap between the bushing front lip and the housing. Mark the
housing at the point where the measurement was taken.
Axle tube bushing
3. Position the Front Axle Mounting Bushing Cup Remover, Front Differential Housing Bushing
Remover/Installer and Front Axle Mounting Bushing Drawbolt Installer as shown. Turn in the drawbar
to remove the bushing.
Rear housing bushing
4. Position the Front Differential Housing Bushing Remover, Front Axle Mounting Bushing Cup
Remover, Front Differential Housing Bushing Remover/Installer and Front Axle Mounting Bushing
Drawbolt Installer as shown. Turn in the drawbar to remove the bushing.
Front housing bushing
5. Remove the pinion flange. For additional information, refer to Drive Pinion Flange and Seal in this
section.
6. Position the Front Axle Mounting Bushing Cup Remover, Front Differential Housing Bushing
Remover/Installer and Front Axle Mounting Bushing Drawbolt Installer as shown. Turn in the drawbar
to remove the bushing.
All bushings
7. Inspect the bushing bores for wear or damage.
Installation
Axle tube bushing
1. Position the bushing and the Front Axle Mounting Bushing Remover, Front Differential Mounting
Bushing Installer, Front Axle Mounting Bushing Cup Remover and Front Axle Mounting Bushing
Drawbolt Installer as shown. Draw the bushing into the bushing bore to the same depth and point
measured before removal.
Rear housing bushing
2. Position the bushing and the Front Axle Mounting Bushing Remover, Front Differential Mounting
Bushing Installer, Front Axle Mounting Bushing Cup Remover and Front Axle Mounting Bushing
Drawbolt Installer as shown. Draw the bushing into the bushing bore to the same depth and point
measured before removal.
Front housing bushing
3. Position the bushing and the Front Differential Housing Bushing Remover/Installer, Wheel Hub Dust
Seal Installer, Front Differential Housing Bushing Remover, Front Differential Mounting Bushing
Installer and Front Axle Mounting Bushing Drawbolt Installer as shown. Draw the bushing into the
bushing bore to the same depth and point measured before removal.
4. Install the U-joint flange. For additional information, refer to Drive Pinion Flange and Seal in this
section.
All bushings

Special Tool(s)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent

205-105 (T76P-4020-A3)

205-109 (T76P-4020-A9)

205-110 (T76P-4020-A10)

205-111 (T76P-4020-A11)

205-129 (T79P-4020-A18)

Spreader
205-368 (T96T-4000-A)

Fixture
100-002 (TOOL-4201-C)

308-021 (T75L-4201-A)

205-336 (T93P-4020-A)

Flange
205-126 (T78P-4851-A)

307-003 (T57L-500-B)

Bearing
205-D044 (D81T-4221-A) or
equivalent

205-010 (T57L-4221-A2)

Cone
205-005 (T53T-4621-C)

Cup
205-024 (T67P-4616-A)

205-002 (TOOL-4858-E)

205-208 (T83P-4676-A)

205-460
Remover, Bearing
205-055 (T71P-4621-B)

308-047 (T77F-1102-A)

Pump
307-397
Slide Hammer
100-001 (T50T-100-A)

205-001 (TOOL-4000-E)

(Plate)
205-335 (T93P-4000-A) (RH)
Material
Item Specification
XG-14
XY-80W90-QL (US); CXY-80W90-
1L (Canada)
(Canada)
TA-30 A4
Part

3 — Differential bearing cap bolt (part of 3A412) (4
required)
4 — Differential bearing cap (part of 3A412) (2 required)
5 3C202 Differential assembly
8 4A451 Differential bearing shims (2 required)
9 — Pinion gear (part of 4209)
10 4663 Drive pinion bearing adjustment shim
11 4628 Inner drive pinion bearing cup
12 4630 Inner drive pinion bearing
13 4662 Drive pinion collapsible spacer
14 3A380 Intermediate axle shaft
15 3A412 Differential housing
16 4631 Drive pinion oil baffle
17 4616 Drive pinion outer bearing cup
18 4621 Drive pinion outer bearing
19 386989 Drive pinion oil slinger
22 389546 Drive pinion nut and washer
Removal

z Drain the fluid.
Spreader.

9. NOTICE: Mark the differential bearing caps Top or Bottom and LH or RH appropriately before
removing them. Always install the bearing caps in their original location and position or

2. Remove the 2 differential bearing caps.
10. NOTE: Use wood blocks to avoid axle housing damage.

16. Using the Bearing Remover and a press, remove the drive pinion inner bearing.
1. Position the Bearing Remover under the drive pinion inner bearing.
2. Using a press, remove the inner drive pinion bearing and shim.
17. NOTE: Do not damage the carrier housing while removing the pinion seal.

z Pry up on the seal flange. Install gripping pliers and strike with a hammer to remove the seal.
19. Using the Bearing Cup Remover and Slide Hammer, remove the inner drive pinion bearing cup.
remove the baffle.
21. Remove the outer drive pinion bearing cup by tapping alternately on each side to prevent the drive
pinion bearing cup from becoming misaligned.
Installation
1. NOTICE: Do not omit the drive pinion bearing oil baffle or drive pinion bearing failure may
result.
If removed, position the drive pinion bearing oil baffle on the Differential Carrier Bearing Installer.
2. Using the Differential Carrier Bearing Installer, install the drive pinion bearing oil baffle.
3. Using the Drive Pinion Bearing Cup Installer, install the drive pinion bearing cups.

1 205-109 Adapter for 205-S127 (T76P-4020-A9)
2 205-105 Adapter for 205-S127 (T76P-4020-A3)
4 205-129 Adapter for 105-S127 (T79P-4020-A18)
5 205-110 Adapter for 205-S127 (T76P-4020-A10)
7 205-111 Adapter for 205-S127 (T76P-4020-A11)


which results in a deep tooth contact in final assembly of integral axle assemblies.
selection.
all of the Adapters.
9. Position the drive pinion bearing adjustment shim and the inner pinion bearing on the drive pinion
gear stem.
10. NOTE: The same drive pinion bearing from the previous steps must be used.
Install the inner drive pinion bearing.

z Place the drive pinion bearing adjustment shim on the drive pinion gear.
z Using a suitable press and the Drive Pinion Bearing Cone Installer, press the inner drive pinion
bearing until it is firmly seated on the pinion gear.
11. Place a new drive pinion collapsible spacer on the drive pinion gear.
12. Install the outer drive pinion bearing.
13. Install the drive pinion oil slinger.
14. NOTE: Coat the drive pinion seal lips with long-life grease.
Install the drive pinion seal on the Drive Pinion Oil Seal Installer.
15. NOTE: If the drive pinion seal becomes misaligned during installation, remove it and install a new
drive pinion seal.
16. Lightly lubricate the drive pinion gear splines with rear axle lubricant.
17. Position the drive pinion gear in the axle housing.
18. Position the pinion flange.
20. Apply a small amount of axle lubricant to the washer side of the new pinion nut and install the new
pinion nut.
21. NOTICE: Do not loosen the pinion nut to reduce drive pinion bearing preload under any
circumstance. If it is necessary to reduce drive pinion bearing preload, install a new drive
pinion collapsible spacer and pinion nut or damage to the component may occur.
Install the Drive Pinion Flange Holding Fixture and tighten the pinion nut. Refer to the torque
specifications in the Specifications portion of this section.
z Rotate the drive pinion gear occasionally to make sure the drive pinion bearings are seating
correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear
with a Nm (lb-in) torque wrench.
22. Press the left and right differential bearing on the differential case.
1. Position the differential bearing.
2. Using the Differential Side Bearing Installer, press the differential bearing on the differential
case.
z Repeat for the other side.

1. Position the 2 differential bearing cups on the differential bearings.
25. NOTE: Apply pressure toward the left side to make sure the left bearing cap is seated.
Install progressively thicker differential bearing shims on the right side until the thickest differential

31. Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, measure the
differential ring gear backlash at 4 equally spaced points.
1. Attach the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
2. Position the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge tip centrally
on a drive tooth.
3. Zero the Dial Indicator.
4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator
reading. The allowable backlash is 0.203 mm (0.008 in) to 0.305 mm (0.012 in) and must not
vary more than 0.101 mm (0.004 in) between points measured.
To correct for a high or low backlash, proceed as follows.

mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006

0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018
0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart — 4067

Dimension A
Numbers of Stripes and Color Code mm Inch
2 — C-COAL 7.7978- 7.8105 0.3070- 0.3075
1 — C-COAL 7.7470- 7.7597 0.3050- 0.3055
5 — BLU 7.6962- 7.7089 0.3030- 0.3035
4 — BLU 7.6454- 7.6581 0.3010- 0.3015
3 — BLU 7.5946- 7.6073 0.2990- 0.2995
2 — BLU 7.5458- 7.5565 0.2970- 0.2975
1 — BLU 7.493- 7.505 0.2950- 0.2955
5 — PINK 7.4422- 7.4549 0.2930- 0.2935
4 — PINK 7.3914- 7.4041 0.2910- 0.2915
3 — PINK 7.3406- 7.3533 0.2890- 0.2895
2 — PINK 7.2898- 7.3025 0.2870- 0.2875
1 — PINK 7.2390- 7.2517 0.2850- 0.2855
5 — GRN 7.1882- 7.2009 0.2830- 0.2835
4 — GRN 7.1374- 7.1501 0.2810- 0.2815
3 — GRN 7.0866- 7.0993 0.2790- 0.2795
2 — GRN 7.0358- 7.0485 0.2770- 0.2775
1 — GRN 6.9850- 7.0485 0.2750- 0.2755
5 — WH 6.9342- 6.9469 0.2730- 0.2735
4 — WH 6.8834- 6.8961 0.2710- 0.2715
3 — WH 6.8326- 6.8453 0.2690- 0.2695
2 — WH 6.7818- 6.7945 0.2670- 0.2675
1 — WH 6.7310- 6.7437 0.2650- 0.2655
5 — YEL 6.6802- 6.6929 0.2630- 0.2635

4 — YEL 6.6294- 6.6421 0.2610- 0.2615
3 — YEL 6.5786- 6.5913 0.2590- 0.2595
2 — YEL 6.5278- 6.5405 0.2570- 0.2575
1 — YEL 6.4770- 6.4897 0.2550- 0.2555
5 — ORNG 6.4262- 6.4389 0.2530- 0.2535
4 — ORNG 6.3754- 6.3881 0.2510- 0.2515
3 — ORNG 6.3246- 6.3373 0.2490- 0.2495
2 — ORNG 6.2738- 6.2865 0.2470- 0.2475
1 — ORNG 6.2223- 6.2357 0.2450- 0.2455
2 — RED 6.1722- 6.1849 0.2430- 0.2435
1 — RED 6.1214- 6.1341 0.2410- 0.2415

Spreader.
NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader

2. Tighten the screw until spreading the differential housing to the specification.
38. NOTICE: To avoid galling the case, insert shims with a light coating of grease before installing
the differential assembly. If not carried out in this order, the aluminum housing can be
damaged.

40. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the Differential Carrier
Spreader.
Install the 2 differential bearing caps and the 4 differential bearing cap bolts in their original locations
and positions.

section.
48. Install the axle housing tube and the 4 bolts.

this section.
52. Remove the axle assembly from the Transmission Holding Fixture and place it on the bench.
54. Install the differential housing cover and the 10 bolts.

56. Remove the fill plug and fill the axle assembly with the specified type and amount of axle lubricant.

Special Tool(s)
Spreader
205-368 (T96T-4000-A)

Fixture
100-002 (TOOL-4201-C)

308-021 (T75L-4201-A)

307-003 (T57L-500-B)

Pump
307-397
Slide Hammer
100-001 (T50T-100-A)

205-001 (TOOL-4000-E)

(Plate)
205-335 (T93P-4000-A) (RH)
Material
Item Specification
Motorcraft® SAE 80W-90 WSP-M2C197-
Premium Rear Axle Lubricant A
XY-80W90-QL (US); CXY-80W90-
1L (Canada)
(Canada)
TA-30 A4
Part
required)
Removal

z Drain the fluid.
7. Position the Differential Carrier Spreader on the spreader adapters.
8. Install the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
9. NOTICE: Overspreading may damage the component.

3. Remove the Dial Indicator Gauge with Holding Fixture.
removing them. Always install the differential bearing caps in their original positions or

11. NOTE: Use wood blocks to avoid axle housing damage.
Remove the differential carrier from the axle housing.

3. Remove the differential carrier.
Installation
1. NOTE: Make sure the Dial Indicator needle is in the spreader adapter hole.
Install the Dial Indicator Gauge with Holding Fixture, Clutch Housing Gauge and Differential Carrier
Spreader.
2. NOTICE: Overspreading may damage the component.

z Remove the Dial Indicator.
3. NOTICE: Never attempt to drive the differential bearing shim in place. Permanent damage to
the machined axle housing surfaces may occur.
Position the differential bearing shims.

1. Apply a light coating of grease to one side of the differential bearing shims to help hold them in
place.
2. Position the differential bearing shims.
4. NOTE: Push the differential carrier downward to fully seat the differential bearing cups in the axle
housing.
Position the differential carrier.

2. Lower the differential assembly in place between the differential bearing shims.
5. Install the differential bearing caps in their original positions and tighten with the housing still spread.
1. Position the 2 differential bearing caps.
1. Attach the Dial Indicator Gauge with Holding Fixture.
2. Position the Clutch Housing Gauge tip centrally on a drive tooth.
4. Turn the differential ring gear without turning the drive pinion gear.
8. Install the axle housing tube and the 4 bolts.

this section.
14. Install the differential housing cover and the 10 differential housing cover bolts.
16. Remove the fill plug and fill the axle assembly with the specified type and amount of axle lubricant.

Special Tool(s)
2 Jaw Puller
205-D072 (D97L-4221-A) or
equivalent

205-105 (T76P-4020-A3)

205-109 (T76P-4020-A9)

205-110 (T76P-4020-A10)

205-111 (T76P-4020-A11)

205-129 (T79P-4020-A18)

Spreader
205-368 (T96T-4000-A)

Fixture
100-002 (TOOL-4201-C)

308-021 (T75L-4201-A)

205-336 (T93P-4020-A)

Flange
205-126 (T78P-4851-A)

307-003 (T57L-500-B)

Bearings
205-D044 (D81T-4221-A) or
equivalent

205-010 (T57L-4221-A2)

Cone
205-005 (T53T-4621-C)

Cup
205-024 (T67P-4616-A)

205-002 (TOOL-4858-E)

205-208 (T83P-4676-A)

205-460

308-047 (T77F-1102-A)

Pump
307-397
Slide Hammer
100-001 (T50T-100-A)

205-001 (TOOL-4000-E)

(Plate)
205-335 (T93P-4000-A) (RH)
Step Plate
205-D061 (D83T-4205-C2) or
equivalent
Material
Item Specification
XG-14
XY-80W90-QL (US); CXY-80W90-
1L (Canada)
(Canada)
TA-30 A4
Part

required)
9 4A451 Differential bearing shims (2 required)
10 — Ring gear (part of 4209)
10 — Pinion gear (part of 4209)
11 4663 Drive pinion bearing adjustment shim
12 4628 Inner drive pinion bearing cup
13 4630 Inner drive pinion bearing
14 4662 Drive pinion collapsible spacer
17 4631 Drive pinion oil baffle
18 4616 Drive pinion outer bearing cup
19 4621 Drive pinion outer bearing
20 386989 Drive pinion oil slinger
23 389546 Drive pinion nut and washer
Removal

z Drain the fluid.
Install the Adapter for Differential Housing Spreader and Differential Housing Spreader Plate.
Spreader.

removing them. Always install the bearing caps in their original location and position or

10. NOTICE: Use wood blocks to avoid axle housing damage.

4. Remove the Differential Carrier/Spreader.
15. Discard the drive pinion collapsible spacer.
16. NOTICE: Do not damage the carrier housing while removing the pinion seal.

z Pry up on the seal flange. Install gripping pliers and strike with a hammer to remove the seal.
18. Using the Bearing Cup Remover and Slide Hammer, remove the inner pinion bearing cup.
remove the baffle.
20. Remove the outer pinion bearing cup by tapping alternately on each side to prevent the cup from
cocking.
21. NOTE: Use a drift punch to separate the differential ring gear from the differential case.
Remove and discard the 10 differential ring gear bolts and remove the differential ring gear.
22. Using the 2 Jaw Puller and Step Plate, remove the 2 differential bearings.
Installation
1. NOTICE: Do not omit the drive pinion bearing oil baffle or damage to the component may
occur.
If removed, position the drive pinion bearing oil baffle on the Differential Carrier Bearings Installer.
2. Using the Differential Carrier Bearings Installer, install the drive pinion bearing oil baffle.
3. Using the Drive Pinion Bearing Cup Installer, install the drive pinion bearing cups.

1 205-109 Adapter for 205-S127 (T76P-4020-A9)
2 205-105 Adapter for 205-S127 (T76P-4020-A3)
4 205-129 Adapter for 105-S127 (T79P-4020-A18)
5 205-110 Adapter for 205-S127 (T76P-4020-A10)
7 205-111 Adapter for 205-S127 (T76P-4020-A11)


which results in a deep tooth contact in final assembly of integral axle assemblies.
selection.
all of the special tools.
9. Position the drive pinion bearing adjustment shim and the inner pinion bearing on the new drive
pinion gear stem.
10. NOTE: The same drive pinion bearings from the previous steps must be used.
Install the inner drive pinion bearing.

z Place the drive pinion bearing adjustment shim on the drive pinion gear.
z Using a suitable press and the Drive Pinion Bearing Cone Installer, press the inner drive pinion
bearing until it is firmly seated on the pinion gear.
11. Place a new drive pinion collapsible spacer on the drive pinion gear.
12. Install the outer drive pinion bearing.
13. Install the drive pinion oil slinger.
14. NOTE: Coat the drive pinion seal lips with long-life grease.
Install the drive pinion seal on the Drive Pinion Oil Seal Installer.
15. NOTE: If the drive pinion seal becomes misaligned during installation, remove it and install a new
drive pinion seal.
16. Lightly lubricate the drive pinion gear splines with axle lubricant.
17. Position the drive pinion gear in the axle housing.
18. Position the pinion flange onto the pinion shaft while mounted on the Transmission Holding Fixture.
20. Apply a small amount of axle lubricant to the washer side of the new pinion nut and install the new
pinion nut.
21. NOTICE: Do not loosen the pinion nut to reduce drive pinion bearing preload under any
circumstance. If it is necessary to reduce drive pinion bearing preload, install a new drive
pinion collapsible spacer and pinion nut or damage to the component may occur.
Install the Drive Pinion Flange Holding Fixture and tighten the pinion nut. For additional information,
refer to the torque specifications in the Specifications portion of this section.
z Rotate the drive pinion gear occasionally to make sure the drive pinion bearings are seating
correctly. Take frequent drive pinion bearing preload readings by rotating the drive pinion gear
with a Nm (lb-in) torque wrench.
22. Press the left and right differential bearing on the differential carrier.
1. Position the differential bearing.
2. Using the Differential Side Bearing Installer, press the differential bearing on the differential
carrier.
z Repeat for the other side.

24. Install the 10 new ring gear bolts.


27. NOTE: Apply pressure toward the left side to make sure the left bearing cup is seated.
Install progressively thicker differential bearing shims on the right side until the thickest differential

1. Attach the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge.
2. Position the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge tip centrally
on a drive tooth.
4. Turn the differential ring gear without turning the drive pinion gear. Record the indicator
reading. The allowable backlash is 0.203 mm (0.008 in) to 0.305 mm (0.012 in) and must not
vary more than 0.101 mm (0.004 in) between points measured. A backlash variation of more
than 0.101 mm (0.004 in) between points checked indicates gear/case runout.
To correct for a high or low backlash, proceed as follows.

mm Inch mm Inch
0.025 0.001 0.050 0.002
0.050 0.002 0.050 0.002
0.076 0.003 0.101 0.004
0.101 0.004 0.152 0.006
0.127 0.005 0.152 0.006
0.152 0.006 0.203 0.008
0.177 0.007 0.254 0.010
0.203 0.008 0.254 0.010
0.228 0.009 0.304 0.012
0.254 0.010 0.355 0.014
0.279 0.011 0.355 0.014
0.304 0.012 0.406 0.016
0.330 0.013 0.457 0.018

0.335 0.014 0.457 0.018
0.381 0.015 0.508 0.020
Differential Shim Size Chart — 4067

Dimension A
Numbers of Stripes and Color Code mm Inch
2 — C-COAL 7.7978- 7.8105 0.3070- 0.3075
1 — C-COAL 7.7470- 7.7597 0.3050- 0.3055
5 — BLU 7.6962- 7.7089 0.3030- 0.3035
4 — BLU 7.6454- 7.6581 0.3010- 0.3015
3 — BLU 7.5946- 7.6073 0.2990- 0.2995
2 — BLU 7.5458- 7.5565 0.2970- 0.2975
1 — BLU 7.493- 7.505 0.2950- 0.2955
5 — PINK 7.4422- 7.4549 0.2930- 0.2935
4 — PINK 7.3914- 7.4041 0.2910- 0.2915
3 — PINK 7.3406- 7.3533 0.2890- 0.2895
2 — PINK 7.2898- 7.3025 0.2870- 0.2875
1 — PINK 7.2390- 7.2517 0.2850- 0.2855
5 — GRN 7.1882- 7.2009 0.2830- 0.2835
4 — GRN 7.1374- 7.1501 0.2810- 0.2815
3 — GRN 7.0866- 7.0993 0.2790- 0.2795
2 — GRN 7.0358- 7.0485 0.2770- 0.2775
1 — GRN 6.9850- 7.0485 0.2750- 0.2755
5 — WH 6.9342- 6.9469 0.2730- 0.2735
4 — WH 6.8834- 6.8961 0.2710- 0.2715
3 — WH 6.8326- 6.8453 0.2690- 0.2695
2 — WH 6.7818- 6.7945 0.2670- 0.2675
1 — WH 6.7310- 6.7437 0.2650- 0.2655
5 — YEL 6.6802- 6.6929 0.2630- 0.2635
4 — YEL 6.6294- 6.6421 0.2610- 0.2615
3 — YEL 6.5786- 6.5913 0.2590- 0.2595
2 — YEL 6.5278- 6.5405 0.2570- 0.2575
1 — YEL 6.4770- 6.4897 0.2550- 0.2555
5 — ORNG 6.4262- 6.4389 0.2530- 0.2535
4 — ORNG 6.3754- 6.3881 0.2510- 0.2515
3 — ORNG 6.3246- 6.3373 0.2490- 0.2495
2 — ORNG 6.2738- 6.2865 0.2470- 0.2475
1 — ORNG 6.2223- 6.2357 0.2450- 0.2455

2 — RED 6.1722- 6.1849 0.2430- 0.2435
1 — RED 6.1214- 6.1341 0.2410- 0.2415

Spreader.
NOTE: Tighten and loosen the differential carrier spreader screw to normalize the housing spreader

1. Adjust the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge to zero.
2. Tighten the screw until spreading the differential housing to the specification.
40. NOTICE: To avoid galling the case, insert shims with a light coating of grease before installing
the differential assembly. If not carried out in this order, the aluminum housing may be
damaged.

42. NOTE: Hand-tighten the differential bearing cap bolts prior to releasing the carrier spreader.
Install the 2 differential bearing caps and the 4 differential bearing cap bolts in their original locations
and positions.

section.
50. Install the 4 bolts and the axle housing tube.

this section.
56. Install the differential housing cover and 10 bolts.
58. Remove the fill plug and fill the axle assembly with the specified amount and type of axle lubricant.
SECTION 205-04: Front Drive Halfshafts 2014 F-150 Workshop Manual

Material
Capacity
Constant Velocity Joint Grease WSS-M1C258- —
(High Temperature) A1
XG-5
Item Specification
Left halfshaft assembled length 406.45 mm (16.00 in)
Right halfshaft assembled length 411.85 mm (16.21 in)
Brake flexible hose bracket bolt 30 22 —
Wheel hub nut 40 30 —

Front Drive Halfshafts
The front drive halfshafts consist of the following:
z Inner CV joints
z Outer CV joints
z Interconnecting shafts
z Convoluted CV joint boots
z CV joint boot clamps
z Special CV high-temperature grease
z Tripod joint housings
z Ball and cage housings
z A circlip stopper that holds the cross-groove inboard race assembly (inboard CV joint) together
z A circlip that retains the splined inboard CV joint to the differential side gear
The front drive halfshafts link the front axle to the front wheel hubs. The CV joints allow the halfshafts to
rotate smoothly through the required changes in angles between the stationary axle and the varying angles
of the front wheels including jounce and rebound plus changes while turning. The CV joints are either tri-
lobed style or the caged ball type depending on inboard or outboard. New halfshaft components are
available as kits containing grease, boots and clamps.
Halfshaft Handling
Handle all halfshaft components carefully during removal and installation and during various component
disassembly and assembly procedures.
z Never pick up or hold the halfshaft only by the inboard or outboard CV joint.
z Do not overangle the CV joints.
z Damage will occur to an assembled inboard CV joint if it is overplunged outward from the joint
housing.
z Never use a hammer to remove or install the halfshafts from the hub.
z Never use the halfshaft assembly as a lever to position other components. Always support the free
end of the halfshaft.
z Do not allow the boots to contact sharp edges or hot exhaust components.
z Handle the halfshaft only by the interconnecting shaft to avoid pull-apart and potential damage to the
CV joints.
z Excessive pulling force on the interconnecting shaft between joints of the halfshaft will result in
internal joint damage. Axial loads used in assisting removal must be applied through the inboard joint
housing only.
z Do not drop assembled halfshafts. The impact will cut the boots from the inside without evidence of
external damage.
z Do not remove the outer CV joint by pulling on the interconnecting shaft.
z Inspect all machined surfaces and splines for damage.

Front Drive Halfshafts

Halfshaft
Special Tool(s)
Halfshaft Remover
205-832
Slide Hammer
100-001 T50T-100-A

1 1131 Dust cap
2 N802827- Wheel hub nut
S100
3 W520215 Tie-rod end nut
4 W520215 Upper ball joint nut
5 W505211 Integrated Wheel End (IWE) bolts (3 required)
6 — Vacuum vent and apply tube
7 — Wheel speed sensor harness bracket bolt
8 — Wheel speed sensor harness bracket (part of
2C204)
9 — Brake flexible hose retainer (part of 2078)

10 W611633 Brake flexible hose bracket bolt
NOTICE: Whenever a halfshaft is removed, install a new circlip and stub shaft pilot bearing seal or
02 .
2. Remove the dust cap.
3. Remove and discard the wheel hub nut.

z To install, tighten the new wheel hub nut to 40 Nm (30 lb-ft).
4. Remove the wheel speed sensor harness bracket bolt and position the wheel speed sensor harness
aside.
5. Detach the brake flexible hose retainer from the wheel speed sensor harness.
6. Remove the brake flexible hose bracket bolt and disconnect the brake flexible hose bracket from the
wheel knuckle.
7. Remove the vacuum vent and apply tube at the vacuum vent and apply tube port of the Integrated
Wheel End (IWE) disconnect.
8. Remove the 3 IWE bolts.

9. Remove and discard the tie-rod end nut.

z Disconnect the tie-rod end from the wheel knuckle.
z To install, tighten the new tie-rod end nut to 115 Nm (85 lb-ft).
10. Remove and discard the upper ball joint nut.

z Disconnect the upper ball joint from the wheel knuckle.
z To install, tighten the new upper ball joint nut to 150 Nm (111 lb-ft).
11. NOTE: Do not damage the hub seal.
NOTE: Allow the steering knuckle to swing outboard while keeping the CV shaft pushed inboard.
Once clearance is available, remove the CV shaft joint outboard end and IWE disconnect from the
steering knuckle hub bearing.
12. Remove the IWE disconnect from the outboard CV joint housing.
13. Using the Halfshaft Remover and Slide Hammer, remove the halfshaft from the differential and the
intermediate shaft.
14. Remove and discard the circlip and the stub shaft seal. For additional information, refer to Section
205-03 .
15. NOTICE: Verify the spline engagement by checking for spline lash before installing the
halfshaft nut or component damage may occur.

Halfshaft
Material
Item Specification
Constant Velocity Joint Grease WSS-M1C258-
(High Temperature) A1
XG-5
Part
1 3B436B Outboard CV joint and interconnecting shaft
assembly
2 3A331A Outboard CV boot
3 3A331B Inboard CV boot
4 4B422 Snap ring
5 3B414 Inboard CV joint housing
6 — Inner race (part of 3B436 RH/ 3B437 LH)
7 — Ball (8 required) (part of 3B436 RH/ 3B437 LH)
8 — Ball cage (part of 3B436 RH/ 3B437 LH)
9 3B426 Retaining ring (part of 3B436 RH/ 3B437 LH)
Disassembly
1. Remove the halfshaft from the vehicle. For additional information, refer to Halfshaft in the Removal
and Installation portion of this section.
2. Remove the 2 boot clamps.
3. Separate the boot from the inboard CV joint housing.
4. Remove the retaining ring.
5. Remove the inboard CV joint housing.
6. Index-mark the inner race and ball cage.
7. Remove the 6 balls.
8. Remove the snap ring.
9. Remove the inner race and the ball cage.
10. Remove the inboard boot.
11. Remove the 2 boot clamps.
12. Remove the outboard boot.
13. NOTE: If the grease is contaminated, clean and inspect the joint for wear. Install a new outboard CV
joint and interconnecting shaft assembly if worn/damaged.
Check the CV joint grease for contamination.
Assembly
1. Position the outboard boot on the shaft.
2. Pack the outboard CV joint with 165 g (5.82 oz) of grease.

1. Use CV joint grease or equivalent provided in the boot kit.
2. Spread any remaining grease from the kit evenly inside the boot.
3. Install the outboard boot.

1. Clean the boot mounting surface.
2. Seat the boot in the joint boot groove.
4. Using a suitable boot clamp installer (such as Snap-On® stock #YA3050 or equivalent) install the
large boot clamp.
small boot clamp.
6. Position the boot clamp on the shaft.
7. Position the inboard boot on the shaft.
8. Position the ball cage on the shaft with the tapered end facing the boot.
9. NOTE: Align the index marks.
Position the inner race on the shaft with the counterbored end facing the boot.
10. Install the snap ring.
11. Lubricate and position the 6 balls.

z Use CV joint grease or equivalent provided in the boot kit.
12. Fill the inboard CV joint housing with 235 g (8.29 oz) of grease.
z Use CV joint grease or equivalent provided in the boot kit.
13. Position the boot clamp on the inboard CV joint housing.
14. Position the inboard CV joint housing on the ball and race assembly.
15. Install the retaining ring.
16. Remove any excess grease from the mating surface. Seat the boot in the joint boot groove.
17. Set the halfshaft assembled length to specification. For additional information, refer to Specifications
in this section.
18. NOTICE: Use care when inserting the screwdriver or damage to the boot may occur.
Insert a dull screwdriver blade under the boot to release the pressure.
large boot clamp.
small boot clamp.
21. NOTE: Maintain a clean work surface.
Compress the Integrated Wheel End (IWE) disconnect on the bench to collapse the vacuum
chamber.
22. While the IWE disconnect is collapsed, install a vacuum cap on the vacuum port.
23. NOTICE: Do not install the Integrated Wheel End (IWE) end disconnect in the knuckle. It must
be installed on the outer Constant Velocity (CV) joint housing or damage to the component
may occur.
Install the IWE disconnect on the outer CV joint housing.
24. NOTICE: Verify the spline engagement by checking for spline lash before installing the
halfshaft nut or damage to the component may occur.
Install the halfshaft in the vehicle. For additional information, refer to Halfshaft in the Removal and
Installation portion of this section.
SECTION 206-00: Brake System — General Information 2014 F-150 Workshop Manual
Material
Capacity
Motorcraft® High Performance WSS-M6C62-A 1,420 ml
DOT 3 Motor Vehicle Brake or WSS-M6C65- (3.0 pt)
Fluid (US) / Motorcraft® Brake A1
Fluid - Heavy Duty DOT 3
(Canada)
PM-1-C (US); CPM-1-C
(Canada)
Motorcraft® Metal Brake Parts — —
Cleaner (US) / Motorcraft®
Brake Parts Cleaner (Canada)
(Canada)
Motorcraft® Silicone Brake ESE-M1C171-A —
Caliper Grease and Dielectric
Compound
XG-3-A
Item Specification
Brake Disc
Front brake disc minimum thickness 32 mm (1.259 in)
Rear brake disc minimum thickness 23.0 mm (0.906 in)
Brake Pads
Maximum brake pad taper wear (in any direction) 3.0 mm (0.118 in)
Minimum brake pad thickness 3.0 mm (0.118 in)
Brake caliper bleed screw 10 — 89
Master cylinder primary brake tube fittings 28 21 —
Master cylinder secondary brake tube fitting 20 — 177
Brake System
The brake system consists of the following components:
z Front and rear disc brakes

z Cable/drum-in-hat actuated parking brake
z Brake master cylinder and fluid reservoir
z Vacuum-assisted power brake booster
z Four-wheel ABS
z Red brake warning indicator
The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder.
When the brake pedal is pressed, brake fluid is pushed through the double-walled steel tubes and flexible
hoses to the front and rear disc brake calipers. The brake fluid enters the disc brake calipers, forcing the
caliper pistons and brake pads outward against the brake disc friction surface, slowing or stopping rotation.
When the brake pedal is released, brake fluid pressure is relieved, returning the front and rear disc brake
caliper pistons and brake pads to the unapplied position.
For information on the following:
z Front disc brakes, refer to Section 206-03 .

z Rear disc brakes, refer to Section 206-04 .
z Parking brake actuation, refer to Section 206-05 .
z Hydraulic brake actuation, refer to Section 206-06 .
z Vacuum-assisted power brake booster, refer to Section 206-07 .
z ABS, refer to Section 206-09 .
Component Tests
Brake Booster
1. Disconnect the brake booster vacuum sensor/check valve from the brake booster and connect a
suitable vacuum/pressure tester to the booster side of the vacuum sensor/check valve.
2. Apply the parking brake, start the engine and place the transmission in NEUTRAL.
z Allow the engine to reach normal operating temperature.
3. NOTE: Subtract approximately 3.38 kPa (1 in-Hg) from the specified reading for every 304.8 m (1,000
ft) of elevation above sea level.
Verify that vacuum is available at the vacuum sensor/check valve with engine running at normal idle
speed.
z The vacuum gauge should read between 51-74 kPa (15-22 in-Hg).
z If specified vacuum is available, stop the engine, connect the vacuum sensor/check valve and
continue with Step 5.
z If specified vacuum is not available, continue with Step 4.
4. Disconnect the vacuum sensor/check valve from the vacuum hose and verify that the specified
vacuum is available at the hose with the engine at idle speed and the transmission in NEUTRAL.
z If specified vacuum is available, stop the engine, install a new vacuum sensor/check valve and
continue with Step 5.
z If specified vacuum is not available, stop the engine, connect the vacuum hose to the vacuum
sensor/check valve and refer to Section 303-00 to diagnose the no/low vacuum condition.
z On vehicles equipped with a brake vacuum pump, if specified vacuum is not available, inspect
the vacuum hose and install new as necessary. If vacuum hose is OK, install a new brake
vacuum pump. Refer to Section 206-07 .
5. Apply the brake pedal several times to exhaust all vacuum from the system.
6. Apply the brake pedal and hold it in the applied position. Start the engine and verify that the brake
pedal moves downward after the engine starts.
z If the brake pedal moves, the brake booster is operating correctly.
z If the brake pedal does not move, install a new brake booster. Refer to Section 206-07 .
7. Operate the engine a minimum of 20 seconds at idle. Stop the engine and let the vehicle stand for 10
minutes, then apply the brake pedal. The brake pedal feel should be the same as that noted with the
engine operating.
z If the brake pedal feels hard (no power assist), install a new brake booster vacuum
sensor/check valve and retest.
z If condition still exists, install a new brake booster. Refer to Section 206-07 .
z If the brake pedal feels the same as noted with the engine operating, the vacuum sensor/check
valve is functioning properly.
Brake Master Cylinder — Bypass Condition
1. Inspect the master cylinder. Refer to Brake System Inspection in this section.
2. Disconnect the brake tubes from the master cylinder.
3. Plug the outlet ports of the master cylinder.
4. NOTE: Make sure that the outlet port plugs do not show signs of leakage.
Lightly apply the brakes and hold for 10 seconds. Release the brakes and then reapply with heavy
force. If brake pedal height cannot be maintained, the brake master cylinder has an internal leak and
a new brake master cylinder must be installed.
z If brake pedal height is maintained, reinstall brake tubes and tighten to specifications. Refer to
Specifications in this section. After installation, bleed the brake system. Refer to Brake System
Bleeding in this section.
Brake Master Cylinder — Compensator Port
1. Inspect the master cylinder. Refer to Brake System Inspection in this section.
3. Apply and release the brakes.
4. With the brakes released, attempt to rotate each wheel and check for any brake drag.
z If an excessive amount of brake drag exists at multiple wheels, continue to Step 5.
z If an excessive amount of brake drag exists at only one wheel, it indicates a possible seized
brake caliper, brake wheel cylinder or parking brake component. Repair or install new
5. Check the brake stoplamp switch and the brake pedal free play to verify that the brake pedal is not
partially applied.
6. Loosen the brake master cylinder nuts and position the brake master cylinder away from the brake
booster.
7. With the brakes released, attempt to rotate each wheel and check for any brake drag.
z If the brake drag is no longer present, install a new brake booster. Refer to Section 206-07 .
z If the brake drag is still present, install a new master cylinder. Refer to Section 206-06 .
Inspection And Verification
Material
Item Specification
Motorcraft® High Performance WSS-M6C62-A
DOT 3 Motor Vehicle Brake Fluid or WSS-M6C65-
(US) / Motorcraft® Brake Fluid - A1
Heavy Duty DOT 3 (Canada)
(Canada)
specification. Additionally, do not use brake fluid that has been previously drained. Following these
instructions will help prevent system contamination, brake component damage and the risk of
information seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-
3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available.
Failure to follow these instructions may result in serious personal injury.
NOTICE: Blistering or swelling of rubber brake components can indicate contamination of the brake
fluid by a petroleum-based substance. The entire hydraulic brake system must be flushed with clean,
specified brake fluid and contaminated rubber components must be replaced to prevent
recontamination.
NOTICE: Do not spill brake fluid on painted or plastic surfaces or damage to the surface may occur.
If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water.
The first indication that something may be wrong in the brake system is a change in the feeling through the
brake pedal. The brake warning indicator in the Instrument Cluster (IC) and the brake fluid level in the brake
master cylinder reservoir are also indicators of system concerns.
If a wheel is locked and the vehicle must be moved, open a bleeder screw at the locked wheel to let out
enough fluid to relieve the pressure. Close the bleeder screw. If multiple wheels are locked, check the brake
pedal free play to verify brake pedal is not partially applied. These operations may release the brakes, but
will not correct the concern. If this does not relieve the locked wheel condition, repair the locked components
before proceeding.

z For parking brake concerns, refer to Section 206-05 .
z For ABS concerns, refer to Section 206-09 .
z For adjustable pedal concerns, refer to Section 206-06 .
z For all other concerns, continue with the next step.

z Brake fluid level and condition z Parking brake switch
z Brake master cylinder z Brake fluid level switch
z Brake master cylinder reservoir z Wiring, terminals or connectors
z Brake booster
z Brake booster check valve
z Brake booster vacuum hose
z Brake hoses and tubes
z Brake caliper, guide pins and anchor plate
z Brake disc
z Brake pads
z Brake pedal, bracket and booster linkage
z Aftermarket modifications
3. Visually inspect the suspension system and tires for obvious signs of wear or damage.
z For suspension system concerns, refer to Section 204-00 .
z For tire concerns, refer to Section 204-04 .
5. If the cause is not visually evident, GO to Symptom Chart - Brake System or GO to Symptom Chart -
NVH in this section.
Pinpoint Tests
Pinpoint Test A: Vibration When the Brakes are Applied
Normal Operation
During moderate to heavy braking, noise from the Hydraulic Control Unit (HCU) and pulsation in the brake
pedal can be observed. Pedal pulsation coupled with noise during heavy braking or on loose gravel, bumps,
wet or snowy surfaces is acceptable and indicates correct functioning of the ABS. Pedal pulsation or
steering wheel nibble when the brakes are applied (frequency is proportioned to the vehicle speed) indicates
a concern with a brake or suspension component.
PINPOINT TEST A: VIBRATION WHEN THE BRAKES ARE APPLIED
Result / Action to
Test Step
Take
A1 ROAD TEST THE VEHICLE — LIGHT BRAKING
z Road test the vehicle. Warm the brakes by slowing the vehicle from 80 Yes
to 32 km/h (50 to 20 mph) using light brake force. At highway speeds of GO to A4 .
89-97 km/h (55-60 mph), apply the brake using light pedal force.
z Is there a vibration/shudder felt in the steering wheel, seat or No
brake pedal? GO to A2 .
A2 ROAD TEST THE VEHICLE — MODERATE TO HEAVY BRAKING
z Road test the vehicle. At highway speeds of 89-97 km/h (55-60 mph), Yes
apply the brake using a moderate to heavy pedal force. GO to A3 .
z Is there a vibration/shudder?
No
The concern is not
present at this time.
A3 CHECK ABS OPERATION
z NOTE: During moderate to heavy braking, noise from the HCU and Yes
pulsation in the brake pedal can be observed. Pedal pulsation coupled This is a normal
with noise during heavy braking or on loose gravel, bumps, wet or operating condition of
snowy surfaces is acceptable and indicates correct operation of the the ABS.
ABS. Pedal pulsation or steering wheel nibble with the frequency
proportional to vehicle speed indicates a concern with a brake or No
suspension component. GO to A5 .
z Road test the vehicle and apply the brakes on a dry, firm surface, then
apply the brakes on a wet, snowy or loose surface (such as gravel).
z Is the vibration/shudder only present on a wet, snowy or loose
surface?
A4 ISOLATE BRAKE VIBRATION
z NOTE: This test is not applicable to vehicles with drum-in-hat type Yes
parking brakes. For vehicles with drum-in-hat parking brakes, proceed GO to A7 .
to the next test step. For all other vehicles, apply the parking brake to
identify if the problem is in the front or rear brake. No
z Apply the parking brake to identify if the problem is in the front or rear GO to A5 .
brake. At highway speeds of 89-97 km/h (55-60 mph), lightly apply the
parking brake until the vehicle slows down. Release the parking brake
immediately after the test.
z Is there a vibration/shudder?
A5 CHECK THE FRONT SUSPENSION
z Check the front suspension. Refer to Section 204-00 . Yes
z Are all the suspension components in satisfactory condition? GO to A6 .
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation.
A6 CHECK THE FRONT BRAKE DISCS
z Inspect the front brake discs. Refer to Brake System Inspection in this Yes
section. GO to A7 .
z Road test the vehicle.
z Is the vibration/shudder present? No
The concern has
been repaired.
A7 CHECK THE REAR SUSPENSION
z Check the rear suspension. Refer to Section 204-00 . Yes
z Are all the suspension components in satisfactory condition? INSPECT the rear
brake discs. REFER
to Brake System
Inspection in this
section.
No
REPAIR or INSTALL
new components as
necessary. TEST the
system for normal
operation.
Brake System
Applying the brake pedal uses lever action to push a rod into the brake booster, which through the use of
vacuum, boosts the force of the rod and then transmits this force to the primary piston in the master cylinder.
This produces hydraulic pressure in the master cylinder. This pressure builds in the master cylinder and
brake tubes as the brake pedal is applied further. The pressure between the primary and secondary piston
forces the secondary piston to compress, building pressure in its circuit. The hydraulic pressure is
transmitted by brake fluid through the brake tubes to the ABS Hydraulic Control Unit (HCU), which then
distributes that pressure to the individual brake calipers. The brake calipers use hydraulic pressure to apply
the pads. The application of the brake pads will cause the rotation of the wheels to slow or stop, depending
on how much brake pressure is applied. The parking brakes carry out the same function except that they are
mechanically actuated by a cable that connects only to the rear brakes.
Brake Master Cylinder Compensator Ports
The purpose of the compensator ports in the brake master cylinder is to supply additional brake fluid from
the master cylinder reservoir when needed by the brake system due to brake lining wear and allow brake
fluid to return to the master cylinder reservoir when the brakes are released. The returning brake fluid
creates a slight turbulence in the master cylinder reservoir. This is a normal condition and indicates that the
compensator ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not
fully release.
Red Brake Warning Indicator
The red brake warning indicator alerts the driver to certain conditions that exist in the brake system. The
Instrument Cluster (IC) performs a bulb check when the ignition key is turned to the RUN position. The
conditions that cause the indicator to illuminate are low brake fluid level, the parking brake is applied or there
is a fault in the ABS (if the yellow ABS warning indicator is also illuminated). To diagnose red brake warning
indicator concerns, refer to Section 413-01 .
Symptom Chart
Symptom Chart — Brake System
Symptom Chart — Brake System

z The red brake z DTCs in the ABS z REFER to Section 206-09 to
warning indicator module diagnose the ABS.
and the yellow ABS
warning indicator
are illuminated
z The red brake z Brake fluid level z REFER to Section 413-01 to
warning indicator is switch diagnose the red brake warning
always/never on z Parking brake indicator.
switch
z Wiring, terminals
or connectors
z Instrument Cluster
(IC)
z Smart Junction
Box (SJB)
z Vacuum sensor
z Electronic Brake
Distribution (EBD)
z Vehicle pulls or z Tires z REFER to Section 204-04 to
drifts during braking diagnose tire concerns.
z Brake calipers z INSPECT the brake system
and/or guide pins components. REFER to Brake
z Brake flexible System Inspection in this section.
hose
z Brake pads
z Brake discs
z Suspension z REFER to Section 204-00 to
component(s) diagnose suspension system.
and/or wheel
alignment
z Brake pedal goes z Brake fluid leaks z INSPECT the system for leaks.
down fast or eases and/or air in the REPAIR as necessary. BLEED
down slowly system the system. REFER to Brake
System Bleeding in this section.
z Brake master z CARRY OUT the Brake Master
cylinder Cylinder — Bypass Condition
z Hydraulic Control z REFER to Section 206-09 to
Unit (HCU) diagnose the HCU .
z Brakes lock up z Brake pads z INSPECT the brake system
under light brake z Brake flexible components. REFER to Brake

pedal force hose System Inspection in this section.
z Brake disc
z Brake calipers
and/or guide pins
z ABS z REFER to Section 206-09 to
diagnose the ABS.
z Excessive brake z Brake fluid leaks z INSPECT the system for leaks.
pedal travel and/or air in the REPAIR as necessary. BLEED
(low/spongy pedal) system the system. REFER to Brake
System Bleeding in this section.
z Brake master z CARRY OUT the Brake Master
cylinder Cylinder — Bypass Condition
z Brake calipers z INSPECT the brake calipers and
and/or guide pins guide pins. REFER to Brake
System Inspection in this section.
z Brake flexible z INSPECT the brake flexible
hose hoses during brake application.
REFER to Brake System
Inspection in this section.
z HCU z REFER to Section 206-09 to
diagnose the HCU .
z Erratic brake pedal z Brake pedal z INSPECT the brake pedal for
travel binding, obstructions and correct
connection to booster rod.
REPAIR as necessary. CHECK
the brake pedal fasteners for
correct torque. REFER to
Specifications in Section 206-06 .
z ABS z REFER to Section 206-09 to
diagnose the ABS.
z Brakes drag z Stoplamp switch z VERIFY correct installation of the
stoplamp switch. REFER to
Section 417-01 .
z Parking brake z REFER to Section 206-05 to
component diagnose the parking brake
system.
z Brake caliper z INSPECT the brake caliper and
and/or guide pins guide pins. REFER to Brake
System Inspection in this section.
z Brake z CARRY OUT the Brake Master
booster/Master Cylinder — Compensator Port
cylinder Component Test in this section.
z HCU z REFER to Section 206-09 to
diagnose the HCU .
z Excessive brake z Insufficient engine z CARRY OUT the Brake Booster
pedal effort vacuum for brake Component Test in this section.
booster operation z If any DTCs are retrieved for the
z Brake booster brake vacuum pump, resolve
manifold vacuum them first before attempting any
hose base brake repairs.
z Brake booster
z Brake booster
vacuum
sensor/check
valve
z Brake vacuum
pump
z Brake pads z INSPECT the brake pads.
REFER to Brake System
z Vibration when the z Brake disc(s) z GO to Pinpoint Test A .
brakes are applied z Suspension
components
z Brake vibration/shudder z Brake drag z GO to Symptom Chart - Brake
— occurs when the System .
brake pedal is released
z Rear brake noise — z Parking brake z INSPECT the parking brake
occurs when the brake component components. REFER to Section
pedal is unapplied 206-05 .
z Rattling noise z Caliper guide z CHECK the caliper guide pins
pins or guide and guide pin bolts. REFER to
pin bolts Brake System Inspection in this
section.
z Missing or z CHECK the brake pads for
damaged anti- missing clips or broken springs.
rattle clips or INSTALL new components as
springs necessary. REFER to Section
206-03 for front disc brakes or
Section 206-04 for rear disc
brakes.
z Loose brake z TIGHTEN the brake disc shield
disc shield bolts to specification. REFER to
Section 206-03 for front disc
brakes or Section 206-04 for
rear disc brakes.
z Squealing noise — z Brake pads z Acceptable condition. Caused
occurs on first by humidity and low brake pad
(morning) brake temperature.
application
z Squealing noise — a z Brake pads z INSPECT the brake pads.
continuous squeal REFER to Brake System

z Squealing noise — an z Brake pads z Acceptable condition. Caused
intermittent squeal by cold, heat, water, mud or
snow.
z Groaning noise — z Brake pads z Acceptable condition.
occurs at low speeds
with brake lightly
applied (creeping)
z Grinding/moaning noise z Brake pads z INSPECT the brake pads, brake
— continuous z Brake disc discs and attaching hardware.
VERIFY brake components are
within specifications. REFER to
Brake System Inspection in this
section.
Brake Disc Machining
NOTE: Do not use a bench lathe to machine the brake discs. Use an on-vehicle brake lathe only. Read the
entire operating manual and/or view the video shipped with the lathe before installing, operating or repairing
the lathe.
NOTE: An on-vehicle brake lathe with an automatic runout adjustment feature is preferred. However, if the
lathe is not self adjusting, the lathe oscillation must be adjusted using a dial indicator. The total indicated
runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than 0.050 mm
(0.002 in). If the runout adjustment (automatic or manual) is carried out correctly prior to machining, then the
final brake disc runout will be within specification and a runout measurement is not necessary after
machining.
NOTE: Lateral runout and disc thickness variation measurements are not required because correct
adjustment of the on-vehicle brake lathe will make sure that these dimensions are within specification.
2. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose may
occur.
Remove the bolts and position the brake caliper or brake caliper and anchor plate assembly aside, as
required.
z Support the brake caliper using mechanic's wire.
3. Install the hub adapter using:

z four wheel nuts on a 4-stud wheel hub.
z five wheel nuts on a 5-stud wheel hub.
z six wheel nuts on a 6-stud wheel hub.
z four wheel nuts on a 7- or 8-stud wheel hub.
z five wheel nuts on a 10-stud wheel hub.
4. Install the cutting lathe.
5. If the lathe is not self adjusting, adjust the lathe oscillation using a dial indicator. The total indicated
runout target is 0.000 mm (0.000 in). The maximum indicated runout should be no more than 0.050
mm (0.002 in).
6. Center the cutting head, adjust the cutting bits and install the chip deflector/silencer.
7. NOTE: The depth of the cut should be between 0.10 and 0.40 mm (0.004 and 0.015 in). Lighter cuts
will cause the bit to heat up and wear faster. Heavier cuts will cause poor brake disc surface finish.
Machine the brake disc.
8. Remove the lathe and the silencer.
9. Remove the wheel nuts and hub adapter.
10. Remove the metal shavings.
11. Measure the brake disc thickness.

z If the measurement is below the minimum specification, install a new brake disc. For additional
information, refer to Section 206-03 for front disc brakes or Section 206-04 for rear disc
brakes.
12. NOTE: It is not required to install new brake pads if friction material is within specifications. For
Position the brake caliper or brake caliper and anchor plate assembly.
z Install the bolts.
z For fastener torque specifications, refer to Section 206-03 for front disc brakes or Section 206-
04 for rear disc brakes.
Brake System Bleeding
General Equipment
Brake/Clutch System Pressure Bleeder/Filler
Fluid Container and Hose
Pressure
Master cylinder may be damaged if operated without fluid, resulting in degraded braking
performance. Failure to follow this instruction may result in serious personal injury.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
NOTE: The HCU bleeding procedure must be carried out if a new HCU has been installed.
All Vehicles
1. NOTE: Make sure the area around the master cylinder cap is clean and free of foriegn material.
2. Fill the reservoir with clean, specified brake fluid. Refer to Specifications in this section.
3. NOTE: Master cylinder pressure bleeder adapter tools are available from various manufacturers of
pressure bleeding equipment. Follow the instructions of the manufacturer when installing the adapter.
Install the bleeder adapter to the brake master cylinder reservoir and attach the bleeder tank hose to
the fitting on the adapter.
4. NOTE: Make sure the bleeder tank contains enough specified brake fluid to complete the bleeding
operation. Refer to Specifications in this section.
Open the valve on the bleeder tank.

z Apply 207-345 kPa (30-50 psi) to the brake system.
5. With the vehicle in NEUTRAL, position it on a hoist. Section 100-02 .
6. Bleeding steps must be followed in the order indicated in the graphic.
7.
8.
9.
10. Loosen the bleeder screw 180° and leave open until clear bubble free brake fluid flows and then
tighten the bleeder screw.
Vehicles with rear integral parking brake calipers
11. NOTE: Due to the complexity of the fluid path within the rear integral parking brake calipers, it is
necessary to press and release the parking brake during the bleed procedure.
Apply and release the parking brake 5 times. Loosen the rear bleeder screw. Leave open until clear,
bubble-free brake fluid flows, then tighten the rear bleeder screw.
z Repeat until clear, bubble-free fluid comes out.
All vehicles
12. Tighten the bleeder screw to specification. Refer to Specifications in this section.
z Remove the fluid container and hose.
13.
14. Repeat steps 7-13 at the remaining wheel ends.
15. Close the bleeder tank valve and release the pressure. Remove the tank hose from the adapter and
remove the adapter.
16. Fill the reservoir with clean, specified brake fluid. Refer to Specifications in this section.
17.
Hydraulic Control Unit (HCU) Bleeding
NOTE: The HCU bleeding procedure must be carried out if a new HCU has been installed.
NOTE: Pressure bleeding the brake system is preferred to manual bleeding.
1. Follow the pressure bleeding or manual bleeding procedure steps to bleed the system.
2. Connect the diagnostic scan tool and follow the ABS Service Bleed instructions.
3. Repeat the pressure bleeding or manual bleeding procedure steps to bleed the system.
Brake System Inspection
Material
Item Specification
Motorcraft® Metal Brake Parts —
Cleaner (US) / Motorcraft® Brake
Parts Cleaner (Canada)
(Canada)
Motorcraft® Silicone Brake Caliper ESE-M1C171-
Grease and Dielectric Compound A
XG-3-A
Brake Pads
NOTE: It is not required to install new brake pads when the brake discs are machined.
1. Inspect the brake pad friction material for contamination.

z If the friction material shows evidence of contamination, install new brake pads. For additional
information, refer to Section 206-03 for front brake pads or Section 206-04 for rear brake pads.
2. Inspect and measure the thickness of the brake pad friction material. For additional information, refer
to Specifications in this section.
z Minor surface cracks do not require pad replacement, however, if there are missing chunks or
cracks in the lining through to the backing plate, install new brake pads. For additional
information, refer to Section 206-03 for front brake pads or Section 206-04 for rear brake pads.
z If the thickness of the friction material is less than the specified thickness, install new brake
pads. For additional information, refer to Section 206-03 for front brake pads or Section 206-04
for rear brake pads.
z If the friction material shows taper wear that is not within specifications, install new brake pads
and verify the caliper guide pins are functioning correctly. For additional information, refer to
Brake Caliper Guide Pins inspection.
Brake Discs
NOTICE: Using an impact tool without a torque socket will lead to unevenly tightened wheel nuts.
This causes brake disc on-vehicle lateral runout and brake roughness.
1. Inspect the brake discs and measure the brake disc thickness. Record the measurement. Refer to
Specifications in this section.
z If the brake disc is cracked or otherwise damaged, install a new brake disc. For additional
information, refer to Section 206-03 for front brakes or Section 206-04 for rear brakes.
z If the measurement is below the minimum thickness specification, install a new brake disc. For
additional information, refer to Section 206-03 for front brakes or Section 206-04 for rear
brakes.
z If the diagnosis has revealed vibration in the steering wheel, seat or pedal while braking that
varies with vehicle speed, machine the brake disc. Heavily scored brake discs, similar to that
caused by pads worn down to the backing plate, should also be machined. In order to
machine, discs must be above the minimum thickness specification. For additional information,
refer to Specifications and Brake Disc Machining in this section.
Brake Calipers
1. Inspect the brake calipers for leaks, damage to seals and piston corrosion or binding.
z If the brake caliper is leaking or otherwise damaged, install a new brake caliper. For additional
information, refer to Section 206-03 for front brake calipers or Section 206-04 for rear brake
calipers.
Brake Caliper Guide Pins
1. The guide pins should slide with a reasonable amount of hand force. If the brake pads show taper
wear or the guide pins are difficult to move, carry out the following steps.
z Disassemble the brake caliper guide pins and inspect the guide pins and guide pin bores for
wear, damage and corrosion. If the bore is worn or damaged, replace the damaged
component.
z Use a wire brush, rolled-up sandpaper or emery cloth to remove all corrosion and foreign
material from the caliper guide pin bores. Clean any remaining foreign material from the bores
with brake parts cleaner and compressed air.
z Assemble the caliper seals, boots and guide pins. Use an ample amount of the specified
grease to lubricate the bores and guide pins.
z Inspect the brake pads. For additional information, refer to Brake Pads inspection in this
section.
Brake Flexible Hoses and Tubes
NOTICE: Never use copper tubing. It is subject to fatigue, cracking and corrosion, which may result
in brake tube failure.
NOTE: Double-wall steel tubing is used throughout the brake hydraulic system. All brake tube fittings must
be correctly double flared to provide strong, leakproof connections. When bending tubing to fit the
underbody or rear axle contours, be careful not to kink or crack the tube.
1. Inspect brake tubes for corrosion, cracks, leaks or any other signs of damage.
z If a section of the brake tube is damaged, the entire section must be installed with a new tube
of the same type, size, shape and length.
z When installing the hydraulic brake tubing, hoses or connectors, tighten all connections to
specifications. After installation, bleed the brake system. For additional information, refer to
Brake System Bleeding in this section.
2. Inspect the brake flexible hoses for cracks, leaks and swelling during brake application or any other
signs of damage.
z Install a new brake flexible hose if the hose shows signs of softening, cracking or other
damage. For additional information, refer to Section 206-03 for the front brake flexible hose or
Section 206-04 for the rear brake flexible hose.
Brake Master Cylinder
NOTE: During normal operation of the brake master cylinder, the returning brake fluid creates a slight
turbulence in the master cylinder reservoir. This is a normal condition and indicates that the compensator
ports are not clogged. Clogged compensator ports may cause the brakes to hang up or not fully release.
The net fluid level (such as after brake application and release) will remain unchanged. Fluid level will
decrease with pad wear.
NOTE: A trace of brake fluid will exist on the booster shell below the master cylinder mounting flange. This
results from the normal lubricating action of the master cylinder bore and seal.
1. Inspect the brake master cylinder for fluid leaks.

z Install a new master cylinder or brake fluid reservoir if signs of excessive leaking are present.
z To check for correct brake master cylinder operation, refer to Component Tests in this section.
Brake Booster
1. Inspect the brake booster for excessive corrosion or damage. Inspect the vacuum hoses for leaks
and kinks.
z Install a new brake booster if signs of excessive corrosion or damage is found. For additional
z Repair or replace vacuum hoses as necessary.
z To check for correct brake booster operation, refer to Component Tests in this section.
Component Bleeding
General Equipment
Master Cylinder Bleeding Set
Master Cylinder
Master cylinder may be damaged if operated without fluid, resulting in degraded braking
performance. Failure to follow this instruction may result in serious personal injury.
NOTE: When a new brake master cylinder has been installed, it should be primed to prevent air from
entering the system.
1.
2. Refer to Specifications in this section.
3.
4. Use the General Equipment: Master Cylinder Bleeding Set
5. Have an assistant pump the brake pedal slowly until clear bubble free fluid flows from the brake
tubes.
6. Remove the General Equipment: Master Cylinder Bleeding Set
9. Presssure bleed the brake system. Refer to Brake System Bleeding .
Brake Caliper, Wheel Cylinder, Brake Hose or Brake Tube
1. NOTE: Pressure bleeding the brake system is required anytime a hydraulic brake system component
has been disconnected.
Pressure bleed the brake system. Refer to Brake System Bleeding .
SECTION 206-03: Front Disc Brake 2014 F-150 Workshop Manual

Material
Capacity
High Performance DOT 3 WSS-M6C62-A or 1,420 ml
Motor Vehicle Brake Fluid WSS-M6C65-A1 (3 pt)
(Canada)
Metal Brake Parts Cleaner — —
PM-4-A or PM-4-B (US);
CPM-4 (Canada)
Item Specification
Brake Disc
Brake disc minimum thickness 32 mm (1.259 in)
Brake Pads
Brake pad maximum taper wear (in any direction) 3.0 mm (0.118 in)
Brake pad minimum thickness 3.0 mm (0.118 in)
Brake caliper anchor plate bolts 250 184 —
Brake caliper flow bolt 35 26 —
Brake caliper guide pin bolts 37 27 —
Brake flexible hose bracket-to-wheel knuckle bolt 30 22 —
Brake tube fitting 17 — 150

Front Disc Brake
The front brake disc system consists of the following components:
z Brake pads
z Brake caliper anchor plate
z Brake caliper
z Brake disc
z Brake disc shield
z Brake flexible hose
When mechanical force is applied by the driver to the brake pedal, the force is converted into hydraulic
pressure by the master cylinder. The hydraulic force is directed to the disc brake calipers and transferred to
the brake pads. The brake pads are then forced against the brake friction surfaces by the brake caliper
pistons. The friction of the brake pads on the brake disc causes the slowing of wheel rotation and the
vehicle.

Front Disc Brake

Brake Caliper Anchor Plate
Material
Item Specification
Metal Brake Parts Cleaner —
(Canada)
Removal
1. Remove the brake pads. For additional information, refer to Brake Pads in this section.

Apply the specified chemical with a spray can
Clean the specified component with the specified material
z To install, tighten the new bolts to 250 Nm (184 lb-ft).
Installation

Brake Caliper
Removal
NOTE: Removal steps in this procedure may contain installation details.

1. NOTE: Use 2 new copper washers.

2. NOTE: Tighten the lower brake caliper guide pin bolt first.
Installation
2. Bleed the brake caliper. For additional information, refer to Component Bleeding in Section 206-00 .

Brake Disc Shield
Removal
1. Remove the brake disc. For additional information, refer to Brake Disc in this section.
2.
Installation

Brake Disc
Material
Item Specification
(Canada)
Removal
2. NOTICE: Do not allow the caliper and anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Discard the specified component. Follow local disposal regulations.

Relocate and support the component.
3.
Installation
1. Apply the specified chemical with a spray can.

Clean the specified component with the specified material.

Brake Flexible Hose
Removal

1. NOTE: Use new copper washers.

2. To install, tighten to 17 Nm (150 lb-in).
3. To install, tighten to 30 Nm (22 lb-ft).
Installation

z Bleed the brake caliper. For additional information, refer to Component Bleeding in Section
206-00 .

Brake Pads
Material
Item Specification
High Performance DOT 3 WSS-M6C62-A or
Motor Vehicle Brake Fluid WSS-M6C65-A1
(Canada)
Removal
possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in
uneven braking and serious personal injury.
1. Visual check. Extract the fluid with a syringe.

If necessary, remove fluid until the brake master cylinder reservoir is half full.
3. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose can
occur.

4.
5. NOTE: Protect the piston and boots when pushing the caliper piston into the caliper piston bores or
damage to the piston or boots may occur.
If installing new brake pads, Use a C-clamp and a worn brake pad to compress the disc brake caliper
pistons into the brake caliper bore.
Installation
NOTE: If installing new brake pads, make sure to install all new hardware and specified lubricant supplied
with the brake pad kit. Refer to the brake pad instruction sheet when applying lubricant.

1. Fill the master cylinder with clean, specified brake fluid.
2. Apply brakes several times to verify correct brake operation.
SECTION 206-04: Rear Disc Brake 2014 F-150 Workshop Manual

Material
Capacity
High Performance DOT 3 WSS-M6C62-A or 1,420 ml
Motor Vehicle Brake Fluid WSS-M6C65-A1 (3.0 pt)
(Canada)
Metal Brake Parts Cleaner — —
PM-4-A or PM-4-B (US);
CPM-4 (Canada)
Item Specification
Brake Disc
Brake disc minimum thickness 23.0 mm (0.906 in)
Brake Pads
Brake pad maximum taper wear (in any direction) 3.0 mm (0.118 in)
Brake pad minimum thickness 3.0 mm (0.118 in)
Axle vent valve 18 — 159
Brake caliper bleeder screw 10 — 89
Brake caliper flow bolt 35 26 —
Brake caliper guide pin bolts 33 24 —
Brake caliper support bracket bolts 150 111 —
Brake flexible hose bracket-to-axle bolt 30 22 —
Brake flexible hose bracket-to-frame bolt 17 — 150
Brake tube fitting 17 — 150

Rear Disc Brake
The rear disc brake system consists of the following components:
z Brake caliper
z Brake caliper support bracket
z Brake disc
z Brake pads
z Inner brake flexible hose
z Outer brake flexible hose
When mechanical force is applied by the driver to the brake pedal, the force is converted into hydraulic
pressure by the master cylinder. The hydraulic force is directed to the disc brake calipers and transferred to
the brake pads. The brake pads are then forced against the brake friction surfaces by the brake caliper
pistons. The friction of the brake pads on the brake disc causes the slowing or stopping of wheel rotation
and the vehicle.

Rear Disc Brake

Brake Caliper
Removal
3.
Installation
1.
2. NOTE: Use 2 new copper washers.

Brake Disc Shield
Removal
1. Remove the rear axle. For additional information, refer to Section 205-02A or Section 205-02B .
2. Remove the parking brake shoes. For additional information, refer to Section 206-05 .
Installation

Brake Disc
Material
Item Specification
(Canada)
Removal
2. NOTICE: Do not allow the caliper assembly to hang from the brake hose or damage to the
hose can occur.

3.
Installation
1. Apply the specified chemical with a spray can. Clean the specified component with the specified
material.

z Apply brakes several times to verify correct brake operation.

Brake Flexible Hose — Inner
Removal
02 .
2.
3.
Installation
2. Bleed the brake calipers. For additional information, refer to Component Bleeding in Section 206-00 .

Brake Flexible Hose — Outer
Removal
02 .
2. NOTE: RH shown LH similar.
Discard the specified component. Follow local disposal regulations.

2. NOTE: Use new copper washers.
4.
Installation

Brake Pads
Material
Item Specification
Molykote® M77 —
8U7Z-19A506-A
Removal
possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in
uneven braking and serious personal injury.
1. Visual check. Extract the fluid with a syringe.

If necessary, remove fluid until the brake master cylinder reservoir is half full.
3. NOTICE: Do not allow the caliper to hang from the brake hose or damage to the hose can
occur.
4.
5. Visual check.
Measure the brake disc thickness and install a new brake disc if it is not within specification.
6.
Installation
NOTE: If installing new brake pads, make sure to install all new hardware and specified lubricant supplied
with the brake pad kit. Refer to the brake pad instruction sheet when applying lubricant.
1. NOTICE: Protect the caliper pistons and boots when pushing the caliper piston into the caliper
piston bores or damage to components may occur.
2. NOTICE: Do not allow grease, oil, brake fluid or other contaminants to contact the pad lining
material or damage to components may occur. Do not install contaminated pads.
NOTE: Install all new hardware supplied with the pad kit.
3.
4.
5. Fill the master cylinder with clean specified brake fluid.

SECTION 206-05: Parking Brake and Actuation 2014 F-150 Workshop Manual
Material
Molykote® M77 — —
8U7Z-19A506-A
Item Specification
Parking brake shoe clearance 0.59 mm (0.023 in)
Parking brake cable bracket bolt (RH) 30 22 —
Parking brake control bolts 20 — 177
Parking Brake
The parking brake and actuation system consists of the following components:
z Parking brake cables

z Parking brake control
z Parking brake shoes
z Red brake warning indicator
The parking brake system is a foot-operated/cable-actuated system that applies a drum-in-hat assembly
within each rear brake disc. A red brake warning indicator is located in the instrument cluster and will
illuminate when the system is actuated to alert the driver that the parking brakes are applied.
Parking Brake
Parking Brake System
The parking brake system is an independent, cable-actuated system controlled by an foot-operated parking
brake control that is self adjusting. The parking brake control applies tension to the front parking brake cable
and conduit. The front parking brake cable is coupled to the LH rear parking brake cable and conduit which
is coupled to the RH rear parking brake cable. The parking brake cable and conduits actuate the parking
brake levers, engaging the parking brake shoes with the parking brake drum-in-hat assembly. The system is
returned to the released position by pulling the parking brake control release handle. Springs in the parking
brake system apply the necessary force to return the system to the unapplied position. The parking brake
warning indicator is located in the instrument cluster. It illuminates to signal the driver that the parking brake
is applied or to signal a low brake fluid condition. The warning indicator system is diagnosed in Section 413-
01 .
NOTE: Prior to carrying out any diagnosis, make sure the red brake warning indicator is functional. Refer to
Section 413-01 .
The first indication that something may be wrong in the brake system is a change in the feeling through the
parking brake control. The parking brake not holding on an incline or dragging after being released are also
indicators of system concerns.
Check the operation of the parking brake system with the vehicle on a hoist and the parking brake control
fully released. Check for any damaged cables and install new components as necessary. Check the rear
brake adjustment or carry out the brake system diagnosis.

Mechanical
z Parking brake cable(s)
z Parking brake control release handle
z Parking brake shoes and hardware
4. If the cause is not visually evident, verify the symptom and GO to Symptom Chart .
Symptom Chart
Symptom Chart
z The red brake warning z Brake fluid level z REFER to Diagnosis
indicator is always/never on switch and Testing in Section
z Parking brake 413-01 .
switch
z Wiring, terminals
or connectors
z Instrument cluster
z Smart Junction
Box (SJB)
z Vacuum sensor
z The parking brake does not z Parking brake z GO to Pinpoint Test A .
apply cable(s)
z Parking brake
control
z Parking brake
shoes and
hardware
z The parking brake does not z Parking brake z GO to Pinpoint Test B .
release and/or parking brake cable(s)
shoes drag z Parking brake
control
z Parking brake
shoes and
hardware
Pinpoint Tests
Pinpoint Test A: The Parking Brake Does Not Apply
Normal Operation
When the parking brake control is pressed, tension is applied to the front parking brake cable. This tension
pulls on the RH rear parking brake cable, which is attached to the RH rear parking brake shoe actuator and
applies the RH rear brake shoes. At the same time, the tension in the RH rear cable causes the RH rear
conduit to attempt to straighten out. This straightening effect causes the RH rear conduit to pull on the LH
rear parking brake cable, which is attached to the LH rear parking brake shoe actuator and applies the LH
rear brake shoes.

PINPOINT TEST A: THE PARKING BRAKE DOES NOT APPLY

A1 CHECK THE PARKING BRAKE CONTROL
z Press the parking brake control pedal. Yes
z Does the parking brake control pedal move? GO to A2 .
No
GO to A5 .
A2 CHECK FOR BROKEN CABLES
z Have an assistant press and release the parking brake Yes
pedal to help isolate disconnected cables or cables GO to A3 .
that do not move.
z Inspect the following items for damage and correct No
connections. CONNECT the cable(s) or INSTALL
Front cable and conduit new parking brake component(s) as
LH rear cable and conduit necessary. TEST the system for
RH rear cable and conduit normal operation.
Rear cable brackets
z Are the cables in good condition?
A3 CHECK THE PARKING BRAKE SHOES, ACTUATOR
LEVERS AND HARDWARE
z Remove the rear brake disc, refer to Section 206-04 . Yes
Inspect the parking brake shoes, actuator levers and GO to A4 .
hardware.
z Are the parking brake shoes, actuator levers and No
hardware in good condition? INSTALL new components as
necessary. REFER to Parking Brake
Shoes in this section. TEST the system
for normal operation.
A4 CHECK THE PARKING BRAKE SHOE ADJUSTMENT
z Check the parking brake shoe adjustment. Refer to Yes
Parking Brake Shoe Adjustment in this section. INSTALL a new parking brake control.
z Are the parking brake shoes adjusted to REFER to Parking Brake Control in this
specification? section. TEST the system for normal
operation.
No
ADJUST the rear parking brake shoes.
REFER to Parking Brake Shoe
A5 ISOLATE THE PARKING BRAKE CONTROL AND
FRONT PARKING BRAKE CABLE
z Disconnect the front parking brake cable from the RH Yes
rear parking brake cable at the cable union. GO to A6 .
No
GO to A7 .
z Press the parking brake control pedal.

z Does the parking brake control pedal move?
A6 ISOLATE THE REAR PARKING BRAKE CABLES
z Disconnect the LH cable from the RH conduit Yes
equalizer. INSPECT the parking brake shoes,
z Disconnect the rear parking brake cables from the hardware and backing plate. INSTALL
parking brake actuating levers. new components as necessary.
z While holding the cable conduit, attempt to slide the REFER to Parking Brake Shoes in this
cable inside the conduit. section. TEST the system for normal
z Does the cable slide freely inside the conduit? operation.
No
INSTALL new rear brake cable(s).
REFER to Parking Brake Cable —
Rear, LH or Parking Brake Cable —
Rear, RH in this section. TEST the
system for normal operation.
A7 ISOLATE THE FRONT PARKING BRAKE CABLE
z NOTE: The parking brake control take-up spool tab Yes
may need to be bent aside to allow the cable to be INSTALL a new parking brake control.
removed. REFER to Parking Brake Control in this
z Disconnect the front parking brake cable and conduit section. TEST the system for normal
from the parking brake control. operation.
No
INSTALL a new front parking brake
cable. REFER to Parking Brake Cable
— Front in this section. TEST the
z While holding the cable conduit, attempt to slide the

cable inside the conduit.
z Does the cable slide freely inside the conduit?
Pinpoint Test B: The Parking Brake Does Not Release and/or Parking Brake Shoes Drag
Normal Operation
When the parking brake release handle is pulled, the ratchet mechanism and return spring in the parking
brake control release the tension on the parking brake cables and conduits. The cable conduits, cable
springs and parking brake shoe springs provide the force necessary to return the parking brake system to
the released position.

z Parking brake control release handle
z Parking brake shoe actuators
PINPOINT TEST B: THE PARKING BRAKE DOES NOT RELEASE AND/OR PARKING BRAKE SHOES
DRAG

B1 CHECK THE PARKING BRAKE CONTROL RELEASE
HANDLE AND CABLE
z Verify that the release handle and cable are Yes
connected to the parking brake control. GO to B2 .
z Are the release handle and cable connected?
No
CONNECT the handle and cable.
B2 CHECK THE REAR PARKING BRAKE CABLES
z Disconnect the LH cable from the RH conduit Yes
equalizer. GO to B3 .
z Disconnect the front parking brake cable from the RH
rear parking brake cable at the cable union. No
INSTALL new rear brake cable(s).
REFER to Parking Brake Cable —
Rear, LH or Parking Brake Cable —
Rear, RH in this section. TEST the
z Disconnect the rear parking brake cables from the

parking brake actuating levers.
z While holding the rear cable conduit, attempt to slide
the rear cable inside the conduit.
B3 CHECK THE REAR PARKING BRAKE SHOES AND
HARDWARE
z Remove the rear brake disc. Refer to Section 206-04 . Yes
z Inspect the parking brake shoes, hardware and GO to B4 .
backing plate.
z Are the shoes, hardware and backing plate in No
good condition? INSTALL new components as
necessary. REFER to Parking Brake

Shoes in this section. TEST the system
B4 ISOLATE THE FRONT PARKING BRAKE CABLE
z NOTE: The parking brake control take-up spool tab Yes
may need to be bent aside to allow the cable to be INSTALL a new parking brake control.
removed. REFER to Parking Brake Control in this
z Disconnect the front parking brake cable and conduit section. TEST the system for normal
from the parking brake control. operation.
No
INSTALL a new front cable. TEST the
z While holding the cable conduit, attempt to slide the

cable inside the conduit.
Parking Brake Cable Tension Release
1. Release the parking brake.
02 .
3. With an assistant, release the parking brake cable tension by pulling down on the intermediate cable
at the cable-to-cable union until the parking brake control sector rotates to its stop and a 4 mm (0.15
in) x 150 mm (5.9 in) retainer pin can be inserted.
4. Disconnect the cable at the cable-to-cable union.
5. To reload the tension on the parking brake cable, follow the release procedure in reverse.
z Inspect the parking brake system for correct operation.
Parking Brake Shoe Adjustment
Special Tool(s)
Brake Adjusting Gauge
206-D002 (D81L-1103-A) or
equivalent
1. NOTE: Make sure the parking brake is fully released.
Using the release handle, release the parking brake control.
3. Using the Brake Adjusting Gauge, measure the ID of the drum portion of the rear brake disc and set
the locking screw.
z Record the measurement.
4. Place the Brake Adjusting Gauge over the widest diameter of the parking brake shoes.
5. Adjust the parking brake shoe clearance to 0.59 mm (0.023 in) less than the ID of the drum portion of
the rear brake disc.
z Rotate the parking brake shoe adjuster to achieve the correct parking brake shoe-to-brake disc
clearance.
7. Test the parking brake for normal operation.
Parking Brake Cable — Front
1. Release the tension on the parking brake cable. For additional information, refer to Parking Brake
Cable Tension Release in this section.
2. Remove the LH cowl side trim panel. For additional information, refer to Section 501-05 .
3. NOTE: The parking brake control take-up spool tab may need to be bent aside to allow the cable to
be removed.
Disconnect the front parking brake cables from the parking brake control.
4. Release the front parking brake cable conduit from the parking brake control.
5. Detach the cable conduit grommet and remove the cable.

Parking Brake Cable — Rear, LH
Removal
1. Release the parking brake cable tension. For additional information, refer to Parking Brake Cable
Tension Release in this section.
2.
3.
4.
5.
Installation

Parking Brake Cable — Rear, RH
Removal
2.
3.
5.
6.
8.
Installation
Parking Brake Control

1 W707628 Parking brake release handle bolt
2 2783 Parking brake release handle
3 W704522 Parking brake control assembly bolt (3 required)
4 2780 Parking brake control
5 2853 Front parking brake cable
6 N807729 Parking brake warning indicator switch screw
7 15A851 Parking brake warning indicator switch
Removal
1. Remove the LH cowl side trim panel. For additional information, refer to Section 501-05 .
2. Release the tension on the parking brake cable. For additional information, refer to Parking Brake
3. Remove the parking brake release handle bolt and pull the handle assembly down to prevent
breaking off the locator tabs.
4. Disconnect the parking brake release handle cable from the parking brake control.
5. Disconnect the parking brake switch electrical connector.
6. Remove the 3 bolts from the parking brake control.

7. Position the cable conduit grommet up through the floor.

z Release the cable from the parking brake control.
8. Remove the parking brake control from the vehicle.
Installation

Parking Brake Shoes
Material
Item Specification
Molykote® M77 —
8U7Z-19A506-A
Removal
NOTE: One parking brake shoe kit contains the linings required for both the LH and RH side.
3.
Installation
1. NOTE: Using specified grease, lubricate the parking brake shoes where the shoe contacts the
actuator lever and the support bracket.
Apply the substance from the specified tube.
2. NOTE: Completely retract the parking brake adjusting screw before installation.
3. Adjust the parking brake shoe. For additional information, refer to Parking Brake Shoe Adjustment in
this section.
4. Reload the tension on the parking brake cable. For additional information, refer to Parking Brake
Parking Brake Warning Indicator Switch
1. Disconnect the parking brake warning indicator switch electrical connector.
2. Remove the parking brake warning indicator switch screw and the switch.
SECTION 206-06: Hydraulic Brake Actuation 2014 F-150 Workshop Manual

Material
Capacity
Motorcraft® High Performance WSS-M6C62-A 740 ml
DOT 3 Motor Vehicle Brake or WSS-M6C65- (1.56 pt)
Fluid (US) / Motorcraft® Brake A1
Fluid - Heavy Duty DOT 3
(Canada)
(Canada)
Brake booster-to-pedal bracket nuts a — — —
Brake master cylinder nuts 25 18 —
Brake pedal bracket bolts 25 18 —
Brake pedal control switch screw 3 — 27
Coolant expansion tank/lower Air Cleaner (ACL) housing assembly bolts 15 — 133
Hood switch and bracket nut 6 — 53
Primary brake tube fitting 28 21 —
Secondary brake tube fitting 20 — 177

Hydraulic Brake Actuation
Hydraulic Brakes
The hydraulic brake actuation system consists of the following components:
z Brake master cylinder and fluid reservoir

z Brake tubes and hoses
z Brake pedal and bracket
z Hydraulic Control Unit (HCU) (part of ABS)
Adjustable Pedals
Adjustable pedals are available as an optional feature on this vehicle. Two systems are available, with or
without memory and consist of the following components:
z Adjustable brake pedal and bracket

z Adjustable accelerator pedal with motor and attached cable
z Adjustable pedal switch
z Steering Column Control Module (SCCM)
z Memory SET switch (with memory feature only)
z Driver Seat Module (DSM) (with memory feature only)
z Body Control Module (BCM) (with memory feature only)
z Remote Keyless Entry (RKE) (with memory feature only)

Diagnostic Trouble Code (DTC) Charts
Steering Column Control Module (SCCM) DTC Chart

B1368:11 Adjustable Pedal Position Feedback GO to Pinpoint Test C .
Sensor: Circuit Short To Ground
B1368:12 Adjustable Pedal Position Feedback GO to Pinpoint Test C .
Sensor: Circuit Short To Battery
B1369:09 Pedal Adjustment Switch: INSTALL a new brake pedal control switch. REFER
Component Failure to Brake Pedal Control Switch in this section.
CLEAR the DTCs. REPEAT the self-test.
If DTC B1369:09 returns, INSTALL a new Steering

Column Control Module (SCCM). REFER to Section
211-05 .
CLEAR the DTCs. REPEAT the self-test. TEST the

B137D:18 Pedal Adjustment Motor: Circuit GO to Pinpoint Test A .
Current Below Threshold
B137D:19 Pedal Adjustment Motor: Circuit GO to Pinpoint Test A .
Current Above Threshold
B137D:71 Pedal Adjustment Motor: Actuator GO to Pinpoint Test A .
Stuck
B1D36:09 Turn Indicator Switch: Component REFER to Section 417-01 .
Failure
SCCM DTCs

Adjustable Pedal Indexing
NOTICE: The adjustable pedal system must be indexed whenever the brake pedal assembly or
accelerator pedal assembly is installed or damage to the components may result.
1. NOTE: Make sure the electrical connector is connected to the adjustable pedal motor.
Disconnect the accelerator pedal-to-brake pedal cable from the adjustable brake pedal gear set.
2. Operate the accelerator pedal to the full rearward position.
3. Connect the adjustable pedal motor drive cable to the adjustable brake pedal drive.
4. Operate the adjustable pedals to the full forward position.
5. Disconnect the adjustable pedal motor drive cable from the adjustable brake pedal assembly.
6. Operate the adjustable accelerator pedal to the full forward position.
7. Connect the adjustable pedal motor drive cable to the adjustable brake pedal drive.
8. Check that the brake and accelerator pedals can be fully adjusted forward and rearward.

Inspection And Verification
Special Tool(s)
System (IDS) software with
appropriate hardware, or
equivalent scan tool
Adjustable Pedals
Visual Inspection Chart — Without Memory Feature

z Adjustable accelerator pedal and motor with cable z Wiring, terminals or connectors
attached z Body Control Module (BCM) fuse(s):
z Adjustable brake pedal and bracket 23 (15A)
z Foreign objects or material 24 (15A)
z Steering Column Control Module
(SCCM)
z Brake pedal control switch
Visual Inspection Chart — With Memory Feature

z Adjustable accelerate pedal and motor with cable z BCM fuse(s):
attached 23 (15A)
z Adjustable brake pedal and bracket 24 (15A)
z Foreign objects or material z Memory SET switch
z Remote Keyless Entry (RKE)
transmitter
z SCCM
z Wiring, terminals or connectors
5. NOTE: The Vehicle Communication Module (VCM) LED prove out confirms power and ground from


z verify the ignition is ON.
z refer to Section 418-00 to diagnose no response from the PCM.

418-00 .
z If the network test passes, proceed with module self-test diagnostics.
8. Carry out the self-test diagnostics for the SCCM , BCM and Driver Seat Module (DSM).
9. If the DTCs retrieved are related to the concern, go to SCCM DTC Chart. For all other SCCM DTCs,
refer to Section 211-05 . For DSM DTCs, refer to Section 501-10 . For BCM and all other DTCs, refer
to Section 419-10 .

Pinpoint Tests
Special Tool(s)
Flex Probe Kit
NUD105-R025D or equivalent
Fluke 77-IV Digital Multimeter

FLU77-4 or equivalent
Test Light
SGT 27000 or equivalent 250-350
mA incandescent bulb test lamp
SGT 27000

Pinpoint Tests
Pinpoint Test A: The Adjustable Pedals Are Inoperative/Does Not Operate Correctly — Using the
Brake Pedal Control Switch
Refer to Wiring Diagrams Cell 127 , Adjustable Pedals for schematic and connector information.
Normal Operation
The Steering Column Control Module (SCCM) receives fused battery voltage from Body Control Module
(BCM) fuses 23 (15A) and 24 (15A).
When the brake pedal control switch is pressed, the SCCM sends current to the adjustable pedals motor
along one circuit and the current returns to the SCCM along another circuit, which is grounded through the
SCCM to move the pedals in the desired direction.
z DTC B137D:18 (Pedal Adjustment Motor: Circuit Current Below Threshold) — This DTC sets if the
SCCM senses current flow to the adjustable pedals motor below a preset limit while the brake pedal
control switch is pressed, or if there is an open or high resistance in the adjustable pedals motor
circuits when the ignition is ON.
z DTC B137D:19 (Pedal Adjustment Motor: Circuit Current Above Threshold) — This DTC sets if the
SCCM senses current flow to the adjustable pedals motor above a preset limit while the brake pedal
control switch is pressed, or if there is a short to ground in the adjustable pedals motor circuits when
the ignition is ON.
z DTC B137D:71 (Pedal Adjustment Motor: Actuator Stuck) — This DTC sets if the SCCM senses
current flow to the adjustable pedals motor within a specific range but above a preset limit while the
brake pedal control switch is pressed when the ignition is ON.

z Foreign objects or material
z Adjustable accelerator pedal and motor with attached cable
z SCCM
PINPOINT TEST A: THE ADJUSTABLE PEDALS ARE INOPERATIVE/DOES NOT OPERATE

CORRECTLY — USING THE BRAKE PEDAL CONTROL SWITCH
NOTICE: Use the Flex Probe Kit for all test connections to prevent damage to the wiring terminals.
Do not use standard multi-meter probes.

A1 CHECK THE ADJUSTABLE PEDALS MOTOR AND CABLE
INSTALLATION
z Check the adjustable pedals motor and cable for correct Yes
installation. GO to A2 .
z Is the motor and cable correctly installed?
No
CORRECT the adjustable
pedals motor installation.
REFER to Section 310-02 .
CLEAR the DTCs. REPEAT
the self-test. TEST the
A2 INSPECT FOR FOREIGN MATERIAL
z Inspect the adjustable brake pedal and accelerator assemblies Yes
for foreign material causing a binding condition. GO to A3 .
z Are the pedal assemblies free from foreign material?
No
REMOVE the foreign
material. CLEAR the DTCs.
REPEAT the self-test. TEST
the system for normal
operation.
A3 CHECK FOR VOLTAGE AT THE SCCM
z Disconnect: SCCM C2414A and C2414B. Yes
z Measure the voltage between SCCM C2414A-10, circuit SBP23 GO to A4 .

(WH/RD), harness side and ground.
No
VERIFY BCM fuses 23 (15A)
and 24 (15A) are OK. If OK,
REPAIR the affected circuit
(s). If not OK, REFER to the
Wiring Diagrams manual to
identify the cause for the
circuit(s) short. CLEAR the
DTCs. REPEAT the self-test.
TEST the system for normal
operation.
z Measure the voltage between SCCM C2414B-8, circuit SBP24

(VT/RD), harness side and ground.
z Is the voltage greater than 10 volts?

A4 CHECK THE SCCM GROUND CIRCUIT FOR AN OPEN
z Measure the resistance between SCCM C2414A-13, circuit Yes
GD133 (BK), harness side and ground. GO to A5 .
No
(s). CLEAR the DTCs.
operation.
z Measure the resistance between SCCM C2414B-5, circuit

GD138 (BK/WH), harness side and ground.
z Are the resistances less than 5 ohms?

A5 CHECK THE ADJUSTABLE PEDALS MOTOR CIRCUITS FOR
AN OPEN
z Disconnect: Adjustable Pedals Motor C2159 (vehicles with Yes
memory) or C2003 (vehicles without memory). GO to A6 .
z Vehicles with memory, measure the resistance between SCCM
C2414B, harness side and adjustable pedals motor C2159, No
harness side as follows: REPAIR the affected circuit
SCCM Circuit Adjustable Pedals Motor REPEAT the self-test. TEST
C2414B-4 CPP01 (WH/OG) C2159-2 operation.
C2414B-7 CPP02 (BN) C2159-1
z Vehicles without memory, measure the resistance between

SCCM C2414B, harness side and adjustable pedal motor
C2003, harness side as follows:
SCCM Circuit Adjustable Pedals Motor

C2414B-4 CPP01 (WH/OG) C2003-2
C2414B-7 CPP02 (BN) C2003-1

A6 CHECK THE ADJUSTABLE PEDALS MOTOR CIRCUITS FOR A
SHORT TO GROUND
z Measure the resistance between ground and: Yes
SCCM C2414B-4, circuit CPP01 (WH/OG), harness side. GO to A7 .
SCCM C2414B-7, circuit CPP02 (BN), harness side.
No
operation.
z Are the resistances greater than 10,000 ohms?

A7 CHECK THE ADJUSTABLE PEDALS MOTOR CIRCUITS FOR A
SHORT TO VOLTAGE
z Ignition ON. Yes
z Measure the voltage between ground and: REPAIR the affected circuit
SCCM C2414B-4, circuit CPP01 (WH/OG), harness side. (s). CLEAR the DTCs.
SCCM C2414B-7, circuit CPP02 (BN), harness side. REPEAT the self-test. TEST
operation.
No
GO to A8 .
z Is any voltage present?

A8 CHECK FOR SCCM OUTPUT
z Ignition OFF. Yes
z Connect: SCCM C2414A and C2414B. GO to A9 .
z NOTICE: The following step uses a test light to simulate
normal circuit loads. Use only the test light recommended in No
the Special Tools table at the beginning of this section. To GO to A10 .
avoid connector terminal damage, use the Flex Probe Kit for
the test light probe connection to the vehicle. Do not use the
test light probe directly on any connector.
z NOTE: When the adjustable pedals electrical connector is
disconnected, the SCCM only supplies voltage to the adjustable
pedals motor in 1 second intervals due to the open on the Hall-
effect sensor circuits.
z Vehicles with memory, connect the test light as follows:
Connect one lead on the test light to C2159-1, circuit
CPP02 (BN), harness side.
Connect the other lead on the test light to C2159-2, circuit
CPP01 (WH/OG), harness side.
z Vehicles without memory, connect the test light as follows:

Connect one lead on the test light to C2003-1, circuit
CPP02 (BN), harness side.
Connect the other lead on the test light to C2003-2, circuit
CPP01 (WH/OG), harness side.
z Press the brake pedal control switch in the forward and rearward
positions and verify the test light illuminates.
z Does the test light illuminate when the brake pedal control
switch is pressed in each direction?
A9 CHECK THE ADJUSTABLE BRAKE PEDALS CABLE
OPERATION
z Connect: Adjustable Pedals Motor C2159 (vehicles with memory Yes
feature) or C2003 (vehicles without memory feature). INSTALL a new brake pedal
z Disconnect the adjustable brake pedals cable from the assembly. REFER to Brake
adjustable brake pedal and bracket. Pedal and Bracket in this
z Operate the brake pedal control switch and observe the cable in section. CLEAR the DTCs.
the conduit. REPEAT the self test. TEST
z Does the adjustable brake pedals cable turn in the conduit? the system for normal
operation.
No
INSTALL a new adjustable
accelerator pedal and motor
with attached cable. REFER
to Accelerator Pedal —
Adjustable, Exploded View in
Section 310-02 . CLEAR the
DTCs. REPEAT the self test.
operation.
A10 CHECK THE SCCM ADJUSTABLE PEDALS ACTIVE
COMMANDS
z Select PARK. Yes
z Connect: Adjustable Pedals Motor C2159 (vehicles with memory INSTALL a new brake pedal
feature) or C2003 (vehicles without memory feature). control switch. REFER to
z Ignition ON. Brake Pedal Control Switch
z Enter the following diagnostic mode on the scan tool: in this section. CLEAR the
DataLogger — SCCM . DTCs. REPEAT the self-test.
z NOTE: Toggling the active command ON causes the pedal to TEST the system for normal
move in the commanded direction for 2 seconds and then the operation.
pedal stops.
z Toggle the pedals forward (PEDAL_IN) active command ON. No
z Toggle the PEDAL_IN active command OFF. GO to A11 .
z Toggle the pedals rearward (PEDAL_OUT) active command ON.
z Toggle the PEDAL_OUT active command OFF.
z Do the adjustable pedals respond correctly to the
corresponding active commands?
A11 CHECK THE SCCM FOR CORRECT OPERATION
z Disconnect: SCCM C2414A and C2414B. Yes
z Check SCCM C2414A and SCCM C2414B for: INSTALL a new SCCM .
corrosion. REFER to Section 211-05 .
pushed-out pins. CLEAR the DTCs. REPEAT
spread terminals. the self-test. TEST the
z Connect: SCCM C2414A and C2414B. system for normal operation.
z Connect: Adjustable Pedals Motor C2159 (vehicles with memory
feature) or C2003 (vehicles without memory feature).
z Make sure the connectors seat correctly, then operate the No
system and verify the concern is still present. The system is operating
z Is the concern still present? correctly at this time. The
concern may have been
caused by a loose or
corroded connector. CLEAR
the DTCs. REPEAT the self-
test. TEST the system for
normal operation.
Pinpoint Test B: The Adjustable Pedals Are Inoperative/Does Not Operate Correctly — Using the
Memory SET Switch or the Remote Keyless Entry (RKE) Transmitter
Normal Operation
When the desired memory position is selected using the memory SET switch or the Remote Keyless Entry
(RKE) transmitter, the Driver Seat Module (DSM) communicates the desired pedals position in a message
on the Medium Speed Controller Area Network (MS-CAN) bus to the Body Control Module (BCM). The BCM
acts as a gateway module, relaying the message to the Steering Column Control Module (SCCM) over the
High Speed Controller Area Network (HS-CAN) bus. The SCCM then sends current in one direction to the
adjustable pedals motor to move the pedals forward and in another direction (reversed polarity) to move the
pedals rearward.
The SCCM uses a Hall-effect sensor that is integral to the pedals motor to identify the current pedal position.
The SCCM sends a reference voltage along one circuit, through the sensor and back to the SCCM along the
signal return circuit.
If the vehicle is equipped with the memory feature but the SCCM is incorrectly configured, memory recall
may not function correctly when the memory SET switch or the RKE transmitter is used to adjust the pedal
position.

z Foreign objects or material
z RKE transmitter
z DSM
z SCCM
z Incorrect SCCM configuration
z BCM
PINPOINT TEST B: THE ADJUSTABLE PEDALS ARE INOPERATIVE/DOES NOT OPERATE

CORRECTLY — USING THE MEMORY SET SWITCH BUTTONS OR THE RKE TRANSMITTER

B1 CHECK THE ADJUSTABLE PEDALS OPERATION
WITH THE BRAKE PEDAL CONTROL SWITCH
z Press the brake pedal control switch in each direction Yes
for more than one second and observe the pedals. GO to B2 .
z Do the pedals operate for more than one second in
the direction selected using the switch? No
If the pedals do not move using the
brake pedal control switch, GO to
Pinpoint Test A .
If the pedals only move in one second

intervals regardless of button
operation, GO to Pinpoint Test C .
B2 CHECK THE MEMORY SYSTEM OPERATION
z Set a memory position for the driver seat, exterior Yes
mirrors and adjustable pedals to memory SET switch GO to B3 .
button 1. Refer to Memory Position Programming in
Section 501-10 . No
z Select PARK. If all 3 items do not move, REFER to
z Press the memory SET switch button 1 and observe the Diagnosis and Testing in Section 501-
following items: 10 to diagnose the memory SET
Driver seat switch.
Exterior mirrors
Adjustable pedals If only the adjustable pedals do not
z Do all 3 items move when the button is pressed? move, GO to B4 .
If only the driver seat does not move,

REFER to Diagnosis and Testing in
Section 501-10 .
If only the exterior mirrors do not

move, REFER to Diagnosis and
Testing in Section 501-09 .
B3 CHECK THE RKE TRANSMITTER OPERATION
z Set a memory position in the RKE transmitter for the Yes

driver seat, exterior mirrors and adjustable pedals. GO to B4 .
Refer to Remote Memory Activation in Section 501-14 .
z Select PARK. No
z Press the unlock button on the RKE transmitter and If all 3 items do not move, REFER to
observe the following items: Diagnosis and Testing in Section 501-
Driver seat 14 to diagnose the RKE transmitter.
Exterior mirrors
Adjustable pedals If only the adjustable pedals do not
z Do all 3 items move when the button is pressed? move, GO to B4 .
If only the driver seat does not move,

REFER to Diagnosis and Testing in
Section 501-10 .
If only the exterior mirrors do not

move, REFER to Diagnosis and
Testing in Section 501-09 .
B4 CHECK THE ADJUSTABLE PEDALS MOTOR AND
CABLE INSTALLATION
z Check the adjustable pedals motor and cable for correct Yes
installation. GO to B5 .
z Are the motor and cable correctly installed?
No
CORRECT the adjustable pedals
motor installation. REFER to Section
310-02 . TEST the system for normal
operation.
B5 INSPECT FOR FOREIGN OBJECTS OR MATERIAL
z Inspect the adjustable brake pedal and accelerator Yes
assemblies for foreign material causing a binding GO to B6 .
condition.
z Are the pedal assemblies free from foreign No
material? REMOVE the foreign material. TEST
the system for normal operation.
B6 CHECK FOR DSM OR BCM DTCs
z Ignition ON. Yes
z Connect the scan tool. If DTC U0140 is retrieved from the
z Enter the following diagnostic mode on the scan tool: DSM , REFER to Section 501-10 to
Self-Test — DSM . diagnose the lost communication
z Enter the following diagnostic mode on the scan tool: concern.
Self-Test — BCM .
z Record any DTCs retrieved from the DSM or the BCM . If DTC U0212:87 is retrieved from the
z Was DTC U0140 retrieved from the DSM or was DTC BCM , REFER to Section 419-10 to
U0212:87 retrieved from the BCM ? diagnose the lost communication
concern.
No
GO to B7 .
HALL-EFFECT SENSOR CIRCUITS FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: Adjustable Pedals Motor C2159. GO to B8 .
z Disconnect: SCCM C2414B.
z Measure the resistance between SCCM C2414B, No
harness side and adjustable pedals motor C2159, REPAIR the affected circuit(s). TEST
harness side as follows: the system for normal operation.
Adjustable Pedals
SCCM Circuit Motor
C2414B- CPP01 C2159-2
4 (WH/OG)
C2414B- CPP02 (BN) C2159-1
7
z Disconnect: SCCM C2414C.

z Measure the resistance between SCCM C2414C,
harness side and adjustable pedals motor C2159,
harness side as follows
Adjustable Pedals
SCCM Circuit Motor
C2414C- RPP06 (GN) C2159-3
3
C2414C- LPP06 C2159-4
6 (YE/BU)

HALL-EFFECT SENSOR CIRCUITS FOR A SHORT TO
GROUND
adjustable pedals motor C2159-1, circuit CPP02 GO to B9 .
(BN), harness side.

adjustable pedals motor C2159-2, circuit CPP01 No
(WH/OG), harness side. REPAIR the affected circuit(s). TEST
adjustable pedals motor C2159-4, circuit LPP06 the system for normal operation.
(YE/BU), harness side.
adjustable pedals motor C2159-3, circuit RPP06
(GN), harness side.

HALL-EFFECT SENSOR CIRCUITS FOR A SHORT
TOGETHER
z Measure the resistance between adjustable pedals Yes
motor C2159, harness side as follows: GO to B10 .
Adjustable Adjustable No
Pedals Motor Circuit Pedals Motor Circuit REPAIR the affected circuit(s). TEST
C2159-4 LPP06 C2159-2 CPP01
(YE/BU) (WH/OG)
C2159-4 LPP06 C2159-3 RPP06
(YE/BU) (GN)
C2159-4 LPP06 C2159-1 CPP02
(YE/BU) (BN)
C2159-2 CPP01 C2159-3 RPP06
(WH/OG) (GN)
C2159-2 CPP01 C2159-1 CPP02
(WH/OG) (BN)
C2159-3 RPP06 C2159-1 CPP02
(GN) (BN)
z Are the resistance greater than 10,000 ohms?

HALL-EFFECT SENSOR CIRCUITS FOR A SHORT TO
VOLTAGE
z Ignition ON. Yes
z Measure the voltage between ground and: REPAIR the affected circuit(s).
adjustable pedals motor C2159-2, circuit CPP01 CLEAR the DTCs. REPEAT the self-
(WH/OG), harness side. test. TEST the system for normal
adjustable pedals motor C2159-4, circuit LPP06 operation.
(YE/BU), harness side.
adjustable pedals motor C2159-3, circuit RPP06 No
(GN), harness side. CONFIGURE the SCCM using As-
adjustable pedals motor C2159-1, circuit CPP02 Built data. TEST the system for
(BN), harness side. normal operation. If the adjustable
pedals do not operate correctly,
INSTALL a new adjustable pedals
motor and bracket assembly. REFER
to Accelerator Pedal — Adjustable,
Exploded View in Section 310-02 .
CLEAR the DTCs. REPEAT the self-
test. TEST the system for normal
operation.
Pinpoint Test C: The Adjustable Pedals Only Move in 1 Second Intervals
Normal Operation
The Steering Column Control Module (SCCM) uses a Hall-effect sensor integral to the motor to identify the
current pedal position. The SCCM sends a reference voltage along the sensor feed circuit, through the Hall-
effect sensor and back to the SCCM along the signal return circuit.
When the following DTCs are set, the adjustable pedals enters a "jog mode". When the pedals are in jog
mode, the memory system recall does not function from either the Remote Keyless Entry (RKE) transmitter
or memory SET switch. When the pedals are activated using the brake pedal control switch, the motor
moves the pedals for one second regardless of the length of time the button is pressed.
If the vehicle is not equipped with memory and the SCCM is incorrectly configured, the SCCM expects to
receive pedal position information when the vehicle is not equipped to provide it. If this happens, the
adjustable pedals enters a "jog mode" similar to if a fault were present in the adjustable pedals position
sensor circuits.
z DTC B1368:11 (Adjustable Pedal Position Feedback Sensor: Circuit Short to Ground) — This DTC
sets if the SCCM detects a short to ground on the Hall-effect sensor feed and/or return circuits when
the ignition is ON.
z DTC B1368:12 (Adjustable Pedal Position Feedback Sensor: Circuit Short to Battery) — This DTC
sets if the SCCM detects a short to voltage on the Hall-effect sensor feed and/or return circuits when
the ignition is ON.

z SCCM
z Incorrect SCCM configuration
PINPOINT TEST C: THE ADJUSTABLE PEDALS ONLY MOVE IN 1 SECOND INTERVALS
Do not use standard multimeter probes.

C1 CHECK THE SCCM DTCs
z Review the SCCM DTCs retrieved during Yes
Inspection and Verification. GO to C2 .
z Were DTCs B1368:11 or B1368:12 retrieved?
No
If no DTCs were retrieved, CONFIGURE
the SCCM using As-Built data. REPEAT
the self-test. TEST the system for normal
operation. If DTCs B1369:09, B137D:18,
19, or 71 were retrieved, REFER to DTC
Charts in this section. For all other SCCM
DTCs, REFER to the SCCM DTC Chart in
Section 211-05 . CLEAR the DTCs.
REPEAT the self-test. TEST the system for
normal operation.
C2 CHECK THE SCCM HALL-EFFECT SENSOR
CIRCUITS FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: Adjustable Pedals Motor C2159. GO to C3 .
z Disconnect: SCCM C2414C.
z Measure the resistance between SCCM C2414C, No
harness side and adjustable pedals motor C2159, REPAIR the affected circuit(s). CLEAR the
harness side as follows: DTCs. REPEAT the self-test. TEST the
Adjustable Pedals
SCCM Circuit Motor
C2414C- RPP06 (GN) C2159-3
3
C2414C- LPP06 C2159-4
6 (YE/BU)

CIRCUITS FOR A SHORT TO GROUND
SCCM C2414C-6, circuit LPP06 (YE/BU), GO to C4 .
harness side.
SCCM C2414C-3, circuit RPP06 (GN), No
harness side. REPAIR the affected circuit(s). CLEAR the
DTCs. REPEAT the self-test. TEST the

CIRCUITS FOR A SHORT TOGETHER
z Measure the resistance between SCCM C2414C- Yes
3, circuit RPP06 (GN), harness side and SCCM GO to C5 .
C2414C-6, circuit LPP06 (YE/BU), harness side.
No
REPAIR the affected circuit(s). CLEAR the
z Is the resistance greater than 10,000 ohms?

CIRCUITS FOR A SHORT TO VOLTAGE
z Ignition ON. Yes
z Measure the voltage between ground and: REPAIR the affected circuit(s). CLEAR the
SCCM C2414C-6, circuit LPP06 (YE/BU), DTCs. REPEAT the self-test. TEST the
harness side. system for normal operation.
SCCM C2414C-3, circuit RPP06 (GN),
harness side. No
INSTALL a new adjustable accelerator
pedal and motor with attached cable.
REFER to Accelerator Pedal — Adjustable,
Exploded View in Section 310-02 . CLEAR
the DTCs. REPEAT the self-test. TEST the
system for normal operation. If DTC
B1368:11 or B1368:12 return, INSTALL a
new SCCM . REFER to Section 211-05 .

Hydraulic Brakes
The brake pedal is connected to the power brake booster, which is connected to the brake master cylinder.
When the brake pedal is pressed, brake fluid is forced through the double-walled steel tubes and flexible
hoses to the Hydraulic Control Unit (HCU). The brake fluid is then distributed to the front and rear brake
calipers. The fluid enters the caliper, forcing the caliper pistons and brake pads outward against the brake
disc friction surface, slowing or stopping rotation of the brake disc. When the brake pedal is released, brake
fluid pressure is relieved, returning the front and rear brake caliper pistons and brake pads to the unapplied
position.
To diagnose hydraulic brake concerns, refer to Section 206-00 .
For information on the HCU , refer to Section 206-09 .
Adjustable Pedals Without Memory Feature
The adjustable pedals without memory are controlled by the brake pedal control switch and the Steering
Column Control Module (SCCM). The adjustable pedals motor is attached to the accelerator pedal bracket
and controls the accelerator pedals directly. It operates forward and rearward, depending on which direction
the switch is pressed. The adjustable brake pedals is connected to the motor by a cable that rotates inside a
sleeve. This allows both the brake and accelerator pedals to move together as an assembly. When the
brake pedal control switch is pressed, voltage is applied from the SCCM to the adjustable pedals motor. The
end of the motor that is attached to the accelerator pedal bracket rotates the pinion of a worm gear set and
causes the accelerator pedal to move. At the same time, the other end of the motor rotates the cable inside
the sleeve which causes the brake pedal adjuster to move through the use of a worm gear set. The pedals
can be adjusted with the ignition switch in the OFF, ACC or RUN position, regardless of gear selector
position.
The SCCM monitors the adjustable pedals motor and circuits for faults. If a fault is detected, the SCCM is
capable of setting DTCs.
Adjustable Pedals With Memory Feature
The adjustable pedals with memory are controlled by the SCCM , Body Control Module (BCM) and Driver
Seat Module (DSM). The pedals can be adjusted in 3 different ways:
z Using the brake pedal control switch.

z Using the memory SET switch.
z Using the Remote Keyless Entry (RKE) transmitter.
The SCCM monitors the position of the pedals using a Hall-effect sensor that is integral to the adjustable
pedals motor. When a memory position is recalled through either the memory SET switch or the RKE
transmitter, the SCCM monitors the Hall-effect sensor and stops sending voltage to the motor once the
commanded memory position is reached. If the SCCM receives a pedals position input during a memory
position recall function, the module stops the memory recall and responds to the new pedals position input.
When the RKE transmitter is activated, a message is sent over the Medium Speed Controller Area Network
(MS-CAN) to the DSM . When the memory SET switch is pressed, the DSM senses continuity to ground on
the switch circuit. When the DSM receives either the MS-CAN message or the ground input through the
switch circuit, it sends a message over the MS-CAN to the BCM . The BCM acts as a gateway module,
relaying the MS-CAN message that was received from the DSM to the SCCM over the High Speed
Controller Area Network (HS-CAN). The SCCM then sends voltage over the appropriate circuit to the
adjustable pedals motor to adjust the pedals.
The SCCM continuously monitors the adjustable pedals motor and circuits for faults. If a fault is detected,
the SCCM is capable of setting DTCs.
The DSM also controls the driver seat and the exterior mirrors.
For information on setting and recalling a memory pedal position, refer to Memory Position Programming in
Section 501-10 .

Symptom Charts
Symptom Chart
z No communication with the Steering z Fuse z REFER to
Column Control Module (SCCM) z Wiring, terminals or Section
connectors 418-00 .
z SCCM
z Adjustable pedals are z Foreign objects or z GO to
inoperative/does not operate material Pinpoint
correctly — using the brake pedal z Fuse Test A .
control switch z Wiring, terminals or
connectors
z Brake pedal control
switch
z Adjustable accelerator
pedal and motor with
attached cable
z Adjustable brake
pedal and bracket
z SCCM
correctly — using the memory SET z Fuse Test B .
switch buttons z Wiring, terminals or
connectors
z Memory SET switch
attached cable
z Adjustable brake
pedal and bracket
z Incorrect SCCM
configuration
z Driver Seat Module
(DSM)
z SCCM
z Body Control Module
(BCM)
correctly — using the Remote z Wiring, terminals or Test B .
Keyless Entry (RKE) transmitter connectors
attached cable
z Adjustable brake
pedal and bracket
z RKE transmitter
z DSM
z SCCM
z BCM
z The adjustable pedals only move in 1 z Wiring, terminals or z GO to
second intervals connectors Pinpoint
z Adjustable accelerator Test C .
attached cable
z Incorrect SCCM
configuration
z SCCM

Brake Master Cylinder
Material
Item Specification
Motorcraft® High Performance WSS-M6C62-A
DOT 3 Motor Vehicle Brake Fluid or WSS-M6C65-
(US) / Motorcraft® Brake Fluid - A1
Heavy Duty DOT 3 (Canada)
(Canada)
Part
1 2140 Brake master cylinder and reservoir assembly
2 W520212 Brake master cylinder nut (2 required)
3 — Primary brake tube fitting (part of 2A040)
4 — Secondary brake tube fitting (part of 2B253)
5 — Brake fluid level switch electrical connector (part of
12A581)
6 2152 Brake master cylinder-to-booster seal
7 — Vacuum sensor electrical connector (part of 12A581)
8 3B476 Front axle vent hose
1. Relieve the vacuum in the brake booster by pressing and releasing the brake pedal a minimum of 5
times with the engine not running.
2. Remove the Air Cleaner (ACL) element. For additional information, refer to Air Cleaner Element in
Section 303-12 .
3. Remove the nut and position the hood switch and bracket aside.
z To install, tighten nut to 6 Nm (53 lb-in).
4. Remove the 2 bolts and position the coolant expansion tank/lower ACL housing assembly aside.
z To install, tighten bolts to 15 Nm (133 lb-in).
5. Disconnect the brake fluid level switch.
6. If equipped, position the vacuum sensor wiring harness and front axle vent hose aside.
7. Loosen the brake tube fittings and disconnect the brake tubes.
z Plug the master cylinder ports.
z To install, tighten primary brake tube fitting to 28 Nm (21 lb-ft).
z To install, tighten secondary brake tube fitting to 20 Nm (177 lb-in).
8. NOTICE: When the master cylinder is removed, the piston will be exposed. Do not damage the
piston or piston surface or a fluid leak may occur.
Remove the 2 brake master cylinder nuts and the brake master cylinder.

z If a new brake master cylinder has been installed, bleed the master cylinder. Refer to
Component Bleeding in Section 206-00 .
z If the brake master cylinder was removed to access other components, bleed the brake
system. Refer to Brake System Bleeding in Section 206-00 .

Brake Pedal and Bracket
NOTE: Adjustable brake pedal and bracket shown, fixed brake pedal and bracket similar.
Part
1 W702368 Brake pedal bracket bolts
2 — Accelerator pedal-to-brake pedal cable (part of
9F836)
3 2450 Brake pedal and bracket

4 W520212 Brake booster-to-pedal bracket nut (4 required)
5 2L523 Brake pedal pin
Vehicles equipped with adjustable pedals
1. NOTICE: The brake pedal and the accelerator pedal must be in the same position when
installing a new cable or a new pedal. The pedals must be all the way forward or all the way
rearward or damage to components may occur.
Move the pedals to the full forward (away from the driver) position.
2. Disconnect the accelerator pedal-to-brake pedal cable from the adjustable brake pedal gear set.
All vehicles
3. NOTICE: Do not service the brake pedal without first removing the stoplamp switch. Remove
this switch with the brake pedal in the at-rest position. Attempting to remove the switch when
the plunger is extended (during pedal apply) results in damage to the switch.
Remove the stoplamp switch. For additional information, refer to Section 417-01 .
4. NOTE: Use an 11 mm, 12-point socket or wrench to compress the 2 tabs on the brake pedal arm pin.
Remove and discard the brake pedal pin, then disconnect the brake booster push rod from the brake
pedal arm.
5. Remove the bulkhead sound insulator.
6. Remove the 4 brake booster-to-pedal bracket nuts.

z To install, tighten to 25 Nm (18 lb-ft) following a clockwise pattern starting with the upper left
nut.
7. Remove the 2 brake pedal bracket bolts and remove the brake pedal and bracket.
8. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp
switch. Install this switch with the booster push rod attached to the brake pedal and with the
brake pedal in the at-rest position. Installing this switch with the pedal in any other position
results in incorrect adjustment and damages the switch.
Vehicles equipped with adjustable pedals
9. Index the pedal assemblies. For additional information, refer to Adjustable Pedal Indexing in this
section.

NOTE: Steering wheel removed for clarity.

1 W715057 Screw
2 9G604 Brake pedal control switch
NOTE: Turn the steering wheel 90 degrees to the left to access the brake pedal control switch screws.
1. Remove the steering column shrouds. For additional information, refer to Section 211-04 .
2. Remove the screw.

3. Using a suitable tool (such as a pocket screwdriver), carefully disengage the control switch locking
tabs one at a time, then remove the switch.
SECTION 206-07: Power Brake Actuation 2014 F-150 Workshop Manual

Brake booster nuts a — — —
Brake master cylinder nuts 25 18 —
Brake vacuum pump bolts a — — —
Coolant expansion tank/lower Air Cleaner (ACL) housing assembly bolts 15 — 133

Brake Booster
The power brake actuation system consists of the following components:
z Brake booster
z Brake booster check valve
z Brake booster vacuum sensor
z Brake booster vacuum supply hose
z Brake booster vacuum pump (3.5L GTDI engine only)
The brake booster uses vacuum from the intake manifold (3.7L and 5.0L) or an engine mounted vacuum
pump (3.5L GTDI ) to create a partial vacuum inside the vacuum booster on both sides of the diaphragm.
When the brake pedal is pressed, the booster rod opens a valve, allowing air to enter the booster on one
side of the diaphragm while sealing off the opposite side. This increases pressure on that side of the
diaphragm so that it helps push the rod, which in turn pushes the piston in the master cylinder. As the brake
pedal is released, the valve seals off the outside air supply while opening the vacuum valve. This restores
vacuum to both sides of the diaphragm, allowing everything to return to its original position. The ABS
module uses the signals produced by the vacuum sensor to verify the vacuum is maintained in the brake
booster.
Brake Booster Vacuum Pump
Vehicles equipped with a 3.5L GTDI engine are also equipped with an engine mounted/cam-driven brake
booster vacuum pump. The brake vacuum pump is located on the backside of the RH cylinder head. Refer
to Brake Vacuum Pump .
z For vacuum sensor and vacuum pump diagnosis, refer to Section 206-09 .

Power Brake System

Brake Booster Vacuum Sensor
NOTE: Rear Wheel Drive (RWD) shown, Four-Wheel Drive (4WD) similar.

2 2365 Brake booster vacuum sensor
3 — Hose clamp (part of 9C490)
4 — Vacuum supply hose (part of 9C490)
2. Disconnect the vacuum supply hose from the brake booster vacuum sensor.
3. If equipped, disconnect the Four-Wheel Drive (4WD) vacuum reservoir supply hose from the brake
booster vacuum sensor.
4. Disconnect the vacuum sensor electrical connector and remove the vacuum sensor.
5. NOTE: To allow proper drainage of any moisture, the vacuum sensor must be installed in the same
position and orientation as removed.

Brake Booster

1 2L523 Brake pedal pin
2 W520212 Brake booster nut (4 required)
3 2005 Brake booster
4 2365A Vacuum sensor assembly
5 W520212 Brake master cylinder nut (2 required)

6 2140 Brake master cylinder assembly
7 2152 Brake master cylinder-to-booster seal
8 — Gasket (part of 2B022)
9 — Spacer
10 — Gasket (part of 2B022)
12 3B476 Front axle vent hose
2. Remove the Air Cleaner (ACL) element. For additional information, refer to Air Cleaner Element in
Section 303-12 .
3. Remove the 2 bolts and position the coolant expansion tank/lower ACL housing assembly aside.
z To install, tighten bolts to 15 Nm (133 lb-in).
4. Disconnect the brake fluid level switch.
5. If equipped, position the vacuum sensor wiring harness and front axle vent hose aside.
6. NOTICE: When the master cylinder is removed, the piston will be exposed. Do not damage the
piston or piston surface or a fluid leak may occur.
Remove the 2 brake master cylinder nuts and position the master cylinder aside.
z Support the master cylinder with mechanic's wire.
z To install, tighten the nuts to 25 Nm (18 lb-ft).
7. NOTE: To allow proper drainage of any moisture, the vacuum sensor must be installed in the same
position and orientation as removed.
Disconnect the vacuum sensor assembly from the brake booster.
8. NOTICE: Do not service the brake pedal or brake booster without first removing the stoplamp
switch. This switch must be removed with the brake pedal in the at-rest position. The switch
plunger must be compressed for the switch to rotate in the bracket. Attempting to remove the
switch when the plunger is extended (during pedal apply) will result in damage to the switch.
Remove the stoplamp switch. For additional information, refer to Section 417-01 .
9. NOTE: The booster push rod clevis-locking pin is a one-time use only part. Any time the booster push
rod clevis-locking pin is removed, a new booster push rod clevis-locking pin should be used.
NOTE: Remove the clevis-locking pin by squeezing the locking tabs and pulling outward on the
opposite end.
Remove and discard the booster push rod clevis-locking pin.
10. Remove the 4 brake booster nuts and remove the brake booster.
z To access the nuts, fold back the sound insulation.
z To install, tighten the nuts to 25 Nm (18 lb-ft) following a clockwise pattern starting with the
upper left nut.
11. NOTICE: Do not press, pull or otherwise move the brake pedal while installing the stoplamp
switch. This switch must be installed with the booster push rod attached to the brake pedal
and with the brake pedal in the at-rest position. Installing this switch with the brake pedal in
any other position will result in incorrect adjustment and may damage the switch.

Brake Vacuum Pump
Material
Item Specification
Motorcraft® High Performance WSE-M4G323-
Engine RTV Silicone A6
TA-357
ZC-31-A
Removal
1. Remove the RH front fender inner splash shield. Refer to Section 501-02 .
2.
3. NOTICE: Do not use excessive force when removing the vacuum pump or the vacuum pump
oil tube may be dilodged from the pump causing internal oil seal damage to the pump. If the
oil tube becomes dislodged from the pump, a new vacuum pump must be installed.
NOTE: The upper/inboard vacuum pump bolt will remain in the vacuum pump housing when
removing the vacuum pump.
Installation
1.
2. NOTICE: Make sure the oil tube filter screen is free of contaminants prior to the installation of
the pump or damage to components may occur.
Visual check. Install a new gasket as necessary.
3. NOTICE: If the brake vacuum pump is not secured within 10 minutes of sealant application,
the sealant must be removed and the sealing area cleaned with metal surface prep. Failure to
follow this procedure can cause future oil leakage.
NOTE: Make sure the mating surfaces are clean and free of foreign material.
Apply a bead of the specified diameter from the specified tube.
4. NOTE: Manually align the brake vacuum pump drive key with the camshaft slot before installation.
Visual check.
z Stage 1: Tighten in the sequence shown to 10 Nm (89 lb-in).
5.
SECTION 206-09: Anti-Lock Brake System (ABS) and Stability Control 2014 F-150 Workshop Manual
Material
Capacity
High Performance DOT 3 WSS-M6C62-A or 740 ml
Motor Vehicle Brake Fluid WSS-M6C65-A1 (1.56 pt)
(Canada)
ABS module screws 3 — 27
Brake tube-to-Hydraulic Control Unit (HCU) fittings 20 — 177
Front wheel speed sensor bolt 17 — 150
Front wheel speed sensor harness bolt 12 — 106
HCU -to-bracket nuts 8 — 71
HCU bracket bolts 20 — 177
Master cylinder primary brake tube-to- HCU fitting 28 21 —
Master cylinder secondary brake tube-to- HCU fitting 20 — 177
Rear wheel speed sensor bolt 15 — 133
Anti-Lock Brake System (ABS) and Stability Control
AdvanceTrac® With RSC®
The AdvanceTrac® system is made up of the following systems:
z Anti-lock braking
z Traction control
z ESC
The RSC® system is an optional feature that works in conjunction with AdvanceTrac® to aid in maintaining
vehicle stability. AdvanceTrac® with RSC® system consists of the following components:
z ABS module — attached to the Hydraulic Control Unit (HCU), but can be serviced separately from the
HCU .
z Front wheel speed sensors — one sensor is located in each front wheel knuckle. The sensors are
serviced separately from the knuckle.
z Front wheel speed sensor encoders — one encoder strip is located in each wheel bearing and wheel
hub assembly and is serviced with the wheel bearing.
z HCU — contains several valves (inlet, outlet, isolation and dump) and a hydraulic pump motor. It is
mounted behind the radiator, below the air cleaner assembly. The HCU is replaced as a unit,
including the ABS module.
z Rear wheel speed sensors — one sensor is located in each end of the rear axle housing. The
sensors are serviced separately.
z Rear wheel speed sensor tone rings — one tone ring is located on each axle shaft.
z Stability control sensors — located inside the Restraints Control Module (RCM) and consist of the
following sensors: yaw rate, roll rate, lateral and longitudinal accelerometers. The sensors are integral
to the RCM and cannot be serviced separately.
z Steering wheel rotation sensor (6.2L) — located on the end of the steering column near the
intermediate shaft. The sensor is serviced separately from the steering column but the sensor ring is
replaced with the column. For all other applications, the steering wheel rotation sensor is part of the
EPAS .
z Stability/traction control switch — located in the instrument panel finish panel and is serviced
separately from the finish panel.
z Hill Descent Control™ switch — located in the auxiliary switch panel and is serviced separately.
z Brake vacuum pump (3.5L) — a mechanical pump located on the back of the RH cylinder head and
driven by the RH exhaust cam shaft.
Electronic Brake Distribution (EBD)
The ABS module and HCU incorporate a strategy called EBD . The EBD strategy uses the HCU as an
electronic proportioning valve to create a balanced braking condition between the front and rear wheels and
minimizes the chance of rear wheel lockup during hard braking.
A slight bump sensation may be felt in the brake pedal when EBD is active.
Anti-Lock Braking
The conventional ABS aids in the prevention of wheel lock-up during braking events allowing the driver to
maintain steering control and stop in the shortest distance possible under most conditions. This is
accomplished by the ABS module and the HCU modulating brake fluid pressure to the affected brake caliper
(s).
When the ABS activates, both of the following can occur:
z A rumble or grinding sound may be heard

z If the driver's foot is on the brake pedal, a vibration may be felt in the brake pedal
Supplemental Braking Assist
In addition to preventing wheel lock up during braking events, the ABS module also provides supplemental
hydraulic brake assist through the use of the hydraulic pump motor and the HCU . This is done in the event
of a severe vacuum loss at the brake booster.
AdvanceTrac® System
Traction Control System
The traction control system aids in the prevention of excessive wheel spin allowing the vehicle to maintain
traction during acceleration. This is accomplished by the ABS module and the HCU modulating brake fluid
pressure to the affected brake caliper(s) and by the PCM modulating engine torque.
Electronic Stability Control (ESC) System
The ESC system constantly monitors the vehicle's direction of travel relative to the driver's intended course,
except when the vehicle is traveling in reverse, and aids in keeping the vehicle traveling along that course.
This is accomplished by the ABS module and the HCU modulating brake fluid pressure to the affected brake
caliper(s) and by the PCM modulating engine torque.
When the AdvanceTrac® system activates, any of the following can occur:
z A rumble or grinding sound may be heard, much like ABS

z If the driver's foot is on the brake pedal, a vibration may be felt in the brake pedal, much like ABS
z A small deceleration or a reduction in the acceleration of the vehicle
z The stability/traction control indicator (sliding car icon) flashes
Roll Stability Control (RSC®) System
The RSC® system constantly monitors vehicle roll motion, except when the vehicle is traveling in reverse,
and aids in keeping the vehicle stable during sudden or abrupt maneuvers. This is accomplished by the ABS
module and the HCU modulating brake fluid pressure to the affected brake caliper(s) and by the PCM
modulating engine torque. The combination of reduced engine torque and modulated brake fluid pressure
aids in reducing the cornering forces and, therefore, the total roll momentum acting on the vehicle.
When the RSC® system activates, the vehicle produces the same noticeable symptoms as it does when the
AdvanceTrac® system activates.
Trailer Sway Control
Trailer sway control is a unique function in the AdvanceTrac® with RSC® system that recognizes and aids in
reducing trailer sway. The trailer sway control function continually monitors the steering wheel rotation and
yaw rate sensors to identify specific, increasing yaw oscillations that occur during a trailer sway event. If the
trailer sway event exceeds programmed parameters, the ABS module and the HCU modulate brake fluid
pressure to specific brake caliper(s) and the PCM modulates engine torque until the trailer sway is reduced
below the programmed parameters.
For vehicles equipped with an optional TBC module, the trailer sway control system utilizes the module to
apply the trailer brakes to quickly reduce trailer sway.
When the trailer sway control function activates, the vehicle produces the same noticeable symptoms as it
does when the AdvanceTrac® system activates. In addition, the message center displays TRAILER SWAY,
REDUCE SPEED and, if the vehicle is equipped with a TBC module, the module shows output to the trailer
brakes.
The trailer sway control function only activates when the vehicle speed exceeds 64 km/h (40 mph). The
system can be disabled during any key cycle. Refer to the Owner's Literature for information on disabling the
system. The system is re-enabled when the ignition is turned to the OFF position and back to the RUN
position.
MyKey® Interaction
Through the MyKey® feature, the traction control function of the AdvanceTrac® system can be configured to
be always on or to allow the driver to select the traction control function on or off.
When the traction control function is configured to be always on and a MyKey® restricted key is in use, the
IPC will ignore any requests made by the driver to disable the traction control function and will not send any
traction control disable messages to the ABS module. Refer to the Owner's Literature for additional
information on the MyKey® feature and settings.
Hill Start Assist
The hill start assist system is designed to assist the driver during hill-starts. Using the ABS, the hill start
assist system holds the vehicle on an incline for a short time, allowing the driver to release the brake pedal
and press the accelerator pedal without needing to use the parking brake.
Hill Descent Control™
Hill Descent Control™ maintains vehicle speed on a downhill grade, operating at speeds between 3 km/h (2
mph) and 32 km/h (20 mph). If the vehicle is on flat or uphill terrain, the system goes into standby mode,
remaining activated up to 64 km/h (40 mph). At speeds greater than 64 km/h (40 mph), the Hill Descent
Control™ system is deactivated. When Hill Descent Control™ is active, a rumble or grinding sound may be
heard and/or felt.
Traction Control Switch
The stability/traction control switch can be used by the driver to disable and enable the traction control, ESC
and RSC® functions. Refer to the Owner's Literature for instructions on disabling and enabling the traction
control, ESC and RSC® functions.
The conventional ABS cannot be disabled using the stability/traction control switch.
Stability/Traction Control Indicators
The IPC message center is a reconfigurable telltale which is capable of displaying a variety of different
messages and indicators such as the stability/traction control indicator (sliding car icon), stability/traction
control disabled indicator (sliding car OFF icon), the 4WD mode/range or door open messages. For
information about the IPC , refer to Section 413-01 .
There are 2 separate stability/traction control indicators, the sliding car icon and the sliding car OFF icon.
Both icons are located in the IPC message center. The sliding car icon is used to alert the driver that a
stability/traction event is taking place (flashes twice per second) and to alert the driver of potential concerns
in the AdvanceTrac® system (illuminates continuously). The sliding car OFF icon is used to alert the driver
that the traction control portion of the AdvanceTrac® system has been disabled by the driver. This icon only
illuminates continuously and does not flash.
Anti-Lock Brake System (ABS) and Stability Control
Special Tool(s)
Flex Probe Kit

Rotunda Active Wheel Speed

Sensor Tester
105-R0110

Principles of Operations
Anti-Lock Braking
The ABS module continuously monitors brake pedal input, lateral vehicle motion and the rotational speed of
each wheel. The PCM sends the brake pedal switch information to the ABS module over the HS-CAN while
the RCM sends lateral acceleration sensor information to the ABS module over a private HS-CAN . Wheel
speed information is retrieved by the ABS module using 4 active wheel speed sensors. When the ABS
module detects an impending wheel lock during a braking event, the ABS module modulates brake pressure
to the appropriate brake caliper(s) by opening and closing the appropriate solenoid valves inside the HCU
while the hydraulic pump motor is activated. Once the affected wheel(s) return to the desired speed, the
ABS module returns the solenoid valves in the HCU to their normal position.
The ABS module has 2 self-test options, one is carried out after the ignition is turned to the RUN position
and the other is carried out after an ABS stop or after an AdvanceTrac® system activation. When the ignition
is turned to the RUN position, the ABS module carries out a preliminary electrical check of the wheel speed
sensors and their circuits by sending voltage through the sensor and checking for the voltage to return.
When the vehicle is traveling at speeds above 21 km/h (13 mph) and the brake pedal is not being pressed,
the HCU pump motor is commanded on for approximately 0.5 second to check pump motor operation. Also,
during all phases of operation while the vehicle is in motion, the ABS module checks for correct operation of
the wheel speed sensors by comparing wheel speed input to other sensor input. Depending on the nature of
the malfunction detected, the ABS module deactivates the anti-lock control system and sends a message
over the HS-CAN to the IPC . When the IPC receives this message, it illuminates the yellow ABS warning
indicator and the stability/traction control indicator (sliding car icon).
Electronic Brake Distribution (EBD)
On initial application of the brake pedal, full pressure is applied to the rear brakes. The ABS module then
uses wheel speed input to calculate an estimated rate of deceleration. Once vehicle deceleration exceeds a
predetermined threshold, the ABS module commands the HCU to close the appropriate isolation valves to
hold the rear brake pressure constant while allowing the front brake pressure to build. This creates a
balanced braking condition between the front and rear wheels and minimizes the chance of rear wheel
lockup during hard braking. As the vehicle decelerates, the valves are opened to increase the rear brake
pressure in proportion to the front brake pressure.
If ABS is disabled due to DTCs being present in the ABS module, EBD continues to function unless the
DTCs are for wheel speed sensors or the HCU . When EBD is disabled, the red brake warning light, the
ABS warning indicator and the stability/traction control indicator (sliding car icon) illuminate.
Supplemental Braking Assist
The ABS module uses the HCU and hydraulic pump motor to aid in bringing the vehicle to a safe, controlled
stop in the event of severe vacuum loss at the brake booster. The ABS module continually monitors the
vacuum in the brake booster through the use of a vacuum sensor. When the vacuum sensor indicates
vacuum is below a predetermined level, a DTC is set in the ABS module. If this occurs during a braking
event or if the driver attempts to stop the vehicle with a low vacuum condition in the brake booster, the ABS
module activates the hydraulic pump motor in the HCU to assist with vehicle braking.
Traction Control Function
The ABS module continuously monitors and compares the rotational speed of the drive wheels in relation to
the non-driven wheels. When the drive wheels begin to spin faster than the non-driven wheels, the ABS
module commands the HCU to modulate brake pressure to the appropriate brake caliper. This is
accomplished by opening and closing the appropriate solenoid valves inside of the HCU while the hydraulic
pump motor is activated. At the same time, the ABS module sends a message over the HS-CAN that a
traction control event is taking place. When the IPC receives this message, it flashes the stability/traction
control indicator (sliding car icon). If the event is severe enough, the ABS module sends a message to the
PCM over the HS-CAN to assist with traction control. When the PCM receives this message, it adjusts
engine timing and decreases fuel injector pulses. Once the affected wheel returns to normal speed, the ABS
module returns the solenoid valves in the HCU to their normal position, deactivates the hydraulic pump
motor and sends another message over the HS-CAN indicating that the traction event has ended. The PCM
returns engine timing and fuel injectors to normal operation and the IPC turns off the sliding car icon.
Once vehicle speed reaches or exceeds 144 km/h (89 mph), traction control is accomplished only through
PCM intervention.
Certain DTCs in the ABS module disable the traction control system. Depending on the DTCs present, the
red brake warning light, the yellow ABS warning indicator and the sliding car icon illuminate.
Electronic Stability Control (ESC) and Roll Stability Control (RSC®) Functions
The ESC and RSC® functions are controlled by the ABS module and use the same wheel speed sensors
and tone rings used for anti-lock braking. The ESC and RSC® functions also use input from the steering
wheel rotation sensor, the stability control sensors (yaw rate, roll rate, longitudinal and lateral
accelerometers) which are internal to the RCM and information from other modules sent over the HS-CAN to
help maintain vehicle stability.
The ABS module uses the various sensors to continuously monitor vehicle roll motion and direction of travel
relative to the driver's intended course. If the ABS module determines from all these inputs that the vehicle is
unable to travel in the intended direction or that a condition exists for a potential rollover event, it modulates
brake pressure to the appropriate brake caliper(s) by opening and closing the appropriate solenoid valves
inside the HCU while the hydraulic pump motor is activated. At the same time, the ABS module sends a
message over the HS-CAN that a stability event is taking place. When the IPC receives this message, it
flashes the stability/traction control indicator (sliding car icon). During a stability event, conditions may
require the involvement of the PCM to limit engine torque like it does for traction control. Once the stability
condition has been corrected, the ABS module sends another message over the HS-CAN indicating that the
event has ended. The PCM returns engine timing and fuel injectors to normal operation and the IPC turns off
the sliding car icon.
Certain DTCs being present in the ABS module may disable the ESC and RSC® functions. Depending on
the DTCs present, the yellow ABS warning indicator and/or the sliding car icon are illuminated.
Trailer Sway Control Function
Trailer sway control is a unique function of the RSC® system that uses information from the steering wheel
rotation sensor and the yaw information from the RCM to determine if a trailer sway event is taking place.
Trailer sway is the undesirable yaw force a trailer can apply to the towing vehicle. If the ABS module
determines that a trailer sway event is taking place, it takes action similar to the action taken for an ESC and
an RSC® event. At the same time, the ABS module sends a message over the HS-CAN that a trailer sway
event is taking place. When the IPC receives this message, it flashes the stability traction control indicator
(sliding car icon) and displays TRAILER SWAY REDUCE SPEED in the message center. If necessary, the
PCM reduces engine torque as it does for ESC and RSC® . Once the trailer sway has been corrected, the
ABS module sends another message over the HS-CAN indicating that the event has ended. The PCM
returns engine timing and fuel injectors to normal operation and the IPC turns off the stability traction control
indicator (sliding car icon).
If the vehicle is also equipped with a TBC system, the TBC module receives the trailer sway message from
the ABS module and takes appropriate action to assist in reducing the trailer sway. Refer to Section 206-10
for information on the TBC system.
Trailer sway control only activates with vehicle speed greater than 64 km/h (40 mph). Any malfunction that
disables the RSC® function also disables the trailer sway control function. Trailer sway control can also be
disabled through the message center. Refer to the Owner's Literature for the disabling/enabling procedure.
Regardless of the chosen state (enabled or disabled), trailer sway control is re-enabled at each ignition key
cycle.
Hill Start Assist
The hill start assist system engages automatically when the following conditions are met:
z The driver applies the vehicle brake and the vehicle is at a complete stop.
z Road inclination of approximately 4 degrees or more is detected (as indicated by the stability control
sensor information).
z The vehicle transmission information indicates that the driver selects the correct gear, indicating the
intention to drive up the hill.
z The parking brake is not engaged.
Once all the above criteria have been met and the driver releases the brake pedal, hill start assist utilizes the
valves in the Hydraulic Control Unit (HCU) to hold the car stationary for up to 2 seconds giving the driver
time to accelerate the vehicle. As the vehicle accelerates hill start assist gradually releases the brake
pressure to make sure that the vehicle is neither rolling back nor driving off until there is sufficient driving
torque to accelerate the vehicle forward. Hill start assist also functions if the vehicle is facing downhill if the
reverse gear is selected.
Hill Descent Control™ and Hill Descent Control™ Switch
Hill Descent Control™ uses the pump motor and HCU to provide vehicle speed control while descending a
downhill grade, information from the RCM to determine whether or not the vehicle is on a downhill grade and
wheel speed sensor information to determine vehicle speed. When the Hill Descent Control™ switch is
pressed, a ground signal is sent to the IPC indicating that the driver has activated the system. The IPC then
sends a message to the ABS module along the HS-CAN requesting system activation. The ABS module
uses the input from the RCM and wheel speed sensors to determine the mode of operation (active, stand-by
or deactivated). During a hill descent, while the Hill Descent Control™ system is activated, the driver sets
vehicle speed through the use of the accelerator and brake pedals. Once the desired speed has been set,
the system maintains that speed until one of the following occur:
z The vehicle is no longer on a downhill grade.

z The driver presses the switch again.
z Vehicle speed exceeds 64 km/h (40 mph).
z The system is disabled for cooling.
During periods of sustained use, the Hill Descent Control™ system automatically deactivates in order to cool
the brake system. When this occurs, the system notifies the driver with a message in the message center
and by sounding a warning chime. At this time the driver needs to provide brake and/or throttle control to
maintain the desired descent speed. The system remains disabled until it has sufficiently cooled. The length
of time needed for cooling varies depending on operating conditions.
Stability/Traction Control Switch
Unlike conventional ABS, the individual functions of AdvanceTrac® with RSC® can be deactivated by the
driver through the stability/traction control switch. The switch is hard-wired to the IPC and when pressed,
sends a ground signal to the IPC .
If the stability/traction control switch is pressed and held for more than 30 seconds, a DTC sets in the ABS
module.
Once disabled, the system remains in that state until the driver presses the switch again, the ignition is
cycled or the vehicle speed reaches or exceeds 56 km/h (35 mph). Once the vehicle speed reaches or
exceeds 56 km/h (35 mph), RSC® and ESC are reactivated. Once the vehicle speed drops below 48 km/h
(30 mph), traction control returns to the state the driver had originally selected, either on or off.
The functions cannot be disabled when a MyKey® restricted key is in use with the AdvanceTrac® always-on
feature configured to on. If an attempt is made to disable the ESC system while a MyKey® restricted key is
in use, ADVTRAC ON MY KEY SETTING displays in the IPC message center. For information about
MyKey®, refer to Section 419-01B .
Stability/Traction Control Indicators
Both the stability/traction control indicator (sliding car icon) and the stability/traction control disabled indicator
(sliding car OFF icon) alert the driver of stability/traction control system status.
When certain stability control system DTC(s) are present, the ABS module sends a message to the IPC over
the HS-CAN . Depending on the nature of the DTC(s), the IPC responds by either solidly illuminating 1 or
both icons or by flashing the icon(s) once every 2 seconds.
When a stability/traction control event is taking place, the ABS module sends a message to the IPC over the
HS-CAN to flash the sliding car icon twice per second.
When the driver disables the stability/traction control system by using the traction control switch, the IPC
receives a ground signal from the switch and then sends a message over the HS-CAN indicating that the
driver has requested the system be deactivated and illuminates the sliding car OFF icon.
Stability Control Sensors
The stability control sensors provide information to the ABS module for the operation of the ESC function,
RSC® function (if equipped), hill start assist system and the Hill Descent Control™ system (if equipped).
The stability control sensors are housed in the RCM and are serviced with the module. The sensors used for
stability control include the yaw rate sensor, the lateral accelerometer, the longitudinal accelerometer and (if
equipped with RSC® ) the roll rate sensor. Sensor information is sent to the ABS module over a private HS-
CAN .
Steering Wheel Sensor Information
For the 6.2L engine, the steering wheel rotation sensor uses an optical sensor and a slotted wheel to
measure the rate of rotation (angle) of the steering wheel. The steering wheel rotation sensor uses the HS-
CAN to transmit information to the ABS module about steering wheel turning direction (left or right) and how
far the steering wheel is being turned. The steering wheel rotation sensor does not indicate the absolute
position of the steering wheel relative to straight-ahead. The ABS module learns this position by comparing
the steering wheel position with other signals and storing the position it has learned. The module confirms
this position and modifies it as necessary during every new driving cycle.
For all other applications, the steering wheel rotation sensor is part of the EPAS system and is located inside
the PSCM . The sensor is serviced with the PSCM . The PSCM uses the HS-CAN to transmit information to
the ABS module about steering wheel turning direction (left or right) and how far it is being turned. The
PSCM does not indicate the absolute position of the steering wheel relative to straight-ahead. The ABS
module learns this position by comparing the steering wheel position with other signals and storing the
position it has learned. The ABS module confirms this position and modifies it as necessary during every
new driving cycle.
ABS Module Configuration
Module configuration is a scan tool process which configures specific vehicle settings in a new module. If
installing a new ABS module and/or a new HCU , the ABS module must be configured. To configure the
ABS module, refer to PMI in Section 418-01 .
2. Verify the stoplamps operate correctly by applying and releasing the brake pedal. If the stoplamps do
not operate correctly, refer to Section 417-01 . If the stoplamps operate correctly, proceed to the next
step.
3. Verify that the PRNDL operates correctly on the IPC . If the PRNDL does not operate correctly, refer
to Section 413-01 . If the PRNDL operates correctly, proceed to the next step.

z Wheel speed sensor ring z BJB fuses:
z HCU 36 (30A)
z Tire pressure 47 (60A)
z Mismatched wheels or tires on vehicle 54 (5A)
z Base brake system z ABS module
z Brake booster vacuum hose z Wheel speed sensors
z Steering components, suspension components and z Stoplamp switch
tire size z Stability/traction control switch
z Hill Descent Control™ switch (if
equipped)
z Brake fluid level switch
z Brake booster vacuum sensor
If the cause is not visually evident, connect the scan tool to the DLC .
7. NOTE: The VCM LED prove-out confirms power and ground from the DLC are provided to the VCM .


z refer to Section 418-00 The PCM Does Not Respond To The Scan Tool, to diagnose no

418-00 .
z If the network test passes, retrieve and record CMDTCs .
10. Clear the continuous DTCs and carry out the self-test diagnostics for the ABS module.
11. If the DTCs retrieved are related to the concern, go to ABS Module DTC Chart. For all other DTCs,
refer to the Master DTC Chart in Section 419-10 .
DTC Charts
ABS Module DTC Chart
NOTE: Always retrieve the continuous DTCs after running the self-test.

B1342 ECU is Defective NOTICE: Do not power the Electronic Control Unit (ECU) while it is
removed from the HCU . Failure to do so could damage the ECU or
cause the ECU to set unrelated DTCs.
NOTE: If other DTCs are present, repair them before installing a new
component.
CLEAR the DTCs. REPEAT the self-test. RETRIEVE the DTCs. If DTC
B1342 is retrieved, INSTALL a new ABS module. REFER to Anti-Lock
Brake System (ABS) Module in this section. REPEAT the self-test.
B1596 Service Continuous NOTE: This DTC does not indicate a malfunction of the ABS. If other
Codes DTCs are present, REPAIR them before addressing this DTC.
Some DTCs cannot be detected by the ABS module until the ignition is
cycled from ON to OFF and back to ON again. When DTCs are cleared
using the scan tool, the ignition needs to be cycled in order to clear this
DTC and have the ABS module check for other DTCs.
DIAGNOSE all other DTCs. CLEAR the DTCs. CYCLE the ignition.
RETRIEVE the DTCs. GO to the ABS Module DTC Chart.
B1676 Battery Pack Voltage GO to Pinpoint Test A .
Out of Range
B2477 Module Configuration CONFIGURE the ABS module. REFER to Programmable Module
Failure Installation (PMI) in Section 418-01 . CLEAR the DTCs. REPEAT the
self-test.
B2900 VIN Mismatch GO to Pinpoint Test B .
C109D Low Vacuum Condition GO to Pinpoint Test I .

Detected
C109E Vacuum Sensor Circuit GO to Pinpoint Test I .
Fault
C109F Vacuum Sensor Signal GO to Pinpoint Test I .
Fault
C1145 Wheel Speed Sensor GO to Pinpoint Test D .
RF Input Circuit Failure
LF Input Circuit Failure
RR Input Circuit Failure
LR Input Circuit Failure
C116A ABS Pressure GO to Pinpoint Test G .
Transducer / Brake
Switch Mismatch
C1222 Wheel Speed GO to Pinpoint Test E .
Mismatch
C1266 ABS Valve Power GO to Pinpoint Test F .
Relay Circuit Failure
C1278 Steering Wheel Angle This DTC sets when the steering wheel angle sensor data received over
1 and 2 Signal Faulted the HS-CAN is out of range and does not agree with other supporting
sensor data.
For the 6.2L engine, REFER to Section 211-05 to diagnose any SCCM
DTCs.
For all others, REFER to Section 211-05 to diagnose any SCCM DTCs. If
no SCCM DTCs are present, REFER to Section 211-00A to diagnose
any PSCM DTCs.
C1280 Yaw Rate Sensor This DTC indicates a concern with the yaw rate sensor which is integral
Signal Fault to the Restraints Control Module (RCM). REFER to Section 501-20B to
diagnose all the RCM DTCs. If no RCM DTCs are present, GO to
Pinpoint Test P .
C1282 Lateral Accelerometer This DTC indicates a concern with the lateral accelerometer which is
Signal Fault integral to the RCM . REFER to Section 501-20B to diagnose all the
RCM DTCs. If no RCM DTCs are present, GO to Pinpoint Test P .
C1288 Pressure Transducer CLEAR the DTCs. REPEAT the self-test. RETRIEVE the DTCs. If DTC
Main/Primary Input C1288 is retrieved, INSTALL a new Hydraulic Control Unit (HCU).
Circuit Failure REFER to Hydraulic Control Unit (HCU) . CLEAR the DTCs. REPEAT the
self-test.
C1296 Wheel Speed LF GO to Pinpoint Test E .
Signal Fault
C1297 Wheel Speed RF GO to Pinpoint Test E .
Signal Fault
C1298 Wheel Speed RR GO to Pinpoint Test E .
Signal Fault
C1299 Wheel Speed LR GO to Pinpoint Test E .
Signal Fault
C1300 ABS Pump Motor GO to Pinpoint Test C .

Circuit Failure
C1440 Pressure Transducer GO to Pinpoint Test G .
Main/Primary Signal
Faulted
C1516 Roll Rate Sensor This DTC indicates a concern with the roll rate sensor which is integral to
Signal Fault the RCM . REFER to Section 501-20B to diagnose all the RCM DTCs. If
no RCM DTCs are present, GO to Pinpoint Test P .
C1963 Stability Control Inhibit GO to Pinpoint Test P .
Warning
C1975 IVD Plausibility Failure GO to Pinpoint Test P .
C2770 Longitudinal This DTC indicates a concern with the longitudinal accelerometer which
Acceleration Sensor is integral to the RCM . REFER to Section 501-20B to diagnose all the
Plausibility Failure RCM DTCs. If no RCM DTCs are present, GO to Pinpoint Test P .
C2775 TC/AYC ON/OFF GO to Pinpoint Test R .
Switch Stuck Failure
C2809 Hill Descent Control GO to Pinpoint Test J .
Switch Stuck
U0073 Control Module REFER to Section 418-00 to diagnose the High Speed Controller Area
Communication Bus A Network (HS-CAN).
Off
U0100 Loss of GO to Pinpoint Test K .
Communication with
ECM/PCM
U0114 Lost Communication GO to Pinpoint Test L .
With Four-Wheel Drive
Clutch Control Module
U0131 Lost Communication GO to Pinpoint Test M . For the 6.2L engine, GO to Pinpoint Test N .
With Power Steering
Control Module (VAPS)
U0140 Lost Communication GO to Pinpoint Test O .
With Body Control
Module (GEM)
U0151 Lost Communication GO to Pinpoint Test P .
With Restraints Control
Module
U0155 Lost Communication GO to Pinpoint Test Q .
With Instrument Panel
Cluster (IC) Control
Module
U0401 Invalid Data Received This DTC sets when the ABS module receives invalid network data from
From ECM/PCM the PCM. RETRIEVE and REPAIR all non-network DTCs in the PCM.
from Four-Wheel Drive the Transfer Case Control Module (TCCM). RETRIEVE and REPAIR all
Clutch Control Module non-network DTCs in the TCCM . REFER to Section 308-07A .
From Instrument Panel the Instrument Panel Cluster (IPC). RETRIEVE and REPAIR all non-
Control Module network DTCs in the IPC . REFER to Section 413-01 .
U0428 Invalid Data Received This DTC sets when the ABS module receives invalid steering angle
from Steering Angle network data.
Sensor Module
For vehicles equipped with Hydraulic Power Assist Steering (HPAS), this
data is sent from the Steering Column Control Module (SCCM).
RETRIEVE and REPAIR all non-network DTCs in the SCCM . REFER to
Section 211-05 .
For vehicles equipped with Electronic Power Assist Steering (EPAS), this
data is sent from the Power Steering Control Module (PSCM).
RETRIEVE and REPAIR all non-network DTCs in the PSCM . REFER to
Section 211-00B .
From Restraints the RCM . RETRIEVE and REPAIR all non-network DTCs in the RCM .
Control Module REFER to Section 501-20B . If no RCM DTCs are present, GO to
Pinpoint Test P .
U2050 No Application Present CONFIGURE the ABS module. REFER to Programmable Module
Installation (PMI) in Section 418-01 . CLEAR the DTCs. REPEAT the self
test.
U2051 One or More CLEAR the DTC. CARRY OUT the ABS module self-test. If DTC U2051
Calibration Files returns, RECONFIGURE the ABS module using as-built data. REFER to
Missing /Corrupt PMI Using the Integrated Diagnostic System (IDS) When the Original
Module is NOT Available in Section 418-01 . CLEAR the DTC and
REPEAT the self-test. If DTC U2051 returns, INSTALL a new ABS
module. REFER to Anti-Lock Brake System (ABS) Module in this section.
CLEAR the DTC. REPEAT the self-test.
U2152 SCP (J1850) Invalid This DTC sets when the ABS module receives invalid network data from
Data from GEM the Body Control Module (BCM). RETRIEVE and REPAIR all non-
network DTCs in the BCM . REFER to Section 419-10 .
Symptom Chart
Symptom Chart
z No communication z Fuse z REFER to Section 418-
with the ABS z Wiring, terminals or 00 .
module connectors
z ABS module
z The yellow ABS z Wiring, terminals or z REFER to Section 413-
warning indicator is connectors 01 .
never on z Instrument Panel Cluster
(IPC)
z The stability/traction z Stability/traction control z REFER to Section 413-
control indicator system 01 .
(sliding car icon) is z ABS module
never on z IPC
z Only the red brake z Wiring, terminals or z REFER to Section 413-
warning indicator is connectors 01 .
always/never on z Parking brake switch
z Brake fluid level switch

(BCM)
z IPC
z The yellow ABS z DTCs in the ABS module z RETRIEVE and
warning indicator is z ABS module RECORD any ABS
always on z IPC module DTCs. GO to the
ABS Module DTC Chart.
z If there are no DTCs
present in the ABS
module, REFER to
Section 413-01 .
z The sliding car icon z DTCs in the ABS module z RETRIEVE and
is always on z Stability/traction control RECORD any ABS
system module DTCs. GO to the
z IPC ABS Module DTC Chart.
z If there are no DTCs
present in the ABS
module, REFER to
Section 413-01 .
z All 3 indicators (red z DTCs in the ABS module z RETRIEVE and
brake warning light, z Wiring, terminals or RECORD any ABS
yellow ABS warning connectors module DTCs. GO to the
indicator and the z Parking brake switch ABS Module DTC Chart.
sliding car icon) are z Brake fluid level switch z If there are no DTCs
always on z Stability/traction control present in the ABS
system module, REFER to
z BCM Section 413-01 .
z ABS module
z IPC
z Spongy brake pedal z Air in the brake hydraulic z BLEED the brake system
with no warning system and the Hydraulic Control
indicator Unit (HCU). REFER to
Brake System Bleeding
in Section 206-00 .
z Damaged or incorrectly z INSPECT the brake
installed brake pedal, brake booster and
components master cylinder for
correct installation.
06 for the brake pedal
and master cylinder or
Section 206-07 for the
brake booster.
CORRECT the
installation or INSTALL
new as necessary. TEST
operation.
z Poor vehicle z Air in the hydraulic brake z GO to Pinpoint Test S .
tracking during anti- system
lock function z Low tire pressure
z HCU
z Base brake system z REFER to Section 206-
concern 00 .
z The stability/traction z Wiring, terminals or z GO to Pinpoint Test R .
control system is connectors

inoperative z Stability/traction control
switch
z ABS module
z IPC
z The stability/traction z If a MyKey® restricted key z GO to Pinpoint Test R .
control system is in use with the
cannot be disabled AdvanceTrac® always on
feature configured to on,
the traction control system
cannot be disabled. An
admin key must be used in
order to enable and
disable the traction control
system
z Wiring, terminals or
connectors
z Stability/traction control
switch
z IPC
z The Hill Descent z ABS module DTCs z CARRY OUT a ABS
Control™ system (if present module self-test.
equipped) is z Hill Descent Control™ z GO to Pinpoint Test J .
inoperative switch
connectors
Pinpoint Tests
Pinpoint Test A: DTC B1676
Refer to Wiring Diagrams Cell 42 , Vehicle Dynamic Systems for schematic and connector information.
Normal Operation
The voltage required for correct ABS operation is between 10 and 17 volts. Voltage outside of this range
causes the ABS module to set DTC B1676.
z DTC B1676 (Battery Pack Voltage Out of Range) — this DTC sets in every ignition cycle if, with the
ignition in the RUN position and vehicle speed greater than 6 km/h (4 mph), the battery voltage is less
than 10 volts or more than 17 volts. DTCs set in the ignition cycle can only be cleared by cycling the
ignition off and on once the fault has been corrected.

z Fuse
z Battery condition
z ABS module
PINPOINT TEST A: DTC B1676
NOTE: DTC B1676 can be set if the vehicle has been recently jump started, the battery has been recently
charged or the battery has been discharged. The battery may become discharged due to excessive load(s)
on the charging system from aftermarket accessories or if the battery has been left unattended with the
accessories on.
NOTE: Carry out a thorough inspection and verification before proceeding with the pinpoint test. Refer to
Inspection and Verification in this section.

A1 RETRIEVE ALL CMDTC IN ALL MODULES
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: Self Test REFER to Section 414-00 for
— All CMDTCs . diagnosis of the battery and
z Is DTC B1317, B1318 or B1676 present in one or more charging system.
modules AND P0563, P0620, P0625, P0626 or P065B
present in the PCM? No
GO to A2 .
A2 CHECK BATTERY CONDITION
z Ignition OFF. Yes
z Carry out the Battery — Condition Test. Refer to Section 414- If the battery passed the
01 . condition test but required a
z Does the battery pass the condition test? recharge, REFER to Section
414-00 to diagnose the
charging system. CLEAR all
CMDTCs . TEST the system
If the battery passed the

condition test and did not
require a recharge, GO to A3 .
No
INSTALL a new battery.
CLEAR all CMDTCs . TEST
operation.
A3 CHECK CHARGING SYSTEM VOLTAGE
NOTE: Do not allow the engine speed to increase above Yes

2,000 rpm while carrying out this step or the generator can self GO to A4 .
excite and result in default charging system output voltage. If
engine speed goes above 2,000 rpm, shut the vehicle off and No
restart the engine before carrying out this step. REFER to Section 414-00 to
diagnose the charging system.
z Start the engine. CLEAR all CMDTCs . TEST
z Measure the voltage of the battery with and without a load on the system for normal
the charging system as follows: operation.
Turn off all accessories and run the engine at 1,500
rpm for a minimum of 2 minutes while measuring
battery voltage.
Turn the headlights on and the HVAC fan on high and
run engine at 1,500 rpm for a minimum of 2 minutes
while measuring battery voltage.
z Are the voltages between 13 and 15.2 volts?

A4 CHECK THE ABS MODULE GROUND CIRCUITS FOR AN
OPEN
z Disconnect: Battery Negative Cable . Yes
z Ignition OFF. GO to A5 .
z Disconnect: ABS Module C135 .
z Measure the resistance between ground and: No
ABS module C135-13, circuit GD121 (BK/YE), harness REPAIR the affected circuit(s).
side. CLEAR all CMDTCs . REPEAT
ABS module C135-38, circuit GD121 (BK/YE), harness the self-test.
side.
z Are the resistances less than 0.5 ohm?

A5 CHECK FOR VOLTAGE AT THE ABS MODULE
z Connect: Battery Negative Cable . Yes
z Ignition ON. GO to A6 .
z Measure the voltage between ground and:
ABS module C135-1, circuit SBB47 (WH/RD), harness No
side. VERIFY that Battery Junction
ABS module C135-25, circuit SBB36 (GN/RD), harness Box (BJB) fuses 36 (30A), 47
side. (60A), and 54 (5A) are OK. If
ABS module C135-35, circuit CBB54 (VT/OG), harness OK, REPAIR the affected
side. circuit(s). If not OK, REFER to
the Wiring Diagrams manual to
identify the possible causes of
the circuit short. CLEAR the
z Are the voltages greater than 10 volts?

A6 CHECK FOR CORRECT ABS MODULE OPERATION
z Disconnect: ABS Module C135 . Yes
z Check the connector for: INSTALL a new ABS module.
corrosion REFER to Anti-Lock Brake
damaged pins System (ABS) Module in this
pushed-out pins section. TEST the system for
z Connect: ABS Module C135 . normal operation.
z Make sure the connector seats correctly, then operate the
system and verify the concern is still present. No
z Is the concern still present? The system is operating
correctly at this time. Concern
may have been caused by a
loose or corroded connector.
the self-test.
Pinpoint Test B: DTC B2900
Normal Operation
When the ignition is turned to the RUN position, the ABS module and the Body Control Module (BCM) share
Vehicle Identification Number (VIN) information over the High Speed Controller Area Network (HS-CAN).
z DTC B2900 ( VIN Mismatch) — this DTC sets in the ignition cycle if the VIN information stored in the
ABS module does not match the information transmitted by the BCM . DTCs set in the ignition cycle
can only be cleared by cycling the ignition off and on once the fault has been corrected.

z Module configuration (ABS and BCM )
z ABS module
PINPOINT TEST B: DTC B2900

B1 VERIFY BCM VIN
z Connect the scan tool. Yes
z Ignition ON. GO to B2 .
z Using the scan tool, carry out
the network test. No
z Enter the following diagnostic RECONFIGURE the BCM . FOLLOW the instructions on the
mode on the scan tool: Log scan tool. CLEAR the DTCs. CYCLE the ignition key.
Viewer . REPEAT the self-test.
z Compare the VIN in log viewer
to the VIN plate.
z Does VIN in log viewer match
the VIN plate?
B2 VERIFY ABS MODULE PART
NUMBER
z Retrieve and record the ABS Yes
module part number from log CONFIGURE the ABS module. REFER to Programmable
viewer and verify that the Module Installation (PMI) Using the Integrated Diagnostic
vehicle has the correct ABS System (IDS) When the Original Module is NOT Available in
module installed. Section 418-01 . CLEAR the DTC. CYCLE the ignition key.
z Is the correct ABS module REPEAT the self-test.
installed in the vehicle?
No
INSTALL a new ABS module. REFER to Anti-Lock Brake
System (ABS) Module in this section. CLEAR the DTC.
CYCLE the ignition key. TEST the system for normal
operation.
Pinpoint Test C: DTC C1300
Normal Operation
The operating voltage required to run the hydraulic pump motor is between 10 and 17 volts. Fused battery
voltage for the hydraulic pump motor is supplied to the ABS module from the Battery Junction Box (BJB).
The hydraulic pump motor is internal to the Hydraulic Control Unit (HCU). If a new hydraulic pump motor is
needed, a new HCU must be installed.
z DTC C1300 (ABS Pump Motor Circuit Failure) — this DTC sets every ignition cycle or in on-demand
memory if there are circuit failures such as a short to ground, open, high circuit resistance, damaged
motor, blown fuse. The module also checks the motor after every actuation. When the pump is shut
off, the ABS module measures the output voltage of the motor. If the voltage drops too quickly, there
may be a locked motor. DTC C1300 sets if this fault is detected 3 times. DTCs set in the ignition cycle
can only be cleared by cycling the ignition off and on once the fault has been corrected.

z Fuse
z HCU
z ABS module
PINPOINT TEST C: DTC C1300
NOTICE: Use the correct probe adapter(s) when making measurements. Failure to use the correct
probe adapter(s) may damage the connector.

C1 CHECK THE ABS PUMP MOTOR
z Ignition ON. Yes
z Is the ABS pump motor running all the time? INSTALL a new ABS module. REFER to
Anti-Lock Brake System (ABS) Module
in this section. TEST the system for
normal operation.
No
GO to C2 .
C2 CHECK THE ABS MODULE PUMP MOTOR
(PMP_MOTOR) OUTPUT COMMAND
z Ignition ON. TOGGLE the PMP_MOTOR output
z Enter the following diagnostic mode on the scan tool: command OFF.
DataLogger — ABS Module .
z Toggle the PMP_MOTOR output command ON. CLEAR the DTCs. CHECK the yellow
z Does the ABS pump motor run for approximately ABS warning indicator while driving the
3 seconds? vehicle (the brakes must not be applied)
above 32 km/h (20 mph).
If the yellow ABS warning indicator

illuminates, RETRIEVE the DTCs. If
DTC C1300 is retrieved again, GO to
C5 .
If the yellow ABS warning indicator does

not illuminate, the system is OK.
No
TOGGLE the PMP_MOTOR output
command OFF. GO to C3 .
C3 CHECK FOR VOLTAGE TO THE ABS MODULE
z Ignition OFF. Yes
z Disconnect: ABS Module C135 . GO to C4 .
z Ignition ON.
z Measure the voltage between ABS module C135-1, No
circuit SBB47 (WH/RD), harness side and ground. VERIFY BJB fuse 47 (60A) is OK. If OK,
REPAIR open in circuit SBB47
(WH/RD). If not OK, REPAIR the short
circuit in circuit SBB47 (WH/RD).
test.

C4 CHECK THE ABS MODULE GROUND CIRCUIT FOR
AN OPEN OR EXCESSIVE RESISTANCE
z Ignition OFF. Yes

z Disconnect: Battery Negative Cable . GO to C5 .
z Measure the resistance between ABS module C135-
13, circuit GD121 (BK/YE), harness side and ground. No
REPAIR circuit GD121 (BK/YE). CLEAR
the DTCs. REPEAT the self-test.
z Is the resistance less than 0.5 ohm?

C5 CHECK THE ABS MODULE POWER CIRCUIT FOR
CONTINUITY
z Measure the resistance between the ABS module Yes
C135-1, circuit SBB47 (WH-RD), harness side and GO to C6 .
battery positive.
No
REPAIR the open circuit SBB47
(WH/RD). CLEAR the DTCs. REPEAT
the self-test.
z Is the resistance less than 0.5 ohms?

C6 CHECK FOR CORRECT ABS MODULE OPERATION
z Check the connector for: INSTALL a new HCU . REFER to
corrosion Hydraulic Control Unit (HCU) in this
damaged pins section. TEST the system for normal
pushed-out pins operation.
z Connect: ABS Module C135 .
z Connect: Battery Negative Cable . No
z Make sure the connector seats correctly, then The system is operating correctly at this
operate the system and verify the concern is still time. The concern may have been
present. caused by a loose or corroded
z Is the concern still present? connector. CLEAR the DTCs. REPEAT
the self-test.
Pinpoint Test D: DTCs C1145, C1155, C1165 and C1175
Normal Operation
Active wheel speed sensors generate a square wave current signal that is sent to the ABS module. The
wheel speed sensor circuitry connects to the ABS module through 2 wires and a connector at each wheel
speed sensor. When the ignition switch is turned to the RUN position, the ABS module carries out a self-test
by sending a reference voltage through the wheel speed sensors and their circuitry to determine if they are
functional. The front wheel bearings contain a magnetic strip that replaces the tone ring. It functions the
same but is not visible for inspection.
Battery voltage and ground are supplied to the active wheel speed sensors from the ABS module.
DTC Description Fault Trigger Condition

z C1145 — These DTCs set in continuous memory if the ABS module detects an open, short
Speed Wheel to ground or voltage or a damaged wheel speed sensor input circuit, the
Sensor RF appropriate DTC sets when the vehicle speed exceeds 6 km/h (4 mph). DTCs set
Input Circuit in the ignition cycle can only be cleared by cycling the ignition off and on once the
Failure fault has been corrected. DTCs C1165 and C1175 also set on-demand.
z C1155 —
Speed Wheel
Sensor LF Input
Circuit Failure
z C1165 —
Speed Wheel
Sensor RR
Input Circuit
Failure
z C1175 —
Speed Wheel
Sensor LR
Input Circuit
Failure

z Wheel speed sensors
z Wheel bearing magnetic strips, rear tone rings
z ABS module
PINPOINT TEST D: DTCs C1145, C1155, C1165 AND C1175
NOTE: If the ignition is turned to the ON position when a wheel speed sensor is disconnected, the ABS
module disables the output to that sensor. Make sure all test connections are made at the wheel speed
sensor connector before turning the ignition to the ON position.

D1 CHECK FOR FAULT REPEATABILITY
z Ignition ON. If the Rotunda Active Wheel Speed
Sensor Tester is available, GO to D2 . If
z Enter the following diagnostic mode on the scan the Rotunda Active Wheel Speed Sensor
tool: Clear the Continuous DTCs . Tester is not available, GO to D4 .
z Drive the vehicle at least 16 km/h (10 mph).
z Retrieve the Continuous Memory Diagnostic Trouble No
Codes (CMDTCs). INSPECT the wheel speed sensors and
z Is DTC C1145, C1155, C1165 or C1175 retrieved? wheel speed sensor wiring. REPAIR or
INSTALL new as necessary. If any other
DTCs are retrieved, GO to the ABS
Module DTC Chart.
D2 CHECK THE ABS MODULE OUTPUT USING THE
ROTUNDA ACTIVE WHEEL SPEED SENSOR TESTER
z Ignition OFF. Yes
z Disconnect: Suspect Wheel Speed Sensor . GO to D3 .
z Connect the Rotunda Active Wheel Speed Sensor
Tester to the wheel speed sensor connectors. No
z Select the correct system polarity on the tester and GO to D6 .
turn the tester power switch to the ON position.
z Ignition ON.
z Is the module output LED illuminated?
D3 CHECK THE WHEEL SPEED SENSOR OUTPUT
WITH THE ROTUNDA ACTIVE WHEEL SPEED SENSOR
TESTER
z Raise the suspect wheel until it can spin freely. Yes
Refer to Section 100-02 . The system is operating correctly at this
z While monitoring the Rotunda Active Wheel Speed time. The concern may have been
Sensor Tester, slowly spin the suspect wheel. caused by a loose or corroded connector.
z Do the sensor output LEDs illuminate and flash CLEAR the DTCs. REPEAT the self-test.
and is the current overload LED not illuminated?
No
If the current overload level LED is not
illuminated and the sensor output LEDs
do not illuminate or if the current overload
level LED is illuminated red, INSTALL a
new wheel speed sensor. REFER to
Wheel Speed Sensor — Front or Wheel
Speed Sensor — Rear in this section.
If the current overload level LED is not

illuminate green but do not flash,
INSTALL a new wheel speed sensor.
REFER to Wheel Speed Sensor — Front
or Wheel Speed Sensor — Rear in this
section. CLEAR the DTCs. REPEAT the
self-test. If the outputs LEDs still do not
flash when spinning the wheel, INSTALL
a new wheel bearing magnetic strip or
tone ring (rear). REFER to Section 204-
01A , Section 204-01B or Wheel Speed
Sensor Ring — Rear in this section.
D4 CHECK THE WHEEL SPEED SENSOR CIRCUITS
FOR A SHORT TO VOLTAGE
Yes
NOTE: Check both circuits for each DTC.
REPAIR the affected circuit(s). CLEAR
z Ignition OFF. the DTCs. REPEAT the self-test.
z Disconnect: ABS Module C135 .

z Disconnect: Suspect Wheel Speed Sensor . No
z Ignition ON. GO to D5 .
z Measure the voltage between the suspect wheel
speed sensor connector, harness side and ground
as follows:
Wheel Speed Sensor Circuit

C150-1 (LF) VCA03 (VT/WH)
C150-2 (LF) RCA17 (YE)
C160-1 (RF) VCA05 (GY/VT)
C160-2 (RF) RCA19 (VT)
C426-1 (RR) VCA06 (WH/OG)
C426-2 (RR) RCA20 (BN)
C440-1 (LR) VCA04 (BU/OG)
C440-2 (LR) RCA18 (BN/GN)

FOR A SHORT TO GROUND
Yes
NOTE: Check both circuits for each DTC.
GO to D6 .
z Ignition OFF.
z Measure the resistance between the wheel speed No
sensor connector, harness side and ground as REPAIR the affected circuit(s). CLEAR
follows: the DTCs. REPEAT the self-test.
Wheel Speed Sensor Circuit

C150-1 (LF) VCA03 (VT/WH)
C150-2 (LF) RCA17 (YE)
C160-1 (RF) VCA05 (GY/VT)
C160-2 (RF) RCA19 (VT)
C426-1 (RR) VCA06 (WH/OG)
C426-2 (RR) RCA20 (BN)
C440-1 (LR) VCA04 (BU/OG)
C440-2 (LR) RCA18 (BN/GN)

FOR AN OPEN
NOTE: Check both circuits for each DTC. Yes

GO to D7 .
z Ignition OFF.
z Disconnect: ABS Module C135 . No
z Disconnect: Suspect Wheel Speed Sensor . REPAIR the affected circuit(s). CLEAR
z Measure the resistance between the ABS module the DTCs. REPEAT the ABS self-test.
connector, harness side and the suspect wheel
speed sensor connector, harness side as follows:
ABS Wheel Speed

Module Circuit Sensor
C135-21 VCA03 C150-1 (LF)
(VT/WH)
C135-34 RCA17 (YE) C150-2 (LF)
C135-18 VCA05 C160-1 (RF)
(GY/VT)
C135-6 RCA19 (VT) C160-2 (RF)
C135-19 VCA06 C426-1 (RR)
(WH/OG)
C135-31 RCA20 (BN) C426-2 (RR)
C135-33 VCA04 C440-1 (LR)
(BU/OG)
C135-20 RCA18 C440-2 (LR)
(BN/GN)

D7 CHECK SHORTED WHEEL SPEED SENSOR
z Measure the resistance between the suspect wheel Yes
speed sensor connector, harness side as follows: GO to D8 .
ABS Wheel Speed No

Module Circuit Sensor REPAIR the affected circuit(s). CLEAR
C135-21 VCA03 C150-1 (LF)
(VT/WH)
C135-34 RCA17 (YE) C150-2 (LF)
C135-18 VCA05 C160-1 (RF)
(GY/VT)
C135-6 RCA19 (VT) C160-2 (RF)
C135-19 VCA06 C426-1 (RR)
(WH/OG)
C135-31 RCA20 (BN) C426-2 (RR)
C135-33 VCA04 C440-1 (LR)
(BU/OG)
C135-20 RCA18 C440-2 (LR)
(BN/GN)

D8 CHECK THE ABS MODULE OUTPUT
NOTE: Make sure all test connections are made at Yes

the wheel speed sensor before the ignition key is INSTALL a new wheel speed sensor.
turned to the ON position. REFER to Wheel Speed Sensor — Front
or Wheel Speed Sensor — Rear in this
NOTE: Use a meter with a min/max feature and/or section. CLEAR the DTCs. REPEAT the
recording capabilities to obtain accurate self-test.
measurements. The ABS module disables the
voltage output immediately if the wheel speed No
sensor is not present. GO to D9 .
z Ignition OFF.
z Connect the meter to the suspect wheel speed
sensor electrical connector pins, harness side.
z Set the meter to measure DC voltage.
z Set the meter range to greater than 15 volts.
z Enable the min/max or recording feature.
z Ignition ON.
z Check the maximum recorded voltage on the meter.
z Is the maximum recorded voltage greater than
10 volts?
D9 CHECK FOR CORRECT ABS MODULE
OPERATION
z Check for: INSTALL a new ABS module. REFER to
corrosion Anti-Lock Brake System (ABS) Module in
damaged pins this section. CLEAR the DTCs. REPEAT
pushed-out pins the self-test.
z Make sure the connector seats correctly, then No
operate the system and verify the concern is still The system is operating correctly at this
present. time. The concern may have been
z Is the concern still present? caused by a loose or corroded connector.
Pinpoint Test E: DTCs C1222, C1296, C1297, C1298 and C1299
Normal Operation
The wheel speed sensor and tone ring generate a square wave current signal to the ABS module that is
proportional to the wheel speed. The ABS module compares the wheel speed inputs from all the wheel
speed sensors to determine an impending wheel lockup. Incorrect tire size or tire pressure can set these
DTCs as well. DTCs set in the ignition cycle can only be cleared by cycling the ignition off and on once the
fault has been corrected.

z C1222 — This DTC sets in the ignition cycle when the vehicle speed exceeds 20 km/h (12
Speed Wheel mph) or the ABS module detects a difference between wheel speed sensor
Mismatch signals. This DTC can also be set by damaged tone rings, mismatched wheel
and/or tire sizes or driving the vehicle on one or more deflated tires.
z C1296 — These DTCs set in the ignition cycle when the vehicle speed exceeds 20 km/h (12
Wheel Speed mph). The appropriate DTC sets if the ABS module does not receive a signal from
LF Signal Fault the wheel speed sensor. These DTCs can also be set by an excessive wheel
z C1297 — speed sensor-to-tone ring air gap or a damaged tone ring, mismatched wheel
Wheel Speed and/or tire sizes or driving the vehicle on one or more deflated tires.
RF Signal
Fault
z C1298 —
Wheel Speed
RR Signal
Fault
z C1299 —
Wheel Speed
LR Signal Fault

z ABS module
z Wheel speed sensor magnetic strip/tone ring
z Wheel speed sensor
PINPOINT TEST E: DTCs C1222, C1296, C1297, C1298 AND C1299
NOTE: If the ignition is turned to ON when one or more wheel speed sensors are disconnected, the ABS
module disables the output to that sensor. Make sure all test connectors are made at the sensor before
turning the ignition to ON.

E1 CHECK THE ABS MODULE DTCs
z Review the ABS module DTCs retrieved and recorded Yes
during Inspection and Verification. GO to Pinpoint Test D .
z Is DTC C1145, C1155, C1165 or C1175 also
present? No
GO to E2 .
E2 MONITOR THE WHEEL SPEED SENSOR PIDs
z Ignition ON. CLEAR the DTCs. DRIVE the vehicle.
z Enter the following diagnostic mode on the scan tool: REPEAT the self-test. RETRIEVE and
DataLogger — ABS Module . RECORD any ABS module DTCs.
z While driving the vehicle at the speed at which the
concern occurred, monitor the following PIDs: If DTC C1296, C1297, C1298 or C1299
Left Front Wheel Speed Sensor (LF_WSPD) returns, GO to E11 .
Right Front Wheel Speed Sensor (RF_WSPD)
Left Rear Wheel Speed Sensor (LR_WSPD) If DTC C1222 is present, GO to E10 .
Right Rear Wheel Speed Sensor (RR_WSPD)
z Are the wheel speed sensor PIDs consistent with For all other ABS module DTCs, GO to
the vehicle speed and each other? the ABS Module DTC Chart.
If no DTCs return, INSPECT the ABS

module and wheel speed sensor
connectors for corrosion, pushed-out
pins, or damaged pins and REPAIR if
necessary. If all connectors are OK, GO
to E7 .
No
If the Rotunda Active Wheel Speed
Sensor Tester is available, GO to E3 .
If the Rotunda Active Wheel Speed

Sensor Tester is not available, GO to
E5 .
E3 CHECK THE ABS MODULE OUTPUT USING THE
ROTUNDA ACTIVE WHEEL SPEED SENSOR TESTER
z Ignition OFF. Yes
z Disconnect: Suspect Wheel Speed Sensor . GO to E4 .
z Connect the Rotunda Active Wheel Speed Sensor
Tester to the wheel speed sensor connectors. No
z Select the correct system polarity on the Rotunda GO to E6 .
Active Wheel Speed Sensor Tester and turn the
power switch to the ON position.
z Ignition ON.
z Is the module output LED illuminated?
E4 CHECK THE WHEEL SPEED SENSOR OUTPUT
WITH THE ROTUNDA ACTIVE WHEEL SPEED SENSOR
TESTER
z Raise the suspect wheel until it can spin freely. Refer Yes
to Section 100-02 . INSPECT the wheel speed sensor tone
z While monitoring the Rotunda Active Wheel Speed ring for damage and looseness.
Sensor Tester, slowly spin the suspect wheel. INSTALL new components as
z Do the sensor output LEDs illuminate and flash necessary. If the tone ring is OK, the
and is the current overload LED not illuminated? concern may have been caused by a
loose or corroded connector. CLEAR
No
If the current level LED is not
do not illuminate or if the current level
LED is illuminated red, INSTALL a new
wheel speed sensor. REFER to Wheel
Speed Sensor — Front or Wheel Speed
Sensor — Rear in this section. CLEAR
If the current level LED is not

illuminate green but do not flash,
INSPECT the wheel speed sensor tone
ring and INSTALL new if necessary. If
the tone ring is OK, INSTALL a new
wheel speed sensor. REFER to Wheel
Speed Sensor — Front or Wheel Speed
Sensor — Rear in this section. CLEAR
E5 CHECK THE ABS MODULE OUTPUT
NOTE: Make sure all test connections are made at Yes

GO to E7 .
the wheel speed sensor before the ignition is turned
to the ON position.
No
NOTE: Use a meter with a min/max feature and/or GO to E6 .

recording capabilities to obtain accurate
measurements. The ABS module disables the voltage
output immediately if the wheel speed sensor is not
present.
z Ignition OFF.
z Connect the meter to the suspect wheel speed sensor
electrical connector pins, harness side.
z Enable the min/max or recording feature.
z Ignition ON.
z Check the maximum recorded voltage on the meter.
z Is the maximum recorded voltage greater than 10
volts?
E6 CHECK THE WHEEL SPEED SENSOR CIRCUITS
FOR AN OPEN
NOTE: Check both circuits for each DTC. Yes

GO to E11 .
z Ignition OFF.
z Disconnect: ABS Module C135 . No
z Disconnect: Suspect Wheel Speed Sensor . REPAIR the affected circuit(s). CLEAR
z Measure the resistance between the ABS module the DTCs. REPEAT the self-test.
connector, harness side and the suspect wheel speed
sensor connector, harness side as follows:
ABS Wheel Speed

Module Circuit Sensor
C135-21 VCA03 C150-1 (LF)
(VT/WH)
C135-34 RCA17 (YE) C150-2 (LF)
C135-18 VCA05 (GY/VT) C160-1 (RF)
C135-6 RCA19 (VT) C160-2 (RF)
C135-19 VCA06 C426-1 (RR)
(WH/OG)
C135-31 RCA20 (BN) C426-2 (RR)
C135-33 VCA04 C440-1 (LR)
(BU/OG)
C135-20 RCA18 C440-2 (LR)
(BN/GN)

E7 CHECK THE WHEEL SPEED SENSOR AND
MOUNTING
z With the vehicle in NEUTRAL, position it on a hoist. Yes
Refer to Section 100-02 . GO to E9 .
z NOTE: Use a good light source and carefully examine
the wheel speed sensor wire. Failure to verify damage No
in the wheel speed sensor wire can lead to TIGHTEN the wheel speed sensor to
unnecessary installation of a new component. specification. REFER to Specifications
z Inspect the wheel speed sensor for looseness. in this section. CLEAR the DTCs. GO to
z Is the wheel speed sensor and mounting OK? E8 .
E8 RECHECK THE WHEEL SPEED SENSOR PIDs
z While driving the vehicle at a constant speed, monitor Yes
the following PIDs: The vehicle is OK. The concern may
Left Front Wheel Speed (LF_WSPD) have been caused by a loose wheel
Right Front Wheel Speed (RF_WSPD) speed sensor.
Left Rear Wheel Speed (LR_WSPD)
Right Rear Wheel Speed (RR_WSPD) No
z Are all the wheel speed sensor PID values GO to E9 .
similar?
E9 CHECK THE WHEEL SPEED SENSOR(S) FOR
DAMAGE
z Ignition OFF. Yes
z With the vehicle in NEUTRAL, position it on a hoist. For DTC C1296 or C1297, INSTALL a
Refer to Section 100-02 . new wheel hub and bearing (wheel
z Remove the wheel speed sensor. Refer to Wheel speed sensor tone rings are part of the
Speed Sensor — Front or Wheel Speed Sensor — wheel hub and bearing assembly).
Rear in this section. REFER to Section 204-01A or Section
z NOTE: Use a good light source and carefully examine 204-01B . For DTC C1298 or C1299,
the wheel speed sensor wire. Failure to verify damage INSTALL a new wheel speed sensor
in the wheel speed sensor wire can lead to tone ring. REFER to Wheel Speed
unnecessary installation of a new component. Sensor Ring — Rear in this section.
z Inspect the wheel speed sensor and attached wire CLEAR the DTCs. REPEAT the self-
harness for general damage. test.
z Is the wheel speed sensor and harness OK?
No
INSTALL a new wheel speed sensor.
REFER to Wheel Speed Sensor —
Front or Wheel Speed Sensor — Rear
in this section. CLEAR the DTC.
REPEAT the self-test.
E10 CHECK THE ABS MODULE CONFIGURATION
z Verify that the tires are the correct size for the vehicle Yes
and inflated to the specified pressures as indicated on GO to E11 .
the Vehicle Certification (VC) label.
z Carry out the ABS module configuration. Verify that No
the vehicle data matches the vehicle options. Refer to The system is operating correctly at this
Programmable Module Installation (PMI) in Section time. The concern may have been
418-01 . caused by an incorrectly configured
z Clear the DTCs. Carry out the ABS module on- ABS module.
demand self-test.
z Is DTC C1222 still present?
E11 CHECK FOR CORRECT ABS MODULE
OPERATION
z Ignition OFF. Yes

z Disconnect: ABS Module C135 . INSPECT the wheel speed sensor tone
z Check ABS module connector for: rings for damage. INSTALL new
corrosion components as necessary. If the tone
damaged pins rings are OK, INSTALL a new ABS
pushed-out pins module. REFER to Anti-Lock Brake
z Connect: ABS Module C135 . System (ABS) Module in this section.
z Make sure the connector seats correctly, then operate TEST the system for normal operation.
the system and verify the concern is still present.
The system is operating correctly at this
time. The concern may have been
caused by a loose or corroded
connector. CLEAR the DTCs. REPEAT
the self-test.
Pinpoint Test F: DTC C1266
Normal Operation
The operating voltage required for ABS module isolation valve operation is between 10 and 17 volts.
Fused battery voltage is supplied to the ABS module for the valves by the Battery Junction Box (BJB).
z DTC C1266 (ABS Valve Power Relay Circuit Failure) — this DTC sets in the ignition cycle if the ABS
module detects an open or a short to ground on the valve power feed circuit. DTCs set in the ignition
cycle can only be cleared by cycling the ignition off and on once the fault has been corrected.

z Fuse
z ABS module
PINPOINT TEST F: DTC C1266

F1 CHECK FOR VOLTAGE TO THE ABS MODULE
z Ignition OFF. Yes
z Disconnect: ABS Module C135 . GO to F2 .
z Measure the voltage between ABS module C135-
25, circuit SBB36 (GN/RD), harness side and No
ground. VERIFY that Battery Junction Box (BJB)
fuse 36 (30A) is OK. If OK, REPAIR circuit
SBB36 (GN/RD). If not OK, REFER to the
Wiring Diagrams manual to identify
possible causes of the circuit short.

F2 CHECK THE ABS MODULE GROUND CIRCUIT
FOR AN OPEN
z Ignition OFF. Yes
z Measure the resistance between ABS module GO to F3 .
C135-38, circuit GD121 (BK/YE), harness side and
ground. No
REPAIR circuit GD121 (BK/YE). CLEAR
z Is the resistance less than 0.5 ohm?

F3 CHECK FOR CORRECT ABS MODULE
OPERATION
z Check ABS module connector for: INSTALL a new ABS module. REFER to
corrosion Anti-Lock Brake System (ABS) Module in
damaged pins this section. CLEAR the DTCs. REPEAT
pushed-out pins the self-test.
time. The concern may have been caused
by a loose or corroded connector. CLEAR
Pinpoint Test G: DTCs C116A, C1440
Normal Operation
The pressure transducer is integral to the Hydraulic Control Unit (HCU). The pressure transducer sends a
signal to the ABS module that varies in relation to the amount of pressure applied to the brake pedal. The
more pressure that is applied, the greater the signal sent to the ABS module. If a new pressure transducer is
needed, then a new HCU must be installed.
When the brake pedal is pressed, the stoplamp switch closes and a voltage is sent to the PCM. The PCM
then sends a message over the High Speed Controller Area Network (HS-CAN) to the ABS module
indicating that the brake pedal has been pressed. DTCs set in the ignition cycle can only be cleared by
cycling the ignition off and on once the fault has been corrected.
z DTC C116A (ABS Pressure Transducer / Brake Switch Mismatch) — this DTC sets in every ignition
cycle if, during normal operation, the stoplamp switch message does not match the HCU transducer,
both signals have to agree about whether the brakes are being applied or not.
z DTC C1440 (Pressure Transducer Main/Primary Signal Faulted) — this DTC sets in every ignition
cycle if the signal that the pressure transducer sends to the ABS module does not agree with the
stoplamp switch position.

z HCU
z ABS module
PINPOINT TEST G: DTCs C116A, C1440

G1 MONITOR THE ABS MODULE BRAKE ON/OFF
(BOO_ABS) PID
z Ignition ON. GO to G3 .
z Enter the following diagnostic mode on the scan tool:
DataLogger — ABS Module . No
z Press and release the brake pedal while monitoring the GO to G2 .
BOO_ABS PID.
z Does the PID display ON with the brake pedal applied
and OFF with the brake pedal released?
G2 MONITOR THE PCM BRAKE ON/OFF (BOO1) PID
z Enter the following diagnostic mode on the scan tool: Yes
DataLogger — PCM . REFER to Section 418-00 to
z Press and release the brake pedal while monitoring the continue diagnosis of the HS-CAN .
BOO1 PID.
z Does the PID display ON with the brake pedal applied
and OFF with the brake pedal released? No
REFER to Section 417-01 to
continue diagnosis of the stoplamp
switch fault.
G3 MONITOR THE INITIAL (BRAKE PEDAL NOT APPLIED)
BRAKE PRESSURE USING THE ABS MODULE BRAKE
PRESSURE (BRAKPRES) PID
DataLogger — ABS Module . GO to G4 .
z With the brake pedal not applied, record the pressure
displayed by the BRAKPRES PID. No
z Is the initial brake pressure less than 275 kPa (40 psi) INSTALL a new HCU . REFER to
with the brake pedal not applied? Hydraulic Control Unit (HCU) in this
section.
G4 MONITOR THE BRAKPRES PID WHILE APPLYING THE

BRAKE PEDAL
DataLogger — ABS Module . The system is operating correctly
z Firmly press and release the brake pedal while monitoring at this time. TEST the system for
the BRAKPRES PID. normal operation.
z Does the PID increase with firm pressure on the brake
pedal and then decrease with the brake pedal No
released? INSTALL a new HCU . REFER to
Hydraulic Control Unit (HCU) in this
section.
Pinpoint Test I: DTCs C109D, C109E and C109F
Normal Operation
The ABS module uses the vacuum sensor to determine if hydraulic pump intervention is necessary due to a
severe loss of vacuum in the booster. The ABS module sends a 5-volt reference voltage to the sensor and
the sensor compares the pressure in the booster to the ambient air pressure in the engine compartment and
sends a varying voltage back to the ABS module based on the difference between the pressures. Normally,
the pressure in the booster is much lower than ambient air pressure. As the pressure in the booster gets
higher (closer to matching ambient air pressure), the lower the voltage sent back to the ABS module
becomes.
z DTC C109D (Low Vacuum Condition Detected) — this DTC sets in continuous memory and every
ignition cycle when the vacuum in the brake booster goes below a predetermined threshold and does
not necessarily indicate a concern with the vacuum sensor, the related wiring or the ABS module.
This DTC indicates a vacuum concern in the brake booster, engine and any related vacuum
hoses/tubes. High altitude locations with low ambient air temperatures can cause a low vacuum
condition to exist in the booster until the engine compartment warms up.
z DTC C109E (Vacuum Sensor Circuit Fault) — this DTC sets in continuous memory and every ignition
cycle if during normal operation or the ABS module on-demand self-test, the ABS module detects an
open circuit, a short to voltage or a short to ground on the vacuum sensor circuits or a failure of the
vacuum sensor.
z DTC C109F (Vacuum Sensor Signal Fault) — this DTC sets in continuous memory and every ignition
cycle if the vacuum sensor ambient air pressure inlet ports, or the vacuum sensor ports become
restricted or clogged.

z Vacuum sensor
z ABS module
PINPOINT TEST I: DTCs C109D, C109E AND C109F
I1 CHECK THE ABS MODULE DTCs

z Review the DTCs recorded during Inspection and Yes
Verification. GO to I2 .
z Was DTC C109D the only recorded DTC?
No
If DTC C109E and/or C109F was
retrieved, GO to I6 .
For all other DTCs, REFER to the

ABS Module DTC Chart in this
section.
I2 CHECK DTC RETURNABILITY
z Using the scan tool, clear the ABS module DTCs. Yes
z Ignition OFF. GO to I3 .
z Disconnect the scan tool.
z Start the engine. No
z NOTE: It may take up to 3 minutes for DTC C109D to set. If DTC C109E and/or C109F was
z Allow the vehicle to idle for a minimum of 4 minutes. Apply retrieved, GO to I6 .
and release the brake pedal for a minimum of 3 times per
minute with normal pedal force for up to 3 minutes For all other DTCs, REFER to the
z Ignition OFF. ABS Module DTC Chart in this
z Connect the scan tool. section.
z Ignition ON.
z Enter the following diagnostic mode on the scan tool: Self If no DTC is set, the system is
Test — ABS Module . operating correctly as this time.
z Is DTC C109D the only vacuum sensor DTC present? The concern may have been
connector. CLEAR the DTC.
I3 CHECK THE ENGINE VACUUM
z Carry out the Intake Manifold Vacuum Test, refer to Yes
Diagnosis and Testing in Section 303-00 . GO to I4 .
z Record the vacuum reading.
z Does the vacuum gauge indicate normal vacuum? No
FOLLOW the diagnostic
procedure in Section 303-00 .
I4 CHECK THE BRAKE BOOSTER
z Carry out the Brake Booster Component Test. Refer to Yes
Section 206-00 . GO to I5 .
z Do the brake booster and check valve pass the
component test? No
REPAIR or INSTALL new as
necessary. CLEAR the DTC.
I5 CHECK THE BRAKE BOOSTER VACUUM LEVEL
(BBVACLVL) PID
z Start the engine. REPAIR any vacuum leaks at the
z Enter the following diagnostic mode on the scan tool: vacuum system. For 4x4 vehicles,
DataLogger — ABS Module . REPAIR any vacuum leaks from
z Compare the recorded vacuum reading the brake booster the vacuum hub lock system.
vacuum level PID. REPEAT the ABS module self-
z Does the PID match the recorded vacuum reading of test.
±3.386 kPa (1 in-Hg)?
No
INSTALL a new brake booster
vacuum sensor. REFER to
Section 206-07 . CLEAR the
DTCs. TEST the system for
normal operation.
I6 CHECK THE BRAKE BOOSTER VACUUM SENSOR
z Inspect the vacuum sensor ambient air pressure inlet ports. Yes
z Are both ports free of contamination, debris and/or GO to I7 .
foreign material?
No
REPAIR or INSTALL a new
vacuum sensor as necessary.
CLEAR the DTCs. REPEAT the
self-test.
z Disconnect: Brake Booster Vacuum Sensor C149 . GO to I8 .
z Measure the resistance between ground and:
brake booster vacuum sensor C149-1, circuit VCA22 No
(GN/BN), harness side. REPAIR the affected circuit(s).
brake booster vacuum sensor C149-2, circuit GD120 CLEAR the DTCs. REPEAT the
(BK/GN), harness side. self-test.
brake booster vacuum sensor C149-3, circuit CCA22
(GY/YE), harness side.

z Measure the resistance between the ABS module C135, Yes
harness side and the brake booster vacuum sensor C149, GO to I9 .
harness side as follows:
No
ABS Module Circuit Vacuum Sensor REPAIR the affected circuit(s).
CLEAR the DTCs. REPEAT the
C135-10 VCA22 (GN/BN) C149-1 self-test.
C135-28 GD120 (BK/GN) C149-2
C135-2 CCA22 (GY/YE) C149-3

z Measure the resistance between: Yes
brake booster vacuum sensor C149-1, circuit VCA22 GO to I10 .
(GN/BN), harness side and brake booster vacuum
sensor C149-2, circuit GD120 (BK/GN), harness No
side. REPAIR the affected circuit(s).
brake booster vacuum sensor C149-1, circuit VCA22 CLEAR the DTCs. REPEAT the
(GN/BN), harness side and brake booster vacuum self-test.
sensor C149-3, circuit CCA22 (GY/YE), harness
side.
brake booster vacuum sensor C149-2, circuit GD120
(BK/GN), harness side, and brake booster vacuum
sensor C149-3, circuit CCA22 (GY/YE), harness
side.

I10 CHECK THE ACTIVE BRAKE BOOSTER VACUUM
SENSOR CIRCUITS FOR A SHORT TO VOLTAGE
z Ignition ON. Yes
z Measure the voltage between ground and: REPAIR the affected circuit(s).
brake booster vacuum sensor C149-1, circuit VCA22 CLEAR the DTCs. REPEAT the
(GN/BN), harness side. self-test.
brake booster vacuum sensor C149-2, circuit GD120
(BK/GN), harness side. No
brake booster vacuum sensor C149-3, circuit CCA22 GO to I11 .
(GY/YE), harness side.

CONNECTOR
z Ignition OFF. Yes
z Check brake booster vacuum sensor connector for: INSTALL a new vacuum sensor.
corrosion REFER to Section 206-07 .
damaged pins CLEAR the DTCs. REPEAT the
pushed-out pins self-test.
z Connect: Brake Booster Vacuum Sensor C149 .
z Make sure the connector seats correctly, then operate the If DTC C109E or C109F return,
system and verify the concern is still present. GO to I12 .
No
The system is operating correctly
at this time. The concern may
have been caused by a loose or
corroded connector. CLEAR the
I12 CHECK THE ABS MODULE CONNECTORS
z Ignition OFF. Yes
z Disconnect: ABS Module C135 . INSTALL a new ABS module.
z Check ABS module connector for: REFER to Anti-Lock Brake
corrosion System (ABS) Module in this
damaged pins section. TEST the system for
pushed-out pins normal operation.
z Make sure the connector seats correctly, then operate the No
system and verify the concern is still present. The system is operating correctly
z Is the concern still present? at this time. The concern may
have been caused by a loose or
corroded connector. CLEAR the
Pinpoint Test J: The Hill Descent Control System Is Inoperative
Normal Operation
Hill Descent Control™ can be activated by momentarily pressing the Hill Descent Control™ switch at speeds
from 3 km/h (2 mph) and 16 km/h (10 mph), but the system stays in control up to 32 km/h (20 mph). At
speeds between 32 km/h (20 mph) and 64 km/h (40 mph), Hill Descent Control™ does not set or maintain
speeds. Hill Descent Control™ automatically disables itself above 64 km/h (40 mph).
When the Hill Descent Control™ switch is pressed, a circuit inside of the switch is closed, ground is provided
to the Instrument Panel Cluster (IPC) disabling or enabling the Hill Descent Control™.
DTC C2809 can be set by manually pressing and holding the Hill Descent Control™ switch for more than 30
seconds.
z DTC C2809 (Hill Descent Control Switch Stuck) — this DTC sets if the ABS module receives the
HILL_DESC_SW message from the High Speed Controller Area Network (HS-CAN) for greater than
30 seconds.

z Hill Descent Control™ switch
z ABS module
PINPOINT TEST J: THE HILL DESCENT CONTROL SYSTEM IS INOPERATIVE

J1 CHECK FOR DTCs
z Ignition ON. For ABS module DTC C2809, GO to
z Enter the following diagnostic mode on the scan tool: J2 .
Self Test — All CMDTCs .
z Are any ABS module, IPC or communication DTCs For all other ABS module DTCs,
present? REFER to the ABS Module DTC Chart.
For IPC DTCs, REFER to the Section

413-01 .
No
System is operating correctly at this
time.
J2 VISUALLY INSPECT THE HILL DESCENT
CONTROL™ SWITCH
z Inspect the Hill Descent Control™ switch for damage. Yes
z Verify that the Hill Descent Control™ switch does not INSTALL a new Hill Descent Control™
stick. switch by removing the auxiliary switch
z Is the Hill Descent Control™ switch damaged or assembly. REFER to the exploded view
sticking? in Section 501-12 . PRESS the tab on
each side of the switch to remove it
from the bezel. After replacing the
switch, CLEAR the DTCs and REPEAT
the self-test. TEST the system for
normal operation.
No
GO to J3 .
J3 ISOLATE THE HILL DESCENT CONTROL™ SWITCH
z Ignition OFF. Yes

z Disconnect: Hill Descent Control™ Switch C3394 . If DTC C2809 was recorded, GO to J4 .
z Measure the resistance between Hill Descent For all other conditions, GO to J5 .
Control™ switch pins 1 and 6, component side, while
pressing and releasing the switch. No
INSTALL a new Hill Descent Control™
switch by removing the auxiliary switch
assembly. REFER to the exploded view
in Section 501-12 . PRESS the tab on
each side of the switch to remove it
from the bezel. After replacing the
switch, CLEAR the DTCs and REPEAT
normal operation.
z Is the resistance less than 5 ohms with the switch

pressed and greater than 10,000 ohms with the
switch released?
J4 CHECK THE HILL DESCENT CONTROL™ SWITCH
SIGNAL CIRCUIT FOR A SHORT TO VOLTAGE
z Disconnect: IPC C220 . Yes
z Ignition ON. REPAIR circuit CET59 (GY/VT).
z Measure the voltage between Hill Descent Control™ CLEAR the DTCs. REPEAT the self-
switch C3394-1, circuit CET59 (GY/VT), harness side test.
and ground.
No
time. The concern may have been
connector. TEST for normal operation.

SIGNAL CIRCUIT FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: IPC C220 . GO to J6 .
z Measure the resistance between Hill Descent
Control™ switch C3394-1, circuit CET59 (GY/VT), No
harness side and IPC C220-22, circuit CET59 REPAIR circuit CET59 (GY/VT). TEST
(GY/VT), harness side. the system for normal operation.
z Is the resistance less than 5 ohms?

GROUND CIRCUIT
z Ignition ON. Yes
z Measure the resistance between Hill Descent GO to J7 .
Control™ switch C3394-6, circuit GD138 (BK/WH),
harness side and ground. No
REPAIR the open in circuit GD138
(BK/WH). CLEAR the DTCs. REPEAT
the self-test.

J7 CHECK FOR CORRECT IPC OPERATION
z Check IPC connector: Yes
corrosion INSTALL a new IPC . REFER to
damaged pins Section 413-01 . TEST the system for
z Connect the IPC connector and make sure it seats
correctly. No
z Operate the system and verify the concern is still The system is operating correctly at this
present. time. The concern may have been
z Is the concern still present? caused by a loose or corroded
connector.
Pinpoint Test K: DTC U0100
Normal Operation
z DTC U0100 (Lost Communication With ECM/PCM) — this DTC sets in continuous memory if the
brake pedal position switch, and traction control messages that should be received from the
ECM/PCM are missing for 5 seconds or longer.

z PCM
z ABS module
PINPOINT TEST K: DTC U0100

K1 VERIFY THE SCAN TOOL
COMMUNICATES WITH THE PCM
z Check that a vehicle session can be GO to K2 .
established using the scan tool.
z Can a vehicle session be No
established? REFER to Section 418-00 to diagnose no
communication with the PCM.
K2 CHECK THE ABS MODULE
CONTINUOUS MEMORY DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode GO to K3 .
on the scan tool: Self Test — ABS
Module . No
z Clear the DTCs. The system is operating correctly at this time. The DTC
z Wait 10 seconds. may have been set due to high network traffic or an
z Repeat the ABS module self-test. intermittent fault condition.
z Is DTC U0100 retrieved again?
K3 RETRIEVE THE RECORDED DTCs
FROM THE PCM KOEO SELF-TEST
z Check for recorded DTCs from the Yes
PCM Key ON Engine OFF (KOEO) For PCM DTCs, REFER to Section 303-14 .
self-test.
z Is DTC P0562 or P0563 recorded? No
GO to K4 .
K4 RETRIEVE THE RECORDED DTCs
FROM THE ABS MODULE SELF-TEST
ABS module self-test. GO to Pinpoint Test A .
z Is DTC B1676 recorded?
No
GO to K5 .
K5 CHECK FOR DTC U0100 SET IN
OTHER MODULES
z Ignition ON. Yes
z Enter the following diagnostic mode INSTALL a new PCM. REFER to Section 303-14 . TEST
on the scan tool: Self Test — All the system for normal operation.
CMDTCs .
z Retrieve the continuous memory No
DTCs from all modules. INSTALL a new ABS module. REFER to Anti-Lock Brake
z Is DTC U0100:00 or U0100 set in System (ABS) Module in this section. TEST the system
more than 1 module? for normal operation.
Pinpoint Test L: DTC U0114
Normal Operation
z DTC U0114 (Lost Communication with Transfer Case Control Module (TCCM)) — this DTC sets in
continuous memory if the Four-Wheel Drive (4WD) message that should be received from the
Transfer Case Control Module (TCCM) is missing for 5 seconds or longer.

z TCCM
z ABS module
PINPOINT TEST L: DTC U0114

L1 VERIFY THE CUSTOMER CONCERN
z Ignition ON. Yes
z Verify there is an observable symptom GO to L2 .
present.
z Is an observable symptom present? No
The system is operating normally at this time. The
DTC may have been set due to high network traffic or
an intermittent fault condition.
L2 CHECK THE COMMUNICATION
NETWORK
z Using a scan tool, carry out a Network Yes
Test. GO to L3 .
z Does the TCCM pass the network
test? No
L3 RETRIEVE THE RECORDED DTCs
FROM THE ABS MODULE AND TCCM
SELF-TESTS
z Enter the following diagnostic mode on Yes
the scan tool: Self Test — ABS For ABS module DTC B1676, GO to Pinpoint Test A .
Module . For TCCM DTCs, REFER to Section 308-07A .
z Enter the following diagnostic mode on
the scan tool: Self Test — TCCM . No
z Is DTC B1676 (or P0562:00) or DTC GO to L4 .
P0563:00 recorded?
L4 RECHECK THE ABS MODULE DTCs
z Clear the DTCs. Yes
z Ignition OFF. GO to L5 .
z Wait 10 seconds.
z Ignition ON. No
z Enter the following diagnostic mode on The system is operating correctly at this time. The
the scan tool: Self Test — ABS DTC may have been set due to high network traffic or
Module . an intermittent fault condition.
z Is DTC U0114 still present?
L5 CHECK FOR DTC U0114 SET IN
OTHER MODULES

z Ignition OFF. INSTALL a new TCCM . REFER to Section 308-07A .
z Ignition ON. CLEAR the DTCs. REPEAT the ABS module self-test.
z Wait 10 seconds.
the scan tool: Self Test — All No
CMDTCs . INSTALL a new ABS module. REFER to Anti-Lock
z Is DTC U0114 set in more than 1 Brake System (ABS) Module in this section. TEST the
module? system for normal operation.
Pinpoint Test M: DTC U0131
Normal Operation
z DTC U0131 (Lost Communication With Power Steering Control Module (VAPS) — this DTC sets in
continuous memory and on-demand if the steering sensor message that should be received from the
Power Steering Control Module (PSCM) is missing for 5 seconds or longer.

z PSCM
z ABS module
PINPOINT TEST M: DTC U0131

M1 VERIFY THE CUSTOMER CONCERN
z Ignition ON. Yes
z Verify there is an observable symptom GO to M2 .
present.
M2 CHECK THE COMMUNICATION
NETWORK
Test. GO to M3 .
z Does the PSCM pass the network
test? No
M3 RETRIEVE THE RECORDED DTCs
FROM THE ABS MODULE AND PSCM
SELF-TESTS
Module . For PSCM DTCs, REFER to Section 211-00B .
the scan tool: Self Test — PSCM . No
z Is DTC B1676 (or U3003:16) or DTC GO to M4 .
U3003:17 recorded?
M4 RECHECK THE ABS MODULE DTCs

z Ignition OFF. GO to M5 .
z Wait 10 seconds.
z Ignition ON. No
M5 CHECK FOR DTC U0131 SET IN
OTHER MODULES
z Ignition OFF. INSTALL a new PSCM . REFER to Section 211-00B .
z Wait 10 seconds.
Pinpoint Test N: DTC U0131
Normal Operation
z NOTE: Vehicles with a 6.2L engine are equipped with a Steering Column Control Module (SCCM).
DTC U0131 (Lost Communication With Power Steering Control Module (VAPS) — this DTC sets in
continuous memory and on-demand if the steering sensor message that should be received from the
SCCM is missing for 5 seconds or longer.

z SCCM .
z ABS module
PINPOINT TEST N: DTC U0131

N1 VERIFY THE CUSTOMER CONCERN
z Ignition ON. Yes
z Verify there is an observable symptom GO to N2 .
present.
N2 CHECK THE COMMUNICATION
NETWORK
Test. GO to N3 .
z Does the SCCM pass the network
test? No

N3 RETRIEVE THE RECORDED DTCs
FROM THE ABS MODULE AND SCCM
SELF-TESTS
Module . For SCCM DTCs, REFER to Section 211-05 .
the scan tool: Self Test — SCCM . No
z Is DTC B1676 (or B11D9:16) or DTC GO to N4 .
B11D9:17 recorded?
N4 RECHECK THE ABS MODULE DTCs
z Ignition OFF. GO to N5 .
z Wait 10 seconds.
z Ignition ON. No
N5 CHECK FOR DTC U0131 SET IN
OTHER MODULES
z Ignition OFF. INSTALL a new SCCM . REFER to Section 211-00A .
z Wait 10 seconds.
Pinpoint Test O: DTCs U0140
Normal Operation
z DTC U0140 (Lost Communication With Body Control Module (GEM)) — this DTC sets in the ABS
module if it cannot transmit to or receive messages from the Body Control Module (BCM) over the
High Speed Controller Area Network (HS-CAN) for 5 seconds or longer.

z ABS module
z BCM
PINPOINT TEST O: DTC U0140

O1 VERIFY THE CUSTOMER CONCERN
z Ignition ON. Yes

z Verify that there is an observable GO to O2 .
symptom present.
z Is an observable symptom No
present? The system is operating normally at this time. The DTC
may have been set due to high network traffic or an
intermittent fault condition.
O2 CHECK THE COMMUNICATION
NETWORK
z Ignition ON. Yes
z Using a scan tool, carry out a Network GO to O3 .
Test.
z Does the BCM pass the network No
test? REFER to Section 418-00 .
O3 RETRIEVE THE RECORDED DTCs
FROM THE ABS MODULE AND BCM
SELF-TESTS
on the scan tool: Self Test — ABS For ABS module DTC B1676, GO to Pinpoint Test A .
Module . For BCM DTCs, REFER to Section 419-10 .
z Enter the following diagnostic mode
on the scan tool: Self Test — BCM . No
z Is DTC B1676 (or U3003:16 ) or DTC GO to O4 .
U3003:17 recorded?
O4 CHECK FOR DTC U0140 OR
U0140:00 SET IN OTHER MODULES
z Ignition OFF. INSTALL a new BCM . REFER to Section 419-10 .
z Ignition ON. TEST the system for normal operation. CLEAR the
z Wait 10 seconds. DTCs. REPEAT the ABS module self-test
on the scan tool: Self Test — All No
z Is DTC U0140 or U0140:00 set in Brake System (ABS) Module in this section. TEST the
more than 1 module? system for normal operation.
Pinpoint Test P: DTCs C1280, C1282, C1516, C1963, C1975, C2770, U0151 and U0452
Normal Operation
The ABS module uses information received from several sensors (wheel speed sensors, steering wheel
rotation sensor, stability/traction control system sensors, etc.) to determine if vehicle stability, traction or roll
warrants ESC or RSC® interaction. If an event is going to occur, the ABS module adjusts the brake torque
at specific wheels and the PCM reduces engine torque to make the vehicle more stable. Once the ABS
module has determined that the stability event has been corrected, it returns the brake and engine torque to
normal and continues to monitor the vehicle. DTCs set in the ignition cycle can only be cleared by cycling
the ignition off and on once the fault has been corrected. The Restraints Control Module (RCM) measures
the yaw rate and vehicle acceleration, then sends the signal through a secondary, dedicated Controller Area
Network (CAN) to the ABS module. The ABS module uses this information for AdvanceTrac® and RSC®
system operation. The ABS module also compares this information to information it receives from other
sensors (brake pedal input, steering wheel) to determine how valid the information is and to determine if an
instability event is about to occur.
The RCM and the ABS module communicate along circuits VCA23 (BU/WH) and VCA24 (GN/OG). An open
circuit or a short to power or ground on any one of these circuits causes the ABS module to set a DTC. Also,
if the RCM is not mounted in the correct position, with the electrical connector facing the driver-side of the
vehicle, the ABS module also sets DTCs.

z C1280 — Yaw Rate If the ABS module receives a message from the RCM that is out of the
Sensor Signal Fault normal operating range or one that does not agree with other sensor
z C1282 — Lateral information, the appropriate signal fault DTC sets.
Accelerometer
Signal Fault
z C1516 — Roll Rate
Sensor Signal Fault
z C2770 —
Longitudinal
Acceleration Sensor
Signal Fault
z C1963 — Stability If conditions or DTCs exist that prevent the AdvanceTrac® and RSC®
Control Inhibit systems from operating, DTCs C1963 and/or C1975 sets. This DTC is
Warning usually set due to the steering wheel rotation sensor or the RCM being
z C1975 — IVD damaged or installed incorrectly. If DTCs are present from the RCM or
Plausibility Failure PSCM , diagnose these DTCs first.
z U0151 — Lost The RCM uses a dedicated communication bus to send information to the
Communication with ABS module. If, during normal operation, the ABS module does not receive
Restraints Control any information from the RCM for more than 250 milliseconds, DTC U0151 or
Module (RCM) U0452 sets. U0151 monitors both the HS-CAN and the dedicated CAN
z U0452 — Invalid circuits. If the ABS module does not receive the RCM serial number, over the
Data Received from HS-CAN , DTC U0151 sets. It also sets if the sensor data is not received over
RCM the dedicated CAN from the RCM . These DTCs can also be caused by
another module software update. CLEAR all module DTCs and carry out
another self-test to recheck the system.
a
Interactive Vehicle Dynamics

z RCM
z ABS module
PINPOINT TEST P: DTCs C1280, C1282, C1516, C1963, C1975, C2770, U0151 and U0452
restraints control module (RCM) while the RCM is connected and the ignition switch is ON. Failure to
follow this instruction may result in the accidental deployment of the Safety Canopy and cause
serious personal injury or death.
assemblies. Failure to follow this instruction may result in the accidental deployment of these
assemblies, which increases the risk of serious personal injury or death.
pretensioners, load limiters and inflators. Never back probe deployable device electrical connectors.
Tampering or back probing may cause an accidental deployment and result in personal injury or
death.
NOTE: Supplemental Restraint System (SRS) components should only be disconnected or

reconnected when instructed to do so within a pinpoint test step. Failure to follow this instruction
may result in incorrect diagnosis of the SRS .
NOTE: The SRS must be fully operational and free of faults before releasing the vehicle to the customer.

P1 CHECK FOR A HS-CAN COMMUNICATION CONCERN
WITH THE RCM OR PSCM
z Ignition ON. GO to P2 .
z NOTE: The Network Test does not test the dedicated
CAN communications between the ABS module and No
RCM . REFER to Section 418-00 to
z Using a scan tool, carry out a Network Test. diagnose the High Speed Controller
z Does the RCM and PSCM pass the Network Test? Area Network (HS-CAN) bus.
P2 CHECK FOR RCM AND PSCM DTCs
Self Test — RCM . For RCM DTCs, REFER to Section
z Enter the following diagnostic mode on the scan tool: 501-20B .
Self Test — PSCM .
z Are any RCM or PSCM DTCs retrieved on-demand For PSCM DTCs, REFER to Section
self-test? 211-00A .
No
If only one of the following ABS
module DTCs C1280, C1282, C1516,
C2770 was retrieved, GO to P3 . If
more than one ABS module DTC
C1280, C1282, C1516, C2770 was
retrieved, GO to P7 . For DTCs
U0151 and U0452, GO to P7 . For all
other DTCs, GO to P3 .
P3 CHECK THE ABS MODULE YAW RATE
(YAW_RATE_2) PID
Data Logger — ABS Module . GO to P4 .
z NOTE: The vehicle must be on level ground and at a
complete standstill. Any vehicle movement results in No
false values for this test. GO to P12 .
z Monitor the YAW_RATE_2 PID.
z Is the YAW_RATE_2 PID value between -3.5 and
3.5?
P4 CHECK THE ABS MODULE LATERAL

ACCELERATION (LAT_ACCL_2) PID
z NOTE: The vehicle must be on level ground and at a Yes
complete standstill. Any vehicle movement results in GO to P5 .
false values for this test.
z Monitor the LAT_ACCL_2 PID. No
z Is the LAT_ACCL_2 PID value between -0.125g and GO to P12 .
0.125g?
P5 CHECK THE ABS MODULE LONGITUDINAL
ACCELERATION (LONG_ACCL) PID
z NOTE: The vehicle must be on level ground and at a Yes
z Monitor the LONG_ACCL PID. No
z Is the LONG_ACCL PID value between -0.15g and GO to P12 .
0.15g?
P6 CHECK THE ABS MODULE ROLL RATE (ROLLRAT)
PID
NOTE: The vehicle must be on level ground and at a Yes

No
z Monitor the ROLLRAT PID. GO to P12 .
z Is the ROLLRAT PID value between -3.5 and 3.5?
P7 CHECK THE DEDICATED CAN CIRCUITS FOR AN
OPEN
z Ignition OFF. Yes
z Depower the SRS . Refer to Supplemental Restraint GO to P8 .
System (SRS) Depowering and Repowering in Section
501-20B . No
z Disconnect: ABS Module C135 . REPAIR the affected circuit(s).
z Disconnect: RCM C310A and C310B . REPOWER the SRS . REFER to
z Measure the resistance between the ABS module Supplemental Restraint System
C135, harness side and the RCM C310B, harness side (SRS) Depowering and Repowering
as indicated in the following chart: in Section 501-20B . CLEAR all
CMDTCs. PERFORM a road test.
ABS Module Circuit RCM REPEAT the self-test.
C135-37 VCA23 (BU/WH) C310B-20

C135-24 VCA24 (GN/OG) C310B-19
P8 CHECK THE DEDICATED CAN CIRCUITS FOR A

SHORT TO GROUND
ABS module C135-24, circuit VCA24 (GN/OG), GO to P9 .
harness side.
ABS module C135-37, circuit VCA23 (BU/WH), No
harness side. REPAIR the affected circuit(s).
REPOWER the SRS . REFER to
Supplemental Restraint System
(SRS) Depowering and Repowering
in Section 501-20B . CLEAR all
CMDTCs . PERFORM a road test.
REPEAT the self test.

SHORT TOGETHER
z Measure the resistance between ABS module C135-24, Yes
circuit VCA24 (GN/OG), harness side and ABS module GO to P10 .
C135-37, circuit VCA23 (BU/WH), harness side.
No
REPAIR the affected circuit(s).
REPOWER the SRS . REFER to
Supplemental Restraint System
(SRS) Depowering and Repowering
in Section 501-20B . CLEAR all
CMDTCs . PERFORM a road test.
REPEAT the self test.

SHORT TO VOLTAGE
z Repower the SRS . Do not prove out the SRS at this Yes
time. Refer to Supplemental Restraint System (SRS) REPAIR the affected circuit(s).
Depowering and Repowering in Section 501-20B . CLEAR all CMDTCs . PERFORM a
z Ignition ON. road test. REPEAT the self test.
ABS module C135-24, circuit VCA24 (GN/OG), No
harness side. GO to P11 .
ABS module C135-37, circuit VCA23 (BU/WH),
harness side.

P11 CHECK RCM TERMINATING RESISTOR
z Ignition OFF. Yes
z Depower the SRS . Refer to Supplemental Restraint GO to P12 .
System (SRS) Depowering and Repowering in Section
501-20B . No
z Prior to reconnecting any previously disconnected SRS INSTALL a new RCM . REFER to
component: Section 501-20B . CLEAR all
inspect connector(s) (including any in-line CMDTCs . PERFORM a road test.
connectors) for pushed-out, loose or spread REPEAT the self test. If the concern
terminals and loose or frayed wire connections at is still present, GO to P14 . If other
terminals. DTCs are present, REFER to the
inspect wire harness for any damage, pinched, appropriate DTC chart.
cut or pierced wires.
inspect RCM C310A and C310B Connector
Position Assurance (CPA) lever/lock for correct
operation. Refer to RCM in Section 501-20B .
repair any concerns found.
Refer to Wiring Diagrams Cell 5 , Connector

Repair Procedures for schematic and connector
information.
z Connect: RCM C310A and C310B .

z Measure the resistance between ABS module C135-37,
circuit VCA23 (BU/WH), harness side and C135-24,
circuit VCA24 (GN/OG), harness side.
z Is the resistance between 108 and 132 ohms?

P12 CHECK THE RCM INSTALLATION AND MOUNTING
SURFACE
z Ignition OFF. Yes
z If not previously directed to do so, depower the GO to P13 .
Supplemental Restraint System (SRS). Refer to
Supplemental Restraint System (SRS) Depowering and No

Repowering in Section 501-20B . REPAIR or INSTALL new as
z Inspect the Restraints Control Module (RCM) necessary. REPOWER the SRS .
installation and make sure that the fasteners are fully REFER to Supplemental Restraint
seated and tightened correctly. Refer to RCM in Section System (SRS) Depowering and
501-20B . Repowering in Section 501-20B .
z Inspect the mounting surface for damage, corrosion or CLEAR all CMDTCs . PERFORM a
foreign material. road test. REPEAT the self test.
z Is the RCM installed correctly and is the mounting
surface clean and free from damage?
P13 CHECK FOR AN INTERMITTENT FAULT
z Disconnect: RCM C310A and C310B . Yes
z Disconnect: ABS module C135 . INSTALL a new RCM . REFER to
inspect connector(s) (including any in-line Section 501-20B . CLEAR all
connectors) for corrosion, loose or spread CMDTCs . PERFORM a road test.
terminals and loose or frayed wire connections at REPEAT the self test. If the concern
terminals. is still present, GO to P14 . If other
inspect wire harness for any damage, pinched, DTCs are present, REFER to the
cut or pierced wires. appropriate DTC chart.
No
Refer to Wiring Diagrams Cell 5 , Connector The fault is not present and cannot be
Repair Procedures for schematic and connector recreated at this time. Do not install
information. any new SRS components at this
time. SRS components should only
be installed when directed to do so
z Connect: All Previously Disconnected Component in the pinpoint test.
(s)/Connector(s) .
z Repower the SRS . Do not prove out the SRS at this
time. Refer to Supplemental Restraint System (SRS)
Depowering and Repowering in Section 501-20B .
z Perform a road test.
z Ignition ON.
Self Test — ABS Module .
P14 CHECK THE ABS MODULE FOR CORRECT
OPERATION
z Depower the SRS . Refer to Supplemental Restraint Yes
System (SRS) Depowering and Repowering in Section INSTALL a new ABS module. REFER
501-20B . to Anti-Lock Brake System (ABS)
z Prior to reconnecting any previously disconnected SRS Module in this section.
component:
inspect connector(s) (including any in-line No
connectors) for pushed-out, loose or spread The system is operating correctly at
terminals and loose or frayed wire connections at this time. The concern may have
terminals. been caused by a loose or corroded
inspect wire harness for any damage, pinched, connector.
cut or pierced wires.
inspect RCM C310A and C310B CPA lever/lock
for correct operation. Refer to RCM in Section
501-20B .
inspect ABS module C135 for dirt, corrosion,
water intrusion, pushed-out, loose or spread
terminals and loose or frayed wire connections at
terminals.
Refer to Wiring Diagrams Cell 5 , Connector

Repair Procedures for schematic and connector
information.
z Connect: All Previously Disconnected Component

(s)/Connector(s) .
z Repower the SRS . Do not prove out the SRS at this
time. Refer to Supplemental Restraint System (SRS)
Depowering and Repowering in Section 501-20B .
z Perform a road test.
z Ignition ON.
Self Test — ABS Module .
Pinpoint Test Q: DTC U0155
Normal Operation
z DTC U0155 (Lost Communication With Instrument Panel Cluster (IC) Control Module) — this DTC
sets in continuous memory and on-demand if the traction control switch information, or other sensor
messages from the IPC are not received for 5 seconds or longer.

z IPC
z ABS module
PINPOINT TEST Q: DTC U0155

Q1 VERIFY THE CUSTOMER CONCERN
z Ignition ON. Yes
z Verify that there is an observable GO to Q2 .
symptom present.
Q2 CHECK THE COMMUNICATION
NETWORK
Test. GO to Q3 .
z Does the IPC pass the network test?
No
Q3 RETRIEVE THE RECORDED DTCs
FROM THE ABS MODULE AND IPC SELF-
TESTS

Module . For IPC DTCs, REFER to Section 413-01 .
the scan tool: Self Test — IPC . No
z Is ABS module DTC B1676 or IPC GO to Q4 .
DTC U3003:16 or DTC U3003:17
received?
Q4 RECHECK THE ABS MODULE DTCs
z Ignition OFF. GO to Q5 .
z Wait 10 seconds.
z Ignition ON. No
Q5 CHECK FOR DTC U0155 OR U0155:00
SET IN OTHER MODULES
z Ignition OFF. INSTALL a new IPC . REFER to Section 413-01 .
z Wait 10 seconds.
z Enter the following diagnostic mode on No
the scan tool: Self Test — All INSTALL a new ABS module. REFER to Anti-Lock
CMDTCs . Brake System (ABS) Module in this section. TEST the
z Is DTC U0155:00 set in more than 1 system for normal operation.
module?
Pinpoint Test R: The Stability/Traction Control System is Inoperative or Cannot be Disabled
Refer to Wiring Diagrams Cell 42 , Instrument Cluster for schematic and connector information.
Normal Operation
The stability/traction control switch is a normally open switch. When the switch is pressed, the Instrument
Panel Cluster (IPC) senses ground through the switch and sends a message to the ABS module along the
High Speed Controller Area Network (HS-CAN) to disable the stability/traction control system. The IPC also
illuminates the traction control message center indicator.
NOTE: If a MyKey® restricted key is in use with the AdvanceTrac® always on feature configured to on, the
traction control system cannot be disabled. An admin key must be used in order to enable and disable the
traction control system .
z DTC C2775 (TC/AYC ON/OFF Switch Stuck Failure) — this DTC sets during the key cycle if the IPC
senses a short to ground on stability/traction control switch circuit, if the stability/traction control
switch is pressed for longer than 30 seconds, or if the stability/traction control switch is pressed
during the on-demand self-test.

z MyKey® restricted key in use
z Stability/traction control switch
z IPC
PINPOINT TEST R: THE STABILITY/TRACTION CONTROL SYSTEM IS INOPERATIVE OR CANNOT BE

DISABLED

R1 VERIFY THAT THE KEY IN USE IS NOT MYKEY®
RESTRICTED
z Ignition ON. Yes
z Attempt to disable the Electronic Stability Control (ESC) INFORM the customer that the key in
system by pressing the stability/traction control switch. use is MyKey® restricted. If
z Is ADVTRAC ON MyKey® SETTING displayed in the necessary, REFER to the Owner's
message center? Literature for information regarding the
programming of MyKey® features.
No
GO to R2 .
R2 CHECK FOR ABS MODULE DTCs
z Attempt to disable the ESC system by pressing the Yes
stability/traction control switch. For DTC U0073, REFER to Section
z Connect the scan tool. 418-00 to diagnose the HS-CAN . For
z Enter the following diagnostic mode on the scan tool: DTC U0155, GO to Pinpoint Test Q .
Self Test — ABS Module . For DTC U0423, CARRY OUT a self-
z Is DTC U0073, U0155 or U0423 present? test of the IPC . REFER to Section
413-01 to diagnose the IPC concern.
No
GO to R3 .
R3 ISOLATE THE STABILITY/TRACTION CONTROL
SWITCH
z Ignition OFF. Yes
z Disconnect: Stability/Traction Control Switch C2355 . GO to R4 .
z Measure the resistance between stability/traction
control switch pins 1 and 4, component side, while No
pressing and releasing the switch. INSTALL a new stability/traction
control switch. REFER to
Stability/Traction Control Switch in this
section. TEST the system for normal
operation.
z Is the resistance less than 5 ohms with the switch

pressed and greater than 10,000 ohms with the
switch released?
R4 CHECK THE SWITCH INPUT CIRCUIT FOR A SHORT

TO GROUND
z Disconnect: Battery Negative Cable . Yes
z Disconnect: IPC C220 . GO to R5 .
z Measure the resistance between stability/traction
control switch C2355-4, circuit CCA15 (YE/GY), No
harness side and ground. REPAIR circuit CCA15 (YE/GY).
operation.

R5 CHECK THE SWITCH INPUT CIRCUIT FOR AN OPEN
z Measure the resistance between stability/traction Yes
control switch C2355-4, circuit CCA15 (YE/GY), GO to R6 .
harness side and IPC C220-18, circuit CCA15 (YE/GY),
harness side. No
REPAIR circuit CCA15 (YE/GY).
operation.

R6 CHECK THE SWITCH GROUND CIRCUIT FOR AN
OPEN
z Measure the resistance between stability/traction Yes
control switch C2355-1, circuit GD133 (BK), harness GO to R7 .
side and ground.
No
REPAIR circuit GD133 (BK). TEST
R7 CHECK FOR CORRECT IPC OPERATION

z Check IPC C220 for: Yes
corrosion INSTALL a new IPC . REFER to
damaged pins Section 413-01 . CLEAR the DTCs.
pushed-out pins REPEAT the self-test.
z Connect the IPC connector and make sure it seats
correctly. No
z Operate the system and verify the concern is still The system is operating correctly at
present. this time. The concern may have been
connector. CLEAR the DTCs.
Pinpoint Test S: Poor Vehicle Tracking During Anti-Lock Function
Normal Operation
The ABS module uses input from several different sensors (wheel speed sensors, Brake Pedal Position
(BPP) switch, sensor cluster, etc.) to determine if an ABS event is necessary. If an ABS event is necessary,
the ABS module commands the hydraulic pump motor on and the Hydraulic Control Unit (HCU) to actuate
the appropriate solenoids. During an ABS event, the front and rear end of the vehicle should track true to the
direction of travel along the vehicle centerline unless driver input dictates otherwise. Other items that could
cause uneven braking during an ABS event are; an internal issue with the HCU , an issue with the base
brake system (caliper, brake pads, etc.) or worn out suspension components.
The operating voltage required for ABS module, hydraulic pump and isolation valve operation is between 10
and 17 volts.

z Air in hydraulic brake system
z Low tire pressure
z Base brake system
z HCU
PINPOINT TEST S: POOR VEHICLE TRACKING DURING ANTI-LOCK FUNCTION

S1 VERIFY VEHICLE TRACKING DURING
NON-ABS BRAKING
z NOTE: Before road testing the vehicle, Yes
check the tire pressure and confirm tire GO to S2 .
pressures are set to the pressure indicated
on the VC label. No
z Test drive the vehicle and verify vehicle The condition can be caused by a base brake
tracking during normal braking. concern or vehicle alignment. REFER to Section
z Does the vehicle track correctly during 206-00 to verify the base brake system and
normal braking? REFER to Section 204-00 to verify suspension
components.
S2 BLEED THE BRAKE SYSTEM

z Bleed the HCU . Refer to Section 206-00 . Yes
z Test drive the vehicle and verify vehicle The brake system is operating correctly. The
tracking during an ABS stop. concern may have been caused by air in the
z Does the vehicle track correctly during hydraulic system or a sticky valve.
an ABS stop?
No
GO to S3 .
S3 CHECK THE ABS INLET VALVE (CLOSED
POSITION)
z Ignition ON. TOGGLE the LF_INLET active command OFF.
z With the vehicle in NEUTRAL, position it on INSTALL a new HCU . REFER to Hydraulic
a hoist. Refer to Section 100-02 . Control Unit (HCU) in this section. TEST the
z Rotate all the wheels to make sure they system for normal operation.
rotate freely (the transmission must be in
NEUTRAL). No
z Apply moderate brake pedal effort. TOGGLE the LF_INLET active command OFF.
z Enter the following diagnostic mode on the GO to S4 .
scan tool: DataLogger — ABS Module .
z Toggle the left front inlet valve (LF_INLET)
active command ON and at the same time,
have an assistant attempt to rotate the LF
wheel.
z Does the LF wheel rotate?
S4 CHECK THE ABS INLET VALVE (OPEN
POSITION)
z Apply moderate brake pedal effort. Yes
z Have an assistant attempt to rotate the LF INSTALL a new HCU . REFER to Hydraulic
wheel. Control Unit (HCU) in this section. TEST the
z Does the LF wheel rotate? system for normal operation.
No
GO to S5 .
S5 CHECK THE ABS OUTPUT VALVE (OPEN
POSITION)
z Toggle the left front outlet valve TOGGLE all active commands OFF. INSTALL a
(LF_OUTLET) and the LF_INLET active new HCU . REFER to Hydraulic Control Unit
commands ON and, at the same time, have (HCU) in this section. TEST the system for normal
an assistant attempt to rotate the LF wheel. operation.
z Does the LF wheel rotate?
No
TOGGLE all active commands OFF. GO to S6 .
S6 CHECK THE ABS INLET AND OUTLET
VALVE (CLOSED POSITION)
z Have an assistant attempt to rotate the LF INSTALL a new HCU . REFER to Hydraulic
wheel. Control Unit (HCU) in this section. TEST the
z Does the LF wheel rotate? system for normal operation.
No
REPEAT this procedure (GO to S3 ) for the RF,
LR and RR wheels using the appropriate active
commands. If no failure occurs, the system is

operating normally.
Anti-Lock Brake System (ABS) Module
Special Tool(s)

1 — ABS module electrical connector (part of 12A581)
2 2M101 ABS module screw (also part of 2C219) (4 required)
3 2C219 ABS module
NOTICE: Do not connect the wiring connector to the ABS module while it is separated from the
HCU , doing so sets DTCs that cannot be cleared.
NOTICE: Electronic modules are sensitive to electrical charges. The ABS module can be damaged if
exposed to these charges.
NOTICE: Do not swap ABS modules between vehicles. Brake fluid pressure sensor calibration varies
depending on vehicle configuration. Swapping ABS modules between vehicles with different
calibrations causes a DTC to set in the ABS module that cannot be cleared.
1. If a new ABS module is being installed, connect the scan tool and upload the module configuration
information from the ABS module. For additional information on configuration, refer to Programmable
Module Installation (PMI) in Section 418-01 .
2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .
3. Disconnect the ABS module electrical connector.
4. NOTICE: Pull the ABS module straight back until the coil packs and motor connector clear the
Hydraulic Control Unit (HCU) or damage to the ABS module may result.
Remove the 4 ABS module screws and the ABS module.


z When installing a new ABS module, it must be configured (using vehicle as-built data or
module configuration information retrieved earlier in this procedure). For additional information
on configuration, refer to PMI in Section 418-01 .
Hydraulic Control Unit (HCU)
Material
Item Specification
High Performance DOT 3 WSS-M6C62-A or
Motor Vehicle Brake Fluid WSS-M6C65-A1
(Canada)
Part
1 — ABS module electrical connector (part of 12A581)
2 — Brake tube-to-Hydraulic Control Unit (HCU) fitting (4
required)
3 2A040 Master cylinder primary brake tube-to- HCU fitting
4 2B253 Master cylinder secondary brake tube-to- HCU fitting
5 — HCU -to-bracket nut (part of kit 2C229) (2 required)
6 2C215 HCU (also part of 2C405)
7 2C304 HCU bracket (also part of 2C405)
8 W506424 HCU bracket bolts (3 required)
NOTICE: Electronic modules are sensitive to electrical charges. The ABS module can be damaged if
exposed to these charges.
NOTICE: Do not allow brake fluid or other contaminates to drip onto the ABS module or into the
electrical connector. Contamination may cause a permanent failure to occur.
NOTE: The Hydraulic Control Unit (HCU) bracket does not have to be removed in order to complete this
procedure.
2. NOTE: The brake tubes must be installed in the same location as removed.
Remove the 4 brake tube-to- HCU fittings.

3. Disconnect the master cylinder primary and secondary brake tube-to- HCU fittings.
z To install, tighten the master cylinder primary brake tube-to- HCU fitting to 28 Nm (21 lb-ft).
z To install, tighten the master cylinder secondary tube brake tube-to- HCU fitting to 20 Nm (177
lb-in).
4. Loosen the 2 HCU -to-bracket nuts and remove the HCU .


z Bleed the brake system. For additional information, refer to Section 206-00 .
Stability/Traction Control Switch
1. Refer to Passenger Air Bag Deactivation (PAD) Indicator in Section 501-20B .
Steering Wheel Rotation Sensor

1 3F818 Steering wheel rotation sensor
Removal
NOTE: Only available on the 6.2L engine. For all other applications, the sensor is part of the Electronic
Power Assist Steering ( EPAS ) and is not serviced seperatley.
1. Remove the clockspring. For additional information, refer to Section 501-20B .
2. Remove the steering wheel rotation sensor.
Installation
1. Align the arrow on the inner ring of the sensor to the notch on the sensor body.
2. Position the sensor on the Steering Column Control Module (SCCM).
3. Install the clockspring. For additional information, refer to Section 501-20B .
Wheel Speed Sensor — Front
Part
1 W710279 Wheel speed sensor harness bolt
2 — Wheel speed sensor bolt (part of 2C204)
3 2C204 Wheel speed sensor
4 — Wheel speed sensor electrical connector (part of
14250)
2. NOTE: The wheel speed sensor harness electrical connector is located in the engine compartment
secured to the fender apron.
Disconnect the wheel speed sensor electrical connector.
3. Detach the 2 wheel speed sensor harness pushpin retainers.
4. Detach the wheel speed sensor harness retainer from the brake hose.
5. Remove the wheel speed sensor harness bolt.
6. Remove the wheel speed sensor bolt and the wheel speed sensor.
Wheel Speed Sensor — Rear
Left Rear Wheel Speed Sensor
Part
1 W500223 Wheel speed sensor bolt

14405)
Right Rear Wheel Speed Sensor
Part
1 W500223 Wheel speed sensor bolt
14405)
02 .
2. Disconnect the wheel speed sensor electrical connector.
3. Detach the wheel speed sensor harness retainers and pushpin retainers.
4. Remove the wheel speed sensor bolt and the wheel speed sensor.
Wheel Speed Sensor Ring — Rear
Removal

1 4234 Axle shaft
2 2C189 Wheel speed sensor ring
1. Remove the rear axle shaft. For additional information, refer to Section 205-02A or Section 205-02B .
2. Using a suitable driver, remove the wheel speed sensor ring from the axle shaft and discard the ring.
Installation
1. NOTICE: Do not apply any amount of force to the tooth area of the wheel speed sensor ring
during installation, the sensor teeth are fragile and can be easily damaged. Apply force only to
the inner lip area of the wheel speed sensor ring.
Using suitable adapters, press the wheel speed sensor ring onto the rear axle shaft.
2. Install the rear axle shaft. For additional information, refer to Section 205-02A or Section 205-02B .
SECTION 206-10: Auxiliary Brake System 2014 F-150 Workshop Manual

Auxiliary Brake System — Trailer Brake Control (TBC) Module
Trailer Brake Control System
The trailer brake control system consists of the following components:
z Trailer Brake Control (TBC) module, which is mounted in the center of the instrument panel just below
the climate controls
z Trailer tow connector
z Instrument Panel Cluster (IPC)
The TBC module has the following driver inputs and outputs:
z Manual slider switch (input)

z Gain buttons (input)
z Gain setting display (output)
z Trailer connectivity icon (output)
z Output bar graph display (output)
The manual slider switch on the TBC module activates the trailer brakes independently from the vehicle
brakes. The manual slider is used in conjunction with the gain buttons to adjust and set the trailer brakes.
When the manual lever is activated with a trailer connected to the vehicle, the trailer stoplamps and the
vehicle stoplamps illuminate. Activating the manual lever without a trailer connected to the vehicle still
illuminates the vehicle stoplamps.
The gain buttons set the TBC system for specific towing conditions such as trailer load, vehicle load, road
conditions and weather. The gain is normally set to provide maximum trailer braking while maintaining trailer
stability. For information on setting the trailer brake gain, refer to the Owner's Literature.
The gain setting and output bar graph displays provide the driver with TBC system information. Trailer
connectivity is provided through the trailer connector icon or message center depending on which IPC the
vehicle is equipped with, the gain setting display provides the driver with the current gain setting and the
output bar graph shows the amount of power going to the trailer brakes relative to brake pedal or manual
lever input (only if a trailer is connected to the vehicle).
TBC System Message Center Messages and Displays
The IPC message center displays the gain setting and relative braking power during a braking event. The
message center also indicates trailer connectivity and trailer wiring faults. The following message center
messages pertain to the TBC system:
z NO TRAILER — This message is displayed whenever the ignition is cycled from OFF to RUN without
a trailer connected to the 7-pin trailer connector.
z TRAILER CONNECTED — This message is displayed when a correct trailer connection at the 7-pin
trailer connector has been made during a given ignition cycle.
z OUTPUT — When the vehicle brake pedal is applied, or when the manual control is activated, bar
indicators illuminate in the message center to indicate the amount of power going to the trailer brakes
relative to the brake pedal or manual control input. One bar indicates the least amount of output with
6 bars indicating maximum output.
z TRAILER DISCONNECTED — This message is displayed and accompanied by a single chime when
a correct trailer connection was made and then a disconnection has been sensed during a given
ignition cycle. This message is also displayed if any of the following occur:
the 7-pin trailer connector becomes disconnected while driving
an intermittent open circuit occurs in the vehicle wiring from the TBC module to the 7-pin trailer
connector or the trailer wiring
during manual activation using the manual control lever without a trailer connected
(accompanied by a single chime)
z TRAILER BRAKE MODULE FAULT — This message is displayed and a DTC is stored when a fault
is detected by the TBC module.
z WIRING FAULT ON TRAILER — This message is displayed when the trailer brake output circuit is
shorted to ground or shorted to voltage. A DTC sets in the TBC module indicating which circuit fault
was observed. It is important to determine if a trailer was connected when this message was
displayed. If this message is only observed with a trailer connected, the concern is related to the
trailer wiring and not the vehicle. If this message is observed without a trailer connected, the concern
is with the vehicle wiring from the TBC module to the 7-pin trailer connector.
z TBC FAULT — This message is displayed if the Instrument Panel Cluster (IPC) is receiving
communications from the TBC module, but has not been configured for a trailer brake system. If the
message center displays TBC FAULT and there are no DTCs stored in the TBC module, follow the
steps in Programmable Parameters to verify and/or modify the TBC module programmable parameter
in the IPC .

Auxiliary Brake System — Trailer Brake Control (TBC) Module
Special Tool(s)
Flex Probe Kit


7-Way Trailer Emulator

TEK-6562A or equivalent
NOTE: A trailer brake emulator tool is available to verify that the Trailer Brake Control (TBC) module and
vehicle wiring are functioning correctly. The trailer emulator requires the trailer tow connector ground and 12
volt trailer tow charge circuit to be connected in order to check the electric brake circuit. Battery Junction Box
(BJB) fuse 21 (30A) and the Trailer Tow/Battery Charge Relay must be installed for battery voltage to be
supplied to the trailer tow connector. The fuse and relay are supplied as loose-shipped items with the vehicle
and may not have been installed during Pre-Delivery Inspection (PDI).
The Trailer Brake Control (TBC) module is an integrated electronic control device designed to provide
variable braking power to the electric-actuated drum brakes on a towed trailer (1 to 4 axles only). The
braking energy provided to the trailer is varied with a Pulse Width Modulated (PWM) signal that switches
between 0 volts and battery voltage, the higher the duty cycle the more braking power available.
The TBC module receives information from the stoplamp switch and the PCM. The brake pressure
transducer is internal to the ABS module.
The stoplamp switch is mounted on the brake pedal bracket and switches on or off depending on the brake
pedal position. The TBC module receives the stoplamp switch and the brake torque information over the
High Speed Controller Area Network (HS-CAN) from the PCM.
The TBC module receives information through the HS-CAN . These inputs are from the PCM, the Instrument
Panel Cluster (IPC) and the ABS module. The Body Control Module (BCM) also sends ignition state, park
lamp status and illumination dimming level data to the TBC module. The information sent from the TBC
module is passed to the IPC and is displayed on the message center.
To adjust the gain setting up or down, the TBC module faceplate provides the driver with control buttons
which determine the maximum power output. The TBC module faceplate also provides a manual control
lever to manually apply the trailer brakes, independent of the vehicle brakes, to calibrate the gain setting to
the specific trailer loading and road conditions. When the manual control lever is activated with a trailer
connected to the vehicle, the trailer stoplamps and the vehicle stoplamps (except the center high mount
stoplamp) illuminate. If a trailer is not connected and the manual control lever is activated, the vehicle still
illuminates the vehicle stoplamps (except the center high mount stoplamp).
Trailer Brake Control (TBC) Module Wake Up
NOTE: These conditions require that a trailer not be connected to the trailer tow connector.
The following conditions describe the normal operation of the TBC module at start up.
When the ignition key is in the RUN position and the manual lever is set all the way to the left with a gain of
10, the message center should display TRAILER DISCONNECTED. At the same time, with the vehicle
stationary, battery voltage should be present at pin 3 of the trailer tow connector.
When not braking the TBC module sends a voltage pulse every 4 seconds to pin 3 of the trailer tow
connector to determine whether a trailer is connected to the trailer tow connector.
Instrument Panel Cluster (IPC) Configuration For Trailer Brake Control (TBC) Functionality
The same IPC is used for vehicles with and without the TBC option. TBC functionality is enabled or disabled
using the scan tool. If the vehicle is equipped with a TBC module, but the IPC was not configured for TBC ,
the TBC module shuts down, no TBC information is displayed in the message center and DTC U2202 sets
in the TBC module.
If the IPC is configured for TBC , but the vehicle is not equipped with a TBC module, TRAILER BRAKE
MODULE FAULT is displayed in the message center. This symptom could occur if a replacement IPC was
installed, but not configured correctly. For information on the TBC programmable parameter, refer to
Programmable Parameters below.
Programmable Parameters
The message center displays TBC FAULT if it is receiving communications from the TBC module, but has
not been configured for a trailer brake system. If the message center displays TBC FAULT and there are no
DTCs stored in the TBC module, follow these steps to verify and/or modify the TBC module programmable
parameter in the Instrument Panel Cluster (IPC).
1. Identify the vehicle using the normal Integrated Diagnostic System (IDS) process.
2. Select Programming and press the check box.
3. Select Module Programming and press the check box.
4. Select Programmable Parameters and press the check box.
5. Select Personality and press the check box.
6. Follow the on-screen directions.
7. NOTE: The scan tool displays either EQUIPPED or NOT EQUIPPED to the left of TBC - IPC .
Highlight TBC - IPC .
8. If the IPC needs to be configured for a trailer brake system, choose EQUIPPED and press the check
box.
9. Clear DTCs from the TBC module, then carry out a self-test on the TBC module. Refer to the Trailer
Brake Control (TBC) Module DTC Chart for any DTCs retrieved.
NOTE: Carry out all pinpoint tests without a trailer connected to the vehicle.
NOTE: A trailer brake emulator tool is available to verify that the TBC module and vehicle wiring are
functioning correctly. The trailer emulator requires the trailer tow connector ground and 12 volt trailer tow
charge circuit to be connected in order to check the electric brake circuit.

z Base brake system z Battery Junction Box (BJB) fuse 17 (30A)
z Trailer z Body Control Module (BCM) fuse 37 (10A)
z Trailer Brake Control (TBC) module



z refer to Section 418-00 , The PCM Does Not Respond To The Scan Tool, to diagnose no

418-00 .
(CMDTCs).
8. Clear the CMDTCs and carry out the self-test diagnostics for the TBC module.
9. If the DTCs retrieved are related to the concern, go to the Trailer Brake Control (TBC) Module DTC
Chart. For all other DTCs, refer to Section 419-10 .
DTC Chart
Trailer Brake Control (TBC) Module DTC Chart

B1317 Battery Voltage High GO to Pinpoint Test D .
B1318 Battery Voltage Low GO to Pinpoint Test E .
B1342 ECU is Faulted INSPECT for a stuck or damaged manual sliding lever and gain
control buttons. REPAIR or CLEAR any obstructions or foreign
material.
REPAIR all other DTCs before repairing B1342. CLEAR the DTCs.
NOTE: It takes 2 minutes for the Trailer Brake Control (TBC)

module to set this DTC due to a stuck manual sliding lever or a
stuck gain control button.
If the DTC returns, INSTALL a new Trailer Brake Control (TBC)

module. REFER to Trailer Brake Control (TBC) Module in this
section.
B1863 TBC Ground Open Circuit GO to Pinpoint Test F .
C2806 Trailer Brakes Wiring Circuit GO to Pinpoint Test A .
Short to Vbatt
C2807 Trailer Brakes Wiring Circuit GO to Pinpoint Test A .
Short to Ground
U0100 Lost Communication With GO to Pinpoint Test G .
ECM /PCM "B"
U0121 Lost Communication With GO to Pinpoint Test H .

Anti-Lock Brake System
(ABS) Control Module
U0140 Lost Communication With GO to Pinpoint Test I .
Body Control Module (GEM)
U0155 Lost Communication With GO to Pinpoint Test J .
Instrument Panel Cluster (IC)
Control Module
U0415 Invalid Data Received from This DTC indicates that the TBC module has received the brake
Anti-Lock Brake System pressure information sent from the ABS module, but that
(ABS) Control Module information does not agree with other sensor inputs. REFER to
Section 206-09 to diagnose the ABS module.
U2202 Invalid Configuration Data The Instrument Panel Cluster (IPC) is not configured for trailer
Received brakes. REFER to Programmable Parameters in this section.
Symptom Chart
Symptom Chart
z No communication with the z Fuse(s) z REFER to Section 418-
Trailer Brake Control (TBC) z Wiring, 00 .
module terminals or
connectors
z TBC module
z The trailer brakes are z Fuse(s) z GO to Pinpoint Test B .
inoperative z Wiring,
terminals or
connectors
z Trailer tow
connector
z TBC module
z Customer
trailer
z The trailer brakes are always z Wiring, z GO to Pinpoint Test C .
engaged terminals or
connectors
z TBC module
z Customer
trailer
z The message center z Wiring, z GO to Pinpoint Test A .
intermittently displays TRAILER terminals or
DISCONNECTED or WIRING connectors
FAULT ON TRAILER while z Customer
towing a trailer trailer
z The message center displays z DTCs present z RETRIEVE and
TBC FAULT RECORD the DTCs.
REFER to the Trailer
Brake Control (TBC)
Module DTC Chart.

z The message center displays z Incorrect IPC z CONFIGURE the IPC .
TRAILER BRAKE MODULE configuration REFER to Programmable
FAULT when the vehicle is not Parameters in this
equipped with a TBC module section.
z The message center displays z Wiring, z GO to Pinpoint Test A .
WIRING FAULT ON TRAILER terminals or
connectors
z TBC module
z Customer
trailer
Pinpoint Tests
Pinpoint Test A: The Message Center Displays WIRING FAULT ON TRAILER
Refer to Wiring Diagrams Cell 95 , Trailer/Camper Adapter for schematic and connector information.
Normal Operation
The braking energy provided to the trailer is varied with a Pulse Width Modulated (PWM) signal that
switches between 0 volts and battery voltage, the higher the duty cycle the more braking power available.
The Trailer Brake Control (TBC) module varies the PWM signal based on various inputs such as the brake
torque message, the manual slider switch and the gain buttons. With the vehicle stationary and the manual
slider switch fully to the left with a gain of 10, there should be more than 10-12 volts supplied to pin 3 of the
7-pin trailer tow connector. When the trailer is connected to the vehicle the Instrument Panel Cluster (IPC)
should show the TRAILER CONNECTED message. If the WIRING FAULT ON TRAILER is only message
displayed when the trailer is connected, the fault is with the trailer wiring.
Every 4 seconds (when not braking) the TBC module sends a voltage pulse to pin 3 of the 7-pin trailer tow
connector to determine whether or not a trailer is connected.
z DTC C2806 (Trailer Brakes Wiring Circuit Short to Vbatt) — this DTC sets in continuous memory
when the TBC module detects that the battery voltage is greater than 9 volts while not braking. The
TBC module shuts off the trailer brake output and then shuts down.
z DTC C2807 (Trailer Brakes Wiring Circuit Short to Ground) — this DTC sets in continuous memory or
on-demand when the TBC module detects that the battery voltage drops by more than 20 percent
during a braking event or the trailer brakes are drawing more than 28 amps. The TBC module shuts
off the trailer brake output and then shuts down.

z TBC module
z Customer trailer
PINPOINT TEST A: THE MESSAGE CENTER DISPLAYS WIRING FAULT ON TRAILER
NOTE: Make sure the trailer brakes are electric-magnet actuated drum type brakes before proceeding with
this pinpoint test.

A1 VERIFY TBC MODULE DTCs
z Verify a trailer is not connected to the trailer tow Yes
connector. GO to A2 .
z Ignition ON.
z Enter the following diagnostic mode on the scan No
tool: TBC Module Self-Test . For all other TBC module DTCs, GO to the
z Clear the DTCs. TBC Module DTC Chart. If no DTCs return,
z Test drive the vehicle in the following manner: the system is operating correctly at this time.
maintain a speed greater than 5 km/h (3 INSPECT the 7-pin trailer tow connector for
mph) water intrusion, corrosion, pushed-out pins
turn the headlights ON and spread terminals. REPAIR or INSTALL
lightly apply the brakes for more than 5 new as necessary. If the 7-pin trailer tow
seconds connector is OK, SEND the trailer to an
activate the left and right turn signals authorized camper/trailer repair facility.
z Ignition OFF.
z Ignition ON.
z Wait at least 10 seconds for all modules to wake
up and prove out.
z Enter the following diagnostic mode on the scan
tool: TBC Module Self-Test .
z Is DTC C2806 or C2807 present?
A2 CHECK THE TRAILER TOW CONNECTOR
z Ignition OFF. Yes
z Disconnect: Trailer Tow C439A . For DTC C2806, GO to A4 . For DTC
z Ignition ON. C2807, GO to A3 .
tool: TBC Module Self-Test . No
z Clear the DTCs. INSTALL a new 7-pin trailer tow connector.
z Test drive the vehicle in the following manner: CLEAR any DTCs present. TEST the
maintain a speed greater than 5 km/h (3 system for normal operation.
mph)
turn the headlights ON
lightly apply the brakes for more than 5
seconds
activate the left and right turn signals
z Ignition OFF.
z Ignition ON.
up and prove out.
A3 CHECK THE TBC MODULE PWM OUTPUT
CIRCUIT FOR A SHORT TO GROUND
z Ignition OFF. Yes
z Connect: Trailer Tow C439A . GO to A5 .
z Disconnect: TBC Module C2142 .
z Measure the resistance between C439A-3, circuit No
CAT19 (BU), harness side and ground. REPAIR circuit CAT19 (BU) for a short to
ground. TEST the system for normal
operation.

A4 CHECK THE TBC MODULE PWM OUTPUT
CIRCUIT FOR A SHORT TO VOLTAGE
z Ignition OFF. Yes
z Connect: Trailer Tow C439A . REPAIR circuit CAT19 (BU) for a short to
z Disconnect: TBC Module C2142 . power. TEST the system for normal
z Ignition ON. operation.
z Measure the voltage between C439A-3, circuit
CAT19, (BU), harness side and ground while No
operating the following lamps in turn: GO to A5 .
Parking lamps
Stop lamps
Reversing lamps

A5 CHECK FOR CORRECT TBC MODULE
OPERATION
z Ignition OFF. Yes
z Inspect the TBC module connector. INSTALL a new TBC module. REFER to
z Repair: Trailer Brake Control (TBC) Module in this
corrosion (install a new connector or section. TEST the system for normal
terminal - clean module pins) operation.
damaged or bent pins - install new
terminals or pins No
pushed-out pins - install new pins as The system is operating correctly at this
necessary time. The concern may have been caused
spread terminals - install new terminals as by a loose or corroded connector.
necessary
z Connect the TBC module connector and make
sure that it seats correctly.
z Test drive the vehicle in the following manner:
maintain a speed greater than 5 km/h (3
mph)
turn the headlights ON
lightly apply the brakes for more than 5
seconds
activate the left and right turn signals
z Ignition OFF.
z Ignition ON.
up and prove out.
Pinpoint Test B: The Trailer Brakes are Inoperative
Normal Operation
The Trailer Brake Control (TBC) module varies the PWM signal based on various inputs such as the brake
torque message, the manual slider switch and the gain buttons. With the vehicle stationary and the manual
slider switch fully to the left with a gain of 10, there should be more than 10-12 volts supplied to the trailer
tow connector.
The TBC module receives stoplamp switch information from the PCM and information from the ABS module
over the High Speed Controller Area Network (HS-CAN). If there is a problem in the ABS module that is
preventing this information from being sent to the TBC module, the TBC module enters a limited operating
mode. The TBC module receives fused battery voltage from Battery Junction Box (BJB) fuse 17 (30A) and
fused ignition voltage from Body Control Module (BCM) fuse 37 (10A).

z Fuse(s)
z Trailer tow connector
z TBC module
z Customer trailer
PINPOINT TEST B: THE TRAILER BRAKES ARE INOPERATIVE
NOTE: Make sure the trailer brakes are electric-magnet actuated drum-type brakes before proceeding with
this pinpoint test.

B1 CHECK FOR ANY PCM DTCs
z Ignition ON. Yes

z Allow at least 10 seconds for all modules to wake up and REFER to Section 303-14 .
prove out.
z Enter the following diagnostic mode on the scan tool: Self No
Test — PCM Key ON Engine OFF (KOEO) . GO to B2 .
z Retrieve and record any PCM DTCs.
z Are any PCM DTCs retrieved?
B2 CHECK FOR ANY ABS MODULE DTCs
z Enter the following diagnostic mode on the scan tool: Self Yes
Test — ABS Module . REFER to Section 206-09 .
z Retrieve and record any ABS module DTCs.
z Are any ABS module DTCs retrieved? No
GO to B3 .
B3 CHECK FOR SCAN TOOL COMMUNICATION WITH THE
TBC MODULE
z Using a scan tool, carry out the network test. Yes
z Did the TBC module pass the network test? GO to B4 .
No
B4 CHECK FOR TBC MODULE DTCs
z Review the DTCs retrieved and recorded during TBC module Yes
self-test. REFER to the Trailer Brake
z Are any TBC module DTCs present? Control (TBC) Module DTC
Chart.
No
GO to B5 .
B5 CHECK THE TBC MODULE FOR MAXIMUM OUTPUT
NOTE: Battery voltage must be greater than 10 volts. Yes

The TBC module is operating
z Ignition ON. correctly. SEND the trailer to an
z Set a gain of 10 in the TBC module. authorized camper/trailer repair
z NOTE: If the manual slider switch is held to the full left center for an overload condition.
position for more than 5 to 20 minutes, the TBC module
automatically shuts down.
z Have an assistant press the manual slider switch fully to the No
left with a gain of 10 on the TBC module. GO to B6 .
z Measure the voltage between trailer tow 7-pin trailer tow
connector electric brake supply pin, component side and
ground.
z Is the voltage greater than 10-12 volts?

B6 CHECK THE TRAILER TOW CONNECTOR FOR AN OPEN
z Ignition OFF. Yes

z Disconnect: Trailer Tow Connector C439A . INSTALL a new trailer tow
z Ignition ON. connector. CLEAR the DTCs.
z Have an assistant press the manual slider switch fully to the TEST the system for normal
left with a gain of 10 on the TBC module. operation.
z Measure the voltage between the trailer tow connector
C439A-3, circuit CAT19 (BU), harness side and ground. No
GO to B7 .

B7 CHECK THE TBC MODULE PWM OUTPUT CIRCUIT FOR
AN OPEN
z Ignition OFF. Yes
z Measure the resistance between the trailer tow connector GO to B8 .
C439A-3, circuit CAT19 (BU), harness side and TBC module
C2142-14, circuit CAT19 (BU), harness side. No
REPAIR the circuit. TEST the

B8 CHECK THE BATTERY VOLTAGE TO THE TBC MODULE
z Ignition OFF. Yes
z Measure the voltage between TBC module C2142-8, circuit GO to B9 .
SBB17 (RD), harness side and ground.
No
VERIFY the BJB fuse 17 (30A)
is OK. If OK, REPAIR circuit
SBB17 (RD) for an open. TEST
B9 CHECK FOR CORRECT TBC MODULE OPERATION

z Disconnect the TBC module connector. Yes
z Check for: INSTALL a new TBC module.
corrosion REFER to Trailer Brake Control
damaged pins (TBC) Module in this section.
pushed-out pins TEST the system for normal
z Connect the TBC module connector and make sure it seats operation.
correctly.
z Operate the system and verify the concern is still present. No
correctly at this time. The
concern may have been caused
by a loose or corroded
connector.
Pinpoint Test C: The Trailer Brakes are Always Engaged
Normal Operation
With the vehicle stationary and the manual slider switch fully to the left with a gain of 10, there should be
more than 10-12 volts supplied to pin 3 of the 7-pin trailer tow connector. The Trailer Brake Control (TBC)
module also receives information from the brake pressure switch (also called the speed control deactivation
switch) and the stoplamp switch from the PCM over the High Speed Controller Area Network (HS-CAN).

z TBC module
z Customer trailer
PINPOINT TEST C: THE TRAILER BRAKES ARE ALWAYS ENGAGED

C1 CHECK FOR ANY PCM DTCs
z Ignition ON. Yes
z Allow at least 10 seconds for all modules to wake up REFER to Section 303-14 .
and prove out.
z Enter the following diagnostic mode on the scan tool: No
Self Test — PCM Key ON Engine OFF (KOEO) . GO to C2 .
z Retrieve and record any PCM DTCs.
z Are any PCM DTCs retrieved?
C2 CHECK FOR ANY TBC MODULE DTCs

Self Test — TBC Module . REFER to DTC Charts in this section.
z Retrieve and record any TBC module DTCs.
z Are any TBC module DTCs retrieved? No
GO to C3 .
C3 OBSERVE THE VEHICLE STOPLAMP OPERATION
z Monitor the vehicle stoplamps while pressing and Yes
releasing the brake pedal. GO to C4 .
z Do the vehicle stoplamps operate correctly?
No
REFER to Section 417-01 to diagnose
the stoplamp switch.
C4 CHECK THE TBC MODULE OUTPUT
NOTE: Every 4 seconds a voltage pulse is applied as Yes

a trailer connectivity test. The TBC module and vehicle wiring
are operating correctly. SEND the
z Ignition ON. trailer to an authorized camper/trailer
z Make sure the brake pedal is not pressed and the repair center.
manual slider switch is not being applied.
z Measure the voltage between 7-pin trailer tow No
connector electric brake supply pin, component side GO to C5 .
and ground.
z Is the voltage approximately 0.3-0.4 volt?

C5 CHECK THE TBC MODULE PWM OUTPUT CIRCUIT
z Ignition OFF. Yes
z Disconnect: TBC Module C2142 . REPAIR the circuit. TEST the system
z Ignition ON. for normal operation.
z Measure the voltage between 7-pin trailer tow
connector electric brake supply pin, component side No
and ground. GO to C6 .
C6 CHECK FOR CORRECT TBC MODULE OPERATION

z Check for: INSTALL a new TBC module. REFER
corrosion to Trailer Brake Control (TBC) Module
damaged pins in this section. TEST the system for
z Connect the TBC module connector and make sure it
seats correctly. No
z Operate the system and verify the concern is still The system is operating correctly at
present. this time. The concern may have been
connector. TEST the system for normal
operation.
Pinpoint Test D: DTC B1317
Refer to Wiring Diagrams Cell 13 , Power Distribution/BCM for schematic and connector information.
Normal Operation
z DTC B1317 (Battery Voltage High) — this DTC sets in continuous memory or on-demand in the
Trailer Brake Control (TBC) module when the TBC module detects that battery voltage has risen
above 16 volts on the voltage supply circuit while not braking.
z Charging system concern

z TBC module
PINPOINT TEST D: DTC B1317
NOTE: DTC B1317 may be stored in the module memory due to previous battery charging or vehicle jump
starting events.

D1 CHECK FOR DTC B1317, B1676, P0563
(PCM) OR U3003:17 SET IN OTHER
MODULES
z Ignition ON. Yes
z Allow at least 10 seconds for all modules REFER to Section 414-00 to diagnose an
to wake up and prove out. overcharging condition.
z Retrieve the continuous memory DTCs
from all modules. No
z Is DTC B1317, B1676, P0563 (PCM) or GO to D2 .
U3003:17 set in more than one
module?
D2 CHECK THE BATTERY VOLTAGE
z Turn off all interior/exterior lights and Yes
accessories. REFER to Section 414-00 to diagnose an
z Start and run the engine at approximately overcharging condition.
2,000 rpm for 3 minutes while monitoring
the battery voltage. No

z Does the battery voltage rise to 16 GO to D3 .
volts or higher?
D3 RECHECK FOR DTC B1317
z Turn the engine off. Yes
z Ignition ON. INSTALL a new TBC module. REFER to Trailer
z Allow at least 10 seconds for all modules Brake Control (TBC) Module module in this section.
to wake up and prove out. TEST the system for normal operation.
the scan tool: Self Test — TBC Module . No
z Clear the continuous memory DTCs. The system is operating normally at this time. The
z Carry out the TBC module self-test. DTC may have been set previously during battery
z Is DTC B1317 present? charging or while jump starting the vehicle.
Pinpoint Test E: DTC B1318
Refer to Wiring Diagrams Cell 13 , Power Distribution/SJB for schematic and connector information.
Normal Operation
z DTC B1318 (Battery Voltage Low) — this DTC sets in continuous memory or on-demand in the
Trailer Brake Control (TBC) module when the TBC module detects that battery voltage has dropped
below 9 volts on the voltage supply circuit while not braking.

z Charging system concern
z TBC module
PINPOINT TEST E: DTC B1318
NOTE: Failure to disconnect the battery when instructed results in false resistance readings. Refer to
Section 414-01 .

E1 RECHECK THE TBC MODULE DTCs
z Ignition ON. Yes
z Allow at least 10 seconds for all modules to wake up and prove GO to E2 .
out.
z Enter the following diagnostic mode on the scan tool: Self Test No
— TBC Module . The system is operating
z Clear the DTCs. Repeat the TBC module self-test. normally at this time. The
z Is DTC B1318 still present? DTC may have been set due
to a previous low battery
voltage condition.
E2 CHECK FOR CHARGING SYSTEM DTCs IN THE PCM
z Enter the following diagnostic mode on the scan tool: Self Test Yes
— PCM Key ON Engine OFF (KOEO) . REFER to Section 414-01 .
z Is DTC P0620, P0622, P0625, P0626 or P065B set in the
PCM? No
GO to E3 .
E3 CHECK THE BATTERY CONDITION AND STATE OF CHARGE
z Check the battery condition and verify the battery is fully Yes
charged. Refer to Section 414-01 . GO to E4 .
z Is the battery OK and fully charged?
No
E4 CHECK THE TBC MODULE VOLTAGE (MODULE_VOLT) PID
z Ignition ON. Yes
z Measure and record the voltage at the battery. GO to E7 .
DataLogger — TBC Module . No
z Monitor the TBC MODULE_VOLT PID. GO to E5 .
z Is the voltage within 0.2 volt of the recorded battery voltage?
E5 CHECK THE TBC MODULE VOLTAGE SUPPLY
z Ignition OFF. Yes
z Disconnect: TBC Module C2142 . GO to E6 .
z Ignition ON.
z Measure the voltage between the TBC module C2142-8, circuit No
SBB17 (RD), harness side and ground; and between the TBC REPAIR the circuit. TEST
module C2142-9, circuit CBP37 (WH), harness side and ground. the system for normal
operation.
z Is the voltage within 0.2 volt of the recorded battery voltage?

E6 CHECK THE TBC MODULE GROUND CIRCUIT FOR HIGH
RESISTANCE
z Ignition OFF. Yes
z Disconnect: Negative Battery Cable . GO to E7 .
z Measure the resistance between the TBC module C2142-3,
circuit GD138 (BK/WH), harness side and ground. No
REPAIR the circuit. CLEAR
the DTC. REPEAT the self-
test.

E7 CHECK FOR CORRECT TBC MODULE OPERATION
z Check for: INSTALL a new TBC
corrosion module. REFER to Trailer
damaged pins Brake Control (TBC) Module
pushed-out pins in this section. TEST the
z Connect the TBC module connector and make sure it seats system for normal operation.
correctly.
z Operate the system and verify the concern is still present.
The system is operating
corroded connector.
Pinpoint Test F: DTC B1863
Normal Operation
The Trailer Brake Control (TBC) module receives battery voltage from Battery Junction Box (BJB) fuse 17
(30A) and ignition voltage from Body Control Module (BCM) fuse 37 (10A).
z DTC B1863 ( TBC Ground Open Circuit) — this DTC sets in continuous memory or on-demand when
the TBC module detects an open circuit in the wiring, a connector condition causes an open in the
ground circuit or if an internal failure of the TBC module causes an open in the ground circuit. The
TBC module also disables trailer braking and sends a TRAILER BRAKE MODULE FAULT message
to the message center. A trailer must be connected for this DTC to set.

z TBC module
PINPOINT TEST F: DTC B1863
NOTE: A trailer must be connected to the 7-pin trailer connector for DTC B1863 to set during the on-
demand self-test.

F1 CHECK THE TBC MODULE GROUND CIRCUIT FOR
AN OPEN
z Ignition OFF. Yes
z Disconnect: TBC Module C2142 . GO to F2 .
z Measure the resistance between TBC module C2142-
3, circuit GD138 (BK/WH), harness side and ground. No
REPAIR the circuit. CLEAR the DTCs.

F2 CHECK FOR CORRECT TBC MODULE OPERATION
z Check for: INSTALL a new TBC module. REFER
corrosion to Trailer Brake Control (TBC) Module
damaged pins in this section. TEST the system for
broken harness wire
broken connector No
z Connect the TBC module connector and make sure it The system is operating correctly at
seats correctly. this time. The concern may have been
z Operate the system and verify the concern is still caused by a loose or corroded
present. connector. TEST the system for normal
z Is the concern still present? operation.
Pinpoint Test G: DTC U0100
Normal Operation
z DTC U0100 (Lost Communication With ECM/PCM "B") — this DTC sets in continuous memory or on-
demand in the Trailer Brake Control (TBC) module if data messages received (vehicle speed) from
the PCM are missing for more than 5 seconds. For a complete list of all network messages, refer to
Section 418-00 .
z PCM
z TBC module
PINPOINT TEST G: DTC U0100

G1 VERIFY THE SCAN TOOL CAN
COMMUNICATE WITH THE PCM
z Ignition ON. Yes
z Allow at least 10 seconds for all modules to GO to G2 .
wake up and prove out.
z Verify that a vehicle session can be No
established with a scan tool. REFER to Section 418-00 to diagnose no
z Can a vehicle session be established? communication with the PCM.
G2 CHECK THE TBC MODULE CONTINUOUS
MEMORY DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the GO to G3 .
scan tool: Self Test — TBC Module .
z Clear the DTCs. Repeat the TBC module No
self-test. Record all TBC module DTCs. The system is operating correctly at this time. The
z Is DTC U0100 retrieved again? DTC may have been set due to high network
traffic or an intermittent fault condition.
G3 RETRIEVE THE RECORDED DTCs FROM
THE TBC MODULE SELF-TEST
z Check for recorded TBC module DTCs from Yes
the previous self-test. For DTC B1317, GO to Pinpoint Test D . For DTC
z Is DTC B1317 or DTC B1318 recorded? B1318, GO to Pinpoint Test E .
No
GO to G4 .
G4 RETRIEVE THE RECORDED DTCs FROM
THE PCM SELF-TEST
z Enter the following diagnostic mode on the Yes
scan tool: Self Test — PCM Key ON Engine REFER to Section 303-14 .
OFF (KOEO) .
z Is DTC P0562 or DTC P0563 recorded? No
GO to G5 .
G5 CHECK FOR DTC U0100:00 SET IN OTHER
MODULES
z Using a scan tool, retrieve the continuous Yes
memory DTCs from the following modules: INSTALL a new PCM. REFER to Section 303-14 .
Accessory Protocol Interface Module
(APIM) (if equipped)
BCM No
Instrument Panel Cluster (IPC) INSTALL a new TBC module. REFER to Trailer
Occupant Classification System Brake Control (TBC) Module in this section. TEST
Module (OCSM) the system for normal operation.
Power Steering Control Module
(PSCM) (if equipped)
Restraints Control Module (RCM)
Transfer Case Control Module
(TCCM) (if equipped)
z Is DTC U0100:00 set in any of these
modules?
Pinpoint Test H: DTC U0121
Normal Operation
z DTC U0121 (Lost Communication With Anti-Lock Brake System (ABS) Control Module) — this DTC
sets in continuous memory or on-demand in the Trailer Brake Control (TBC) module if data messages
such as brake torque information are not received from the ABS module. For a complete list of all
network messages, refer to Section 418-00 .
z ABS module
z TBC module
PINPOINT TEST H: DTC U0121

H1 VERIFY THE CUSTOMER CONCERN
z Ignition ON. Yes
z Allow at least 10 seconds for all GO to H2 .
modules to wake up and prove out.
z Verify that there is an observable No
symptom present. The system is operating normally at this time. The
z Is an observable symptom present? DTC may have been set due to high network traffic or
H2 CHECK THE COMMUNICATION
NETWORK
z Using a scan tool, carry out the network Yes
test. GO to H3 .
z Does the ABS module pass the
network test? No
REFER to Section 418-00 to diagnose the ABS
module does not respond to the scan tool.
H3 RETRIEVE ANY DTCs FROM THE TBC
MODULE
the scan tool: Self Test — TBC Module . For DTC B1317, GO to Pinpoint Test D . For DTC
z Is DTC U3003:16 (or B1318) or DTC B1318, GO to Pinpoint Test E . For the ABS module,
U3003:17 (or B1317) recorded? REFER to Section 206-09 .
No
GO to H4 .
H4 CHECK FOR DTC U0121:00 SET IN
OTHER MODULES
z Ignition OFF. INSTALL a new ABS module. REFER to Section
z Wait at least 5 seconds to allow the TBC 206-09 . CLEAR the DTCs. REPEAT the ABS
module to sleep (power down). module self-test.
z Ignition ON.
z Allow at least 10 seconds for all No
modules to wake up and prove out. INSTALL a new TBC module. REFER to Trailer
z Using a scan tool, retrieve the Brake Control (TBC) Module in this section. TEST the
continuous memory DTCs from the system for normal operation.
following modules:
Body Control Module (BCM)

Instrument Panel Cluster (IPC)
Power Steering Control Module
(PSCM) (if equipped)
Transfer Case Control Module
(TCCM) (if equipped)
z Is DTC U0121:00 set in any of these
modules?
Pinpoint Test I: DTC U0140
Normal Operation
z DTC U0140 (Lost Communication With Body Control Module (GEM)) — this DTC sets in continuous
memory or on-demand in the Trailer Brake Control (TBC) module if data messages such as ignition
state, park lamp status and illumination dimming level data are not received from the Body Control
Module (BCM). For a complete list of all network messages, refer to Section 418-00 .
z BCM
z TBC module
PINPOINT TEST I: DTC U0140

I1 VERIFY THE CUSTOMER CONCERN
z Ignition ON. Yes
z Allow at least 10 seconds for all modules to wake up GO to I2 .
and prove out.
z Verify that there is an observable symptom present. No
z Is an observable symptom present? The system is operating normally at
this time. The DTC may have been
set due to high network traffic or an
I2 CHECK THE COMMUNICATION NETWORK
z Using a scan tool, carry out the network test. Yes
z Does the BCM module pass the network test? GO to I3 .
No
I3 RETRIEVE ANY DTCs FROM THE TBC MODULE
Self Test — TBC Module . For DTC B1317, GO to Pinpoint Test
z Is DTC B1317 or DTC B1318 recorded? D . For DTC B1318, GO to Pinpoint
Test E .
No
GO to I4 .
I4 RETRIEVE ANY DTCs FROM THE BCM

Self Test — BCM . REFER to Section 419-10 .
z Is DTC U3003:16 or DTC U3003:17 recorded?
No
GO to I5 .
I5 RECHECK THE TBC MODULE DTCs
Yes
NOTE: If new modules were installed prior to the DTC
GO to I6 .
being set, the module configuration may be incorrectly
set during Programmable Module Installation (PMI) or
the PMI may not have been carried out. No
The system is operating correctly at
z Clear the DTCs. Repeat the TBC module self-test. this time. The DTC may have been
z Is DTC U0140 still present? set due to high network traffic or an
I6 CHECK FOR DTC U0140 SET IN OTHER MODULES
z Ignition OFF. INSTALL a new BCM . REFER to
z Wait at least 5 seconds to allow the TBC module to Section 419-10 . REPEAT the BCM
sleep (power down). self-test.
z Ignition ON.
z Allow at least 10 seconds for all modules to wake up No
and prove out. INSTALL a new TBC module. REFER
z Using a scan tool, retrieve the continuous memory to Trailer Brake Control (TBC) Module
DTCs from all modules. in this section. TEST the system for
z Is DTC U0140 set in more than one module? normal operation.
Pinpoint Test J: DTC U0155
Normal Operation
z DTC U0155 (Lost Communication With Instrument Panel Cluster (IC) Control Module) — this DTC
sets in continuous memory or on-demand in the Trailer Brake Control (TBC) module if data messages
received from the Instrument Panel Cluster (IPC) are missing. The IPC sends a TRAILER BRAKE
CONFIG message to the TBC module. For a complete list of all network messages, refer to Section
413-01 .
z IPC
z TBC module
PINPOINT TEST J: DTC U0155

J1 VERIFY THE CUSTOMER CONCERN
z Ignition ON. Yes
z Allow at least 10 seconds for all GO to J2 .
modules to wake up and prove out.
z Verify that there is an observable No
symptom present. The system is operating normally at this time. The DTC
z Is an observable symptom may have been set due to high network traffic or an
present? intermittent fault condition.

J2 CHECK THE COMMUNICATION
NETWORK
network test. GO to J3 .
z Does the IPC pass the network
test? No
J3 RETRIEVE THE RECORDED DTCs
FROM THE TBC MODULE AND IPC
SELF-TESTS
on the scan tool: Self Test — TBC For TBC module DTC B1317, GO to Pinpoint Test D .
Module . For TBC module DTC B1318, GO to Pinpoint Test E .
z Record the TBC module DTCs. For IPC DTCs, REFER to Section 413-01 .
on the scan tool: Self Test — IPC . No
z Is DTC U3003:16 (or B1318) or GO to J4 .
DTC U3003:17 (or B1317)
recorded?
J4 CHECK FOR DTC U0155 SET IN
OTHER MODULES
z Ignition OFF. INSTALL a new IPC . REFER to Section 413-01 .
z Wait at least 5 seconds to allow the CLEAR the DTCs. REPEAT the IPC self-test.
TBC module to sleep (power down).
z Ignition ON. No
z Allow at least 10 seconds for all INSTALL a new TBC module. REFER to Trailer Brake
modules to wake up and prove out. Control (TBC) Module in this section. TEST the system
z Retrieve the continuous memory for normal operation.
DTCs from all modules.
z Is DTC U0155:00 or DTC U0155 set
in more than one module?

Trailer Brake Control (TBC) Module

1 W707628 Trailer Brake Control (TBC) module bolt (2 required)
2 — TBC module electrical connector (part of 14401)
3 2C006 TBC module
NOTE: The trailer brake system is normally installed at the assembly plant, however, the system can be
installed at the dealership but only if the vehicle is equipped with the trailer tow option. This option can be
confirmed by verifying the presence of both the 4-pin and the 7-pin connectors at the rear of the vehicle as
well as a receiver hitch. If the vehicle is not equipped with these 3 items, then it is not equipped with trailer
tow and cannot have the factory Trailer Brake Control (TBC) system installed.
On those vehicles equipped with the trailer tow option, the electrical connector for the TBC module is
attached to the 14401 harness behind the steering column opening trim panel. If the system is installed at
the dealership, the TBC module will be installed in place of the coin bin/storage tray and the Instrument
Panel Cluster (IPC) must be configured to communicate with the TBC module. Refer to the Wiring Diagrams
manual, Cell 95 Trailer/Camper Adapter and Cell 151 Component Location Views for connector and wiring
information. Refer to Programmable Parameters in the Diagnosis and Testing portion of this section for
information on IPC configuration.
1. Remove the LH center instrument panel trim panel. For additional information, refer to Center
Instrument Panel Trim Panel in Section 501-12 .
2. Remove the 2 TBC module bolts.
3. Remove the TBC module.

z Disconnect the electrical connector.
SECTION 211-00A: Steering System — Electronic Power Assist Steering

2014 F-150 Workshop Manual
(EPAS)
Procedure revision date:
DESCRIPTION AND OPERATION 10/25/2013
Steering System
Electronic Power Assist Steering (EPAS) System
The Electronic Power Assist Steering (EPAS) system consists of the following components:
z Power Steering Control Module (PSCM) — the PSCM controls the functions of the EPAS system and
communicates with other modules that are on the High Speed Controller Area Network (HS-CAN).
The PSCM is attached to the EPAS gear assembly and is not available separately for service.
z Motor — the EPAS gear uses a 12-volt reversible motor to control the steering effort. The motor is
connected to the steering rack by a toothed belt and a pulley/bearing assembly. The motor is used by
the PSCM to move the rack inside the gear housing. Motor position is used to determine steering
wheel angle/position instead of using a separate sensor. The motor is attached to the RH side of the
EPAS gear assembly and is not available separately for service.
z EPAS gear assembly — the vehicle has two EPAS steering gear options available, one with a 20:1
steering ratio and one with a 17:1 steering ratio. The steering gear installed to the vehicle is
dependant on the wheelbase and trailer tow capacity.
z Steering shaft torque sensor — the steering shaft torque sensor is used by the PSCM to determine
how much force is being used to turn the steering wheel. The sensor sends out 2 signals, one for left
and one for right. When the steering wheel is turned to the left, the left signal increases while the right
signal decreases, likewise when the steering wheel is turned to the right, the right signal increases
while the left signal decreases. This allows the PSCM to determine if the driver intends to go left or
right in order to spin the motor in the appropriate direction. The sensor is mounted inside the EPAS
gear assembly and is not available separately for service.
z Inner tie rod — one inner tie rod is located at each end of the EPAS gear assembly and is available
separately for service, refer to Section 211-02 .
z Outer tie rod — one outer tie rod is located at each end of the EPAS gear assembly and is available
separately for service, refer to Section 211-02 .
z EPAS gear bellows boot — one bellows boot is located on each side of the EPAS gear assembly.
Each boot is held in place with 2 boot clamps. The boots and clamps are available for service, refer to
Section 211-02 .
z EPAS gear isolators — there are two rubber isolators (one at each attaching point) on the EPAS gear
assembly. These isolators aid in reducing NVH concerns and are not available separately for service.
The EPAS system utilizes a rack-and-pinion type steering gear. Power assist is provided by a motor that is
connected to the steering rack by a belt and a pulley and bearing assembly. The steering gear and
motor/module are serviced as an assembly. A new steering gear includes inner tie rods, however, the inner
and outer tie rods can also be serviced separately. For information on tie-rod end service, refer to Section
211-02 .
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file:///C:/TSO/tsocache/VDTOM2_10764/SE2~us~en~file=SE2B0A01.HTM~gen~ref.H... 2014-03-01
SECTION 211-00A: Steering System — Electronic Power Assist Steering

(EPAS)
DIAGNOSIS AND TESTING 10/25/2013
Steering System
Special Tool(s)
Flex Probe Kit
300-NUD105-R025DE or
equivalent


Electronic Power Assist Steering (EPAS) System
The Electronic Power Assist Steering (EPAS) system provides power steering assist to the driver by
replacing the conventional hydraulic valve system with an electric motor coupled to the steering rack by a
toothed belt. The motor is controlled by the Power Steering Control Module (PSCM) that senses steering
effort/use through an internally mounted steering shaft torque sensor. Steering assist is provided in
proportion to the steering input effort and vehicle speed.
The EPAS system requires a 12-volt, hot at all times feed for system operation. The PSCM is activated
when power is applied to the hard-wired ignition/run input. After activation, the PSCM monitors the High
Speed Controller Area Network (HS-CAN) bus to determine if the vehicle is operating in a manner capable
of supporting the EPAS system.
Once this is determined, vehicle speed sent by the PCM over the HS-CAN bus, steering shaft speed and
direction sent by the steering shaft torque sensor and steering wheel angle/position determined by the motor
position all provide the necessary information for the PSCM to determine the amount or level of assist
provided by the EPAS system.
Assist is primarily based off of vehicle speed. As vehicle speed increases, the amount of assist provided by
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the system is decreased to improve and enhance road feel at the steering wheel. As vehicle speed
decreases, the amount of assist provided by the system is increased to ease vehicle maneuvering. If the
vehicle speed is missing or out of range, the PSCM defaults to a safe level of assist for all driving conditions.
If the vehicle speed returns to the correct in-range values, the PSCM adjusts the level of assist accordingly.
Steering wheel/shaft speed, torque and direction information allows the PSCM to determine how much
assist is needed to turn the wheels right and left.
The PSCM continually monitors and adjusts steering efforts based on the torque sensor inputs to enhance
the feel of the steering. Compensation is made to reduce the effect of pull or drift that may be experienced
when driving on roads with a high degree of camber. Active nibble control is also employed by the PSCM to
reduce the vibrating movement felt at the steering wheel that can be caused by driving on rough surfaces or
out of balance wheels.
The PSCM is self-monitoring and has the capability of setting and storing DTCs. Depending on the DTC set,
the control module enters into a "safe mode" of manual steering. In addition, the PSCM may send a request
to the Instrument Panel Cluster (IPC) module over the HS-CAN bus to display a message in the message
center to alert the driver of a potential EPAS concern.
Interactive Diagnostics
For diagnosing and testing please refer to the on-line Workshop Manual. If you do not have an on-line
subscription, go to www.motorcraftservice.com.
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SECTION 211-00B: Steering System — Hydraulic Power Assist Steering

(HPAS)
SPECIFICATIONS 10/25/2013
Material
Capacity
Dye-Lite® ATF/Power Steering — —
Fluid Leak Detection Dye
164-R3701 (Rotunda)
Motorcraft® MERCON® LV MERCON® —
Automatic Transmission Fluid LV
XT-10-QLVC (US); CXT-10-LV12
(Canada)
Item Specification
Steering Gear — SVT Raptor Crew Cab and Base F150 Without Max Trailer Tow
Ratio 17:1
Turns of steering wheel lock to lock (linkage disconnected) 3.26
Steering Gear — SVT Raptor Super Cab and Base F150 With Max Trailer Tow
Ratio 20:1
Turns of steering wheel lock to lock (linkage disconnected) 3.74
Power Steering Pump
Flow 3.0 gpm ± 0.2 @ 145 psi and 1,500 rpm
Minimum capacity 1.6 gpm @ 725 psi and 500 rpm
Relief pressure 1,400-1,520 psi
Power Steering Purge Vacuum
Minimum vacuum 67-84 kPa (20-25 in-Hg)
file:///C:/TSO/tsocache/VDTOM2_10764/SE2~us~en~file=SE2B0B01.HTM~gen~ref.H...
file:///C:/TSO/tsocache/VDTOM2_10764/SE2~us~en~file=SE2B0B01.HTM~gen~ref.H... 2014-03-01

(HPAS)
DESCRIPTION AND OPERATION 10/25/2013
Steering System
The power steering system consists of the following components:
z Power steering pump

z Power steering fluid reservoir
z Steering gear
z Power steering lines
z Steering column
z Steering column shaft
z Power steering cooler (if equipped)
The power steering system transfers driver inputs at the steering wheel to the front wheels of the vehicle.
The steering column, hydraulic system and linkages that transfer these driver inputs make up the steering
system. Gearing and hydraulic assist are used to significantly reduce steering efforts.
For information on the power steering fluid reservoir, power steering pump, power steering lines and
steering gear, refer to Section 211-02 .
For information on the steering wheel, steering column and steering column shaft, refer to Section 211-04 .

(HPAS)
DIAGNOSIS AND TESTING 10/25/2013
Steering System
Special Tool(s)
100W/12 Volt DC UV Lamp
164-R0751
Dial Thermometer 0-220°F

Evacuation Cap, Power Steering

Vacuum Pump Kit

416-D002 (D95L-7559-A) or
equivalent

Material
Item Specification
Dye-Lite® ATF/Power Steering Fluid —
Leak Detection Dye
164-R3701 (Rotunda)
Motorcraft® MERCON® LV MERCON®
(Canada)
Power Steering
The power steering system uses a vane-type pump to move the fluid from the reservoir to the steering gear
and through the rest of the steering hydraulic system. The power steering pump is mounted to the engine
and driven by the engine accessory drive belt. Power steering fluid flows into the pump from the reservoir.
The power steering fluid is trapped between the pump vanes and moved to the high pressure side of the
pump creating a flow of fluid. The restriction of this flow by the steering gear creates the pressure that
provides the steering assist. A combined pressure relief/flow valve is built into the pump to control the
maximum pressure and flow provided to the steering system. This action prevents damage to the system
and provides the correct level of assist during all engine speeds. While under pressure, the power steering
fluid flows through the high pressure power steering line to the steering gear. The fluid exits the gear and
flows through the return line, cooler and finally to the reservoir. The reservoir slows the fluid, allows air to
escape and filters the fluid before returning it to the pump.
NOTICE: Do not adjust the steering gear pinion preload or steering gear wear and/or damage to the
steering gear may occur.
2. Visually inspect for obvious signs of mechanical damage or leaks.

Mechanical
z Fluid level
z Tire pressure
z Tires
z Drive belt
z Drive belt tensioner
z Steering column alignment
z Tie-rod ends
z Suspension components
z Steering column shaft U-joints
z Intermediate shaft bolts
z Power steering reservoir baffle
z Power steering reservoir screen
z Power steering pressure lines, fittings or O-rings
z Power steering return hoses and clamps
z Steering gear
z Power steering fluid cooler (if equipped)
3. Inspect the power steering fluid for the following conditions:

z Aeration or foam: Purge the power steering system. Refer to Power Steering System Purging
in this section.
z Overheating or contamination: Flush the power steering system. Refer to Power Steering
System Flushing in this section.
4. NOTE: It may be necessary to add power steering fluid to achieve the correct level.
Check the fluid level and clean the power steering components.
With the ignition OFF:
z check the power steering fluid level and add fluid as necessary.
z wipe off any visible signs of fluid or residue build up.
z NOTICE: Do not hold the steering wheel at the stops for an extended amount of time.
Damage to the power steering pump may occur.
Start the engine and turn the steering wheel from stop-to-stop several times.
5. Visually inspect the power steering hydraulic line/hose connections for damage or leaks.
z If a leak is detected at a threaded fitting or clamp plate joint, tighten to specification. If the leak is still
evident, visually inspect the O-rings or Teflon® seals. Install new O-rings or Teflon® seals as
necessary. Refer to Section 211-02 .
z If a leak is detected at a constant tension spring clamp, verify that the hose is not damaged and fully
installed on the hose fitting. Make sure that the constant tension spring clamp is positioned 2 mm
(0.078 in) from the end of the hose. If the leak remains, install a new constant tension spring clamp.
z If a leak is detected at a screw clamp joint, verify that the hose is not damaged and fully installed on
the hose fitting and the clamp is positioned 2 mm (0.078 in) from the end of the hose before
tightening the screw clamp. If the leak remains, install a new screw clamp. Refer to Section 211-02 .
6. Visually inspect the power steering components for leaks.
z If a leak is detected in the power steering pressure line or return hose, install a new hose. Refer to
Section 211-02 .
z If a leak is detected in the steering gear turn tubes, repair or install new turn tubes. Refer to Section
211-02 .
z If a leak is detected in the power steering pump, install a new power steering pump. Refer to Section
211-02 .
z NOTE: On vehicles with rack-and-pinion steering gear, it may be necessary to remove the bellows
boot clamp from the steering gear bellows boot to inspect for internal steering gear leaks.
If a leak is detected in the steering gear, repair or install a new steering gear. Refer to Section 211-
02 .
z If a leak is detected in the power steering reservoir, install a new reservoir. Refer to Section 211-02 .
7. For information on power steering leak detection, refer to Component Tests in this section.
before proceeding.
9. If the cause is not visually evident, verify the symptom and GO to Symptom Chart - Steering System
or GO to Symptom Chart - NVH .
Steering System Symptom Definitions
NOTICE: Do not adjust the steering gear pinion preload or steering gear wear and/or damage to the
steering gear may occur.
Drift/Pull
Pull is described as a tugging sensation felt by the hands on the steering wheel that must be overcome to
keep the vehicle going straight.
Drift describes what a vehicle with this condition does with the hands off the steering wheel.
z A vehicle-related drift/pull on a flat road can cause a consistent deviation from the straight-ahead path
and require constant steering input in the opposite direction to counteract the effect.
z Drift/pull can be induced by conditions external to the vehicle, such as wind or road camber.
Excessive Steering Wheel Play
Excessive steering wheel play is a condition in which there is too much steering wheel movement before the
wheels move. A small amount of steering wheel free play is considered normal.
Lack of Assist or Inconsistent Assist
Lack of assist or inconsistent assist is experienced when the steering wheel effort is higher than normal.
Hard steering can remain constant through the full turn or occur near the end of a turn. It is important to
know the difference between hard steering/lack of assist and poor returnability/sticky steering.
Hard steering or lack of assist can result from either hydraulic or mechanical conditions. It is extremely
important to know if this concern occurs during driving or during high-effort parking maneuvers.
Poor Returnability/Sticky Steering
Poor returnability and sticky steering is used to describe the poor return of the steering wheel to center after
a turn or steering correction is completed.
Wander
Wander is the tendency of the vehicle to require frequent, random left and right steering wheel corrections to
maintain a straight path down a level road.
Symptom Chart — Steering System
Symptom Chart — Steering System
NOTICE: Do not adjust the steering gear pinion preload or steering gear wear and/or
damage to the steering gear may occur.
z Steering has lack of z Contaminated z GO to Pinpoint Test A .
assist or inconsistent power steering
assist fluid
z Steering gear
z Power steering
pump
z Restricted power
steering
lines/hoses
z Excessive steering z Steering gear z GO to Pinpoint Test B .
wheel play z Steering column

shaft/coupling
z Steering linkage
z Steering system z Steering column z GO to Pinpoint Test C .
drift/pull/wander shaft/U-joints
z Steering gear
z Steering gear
mounts
z Poor z Binding steering z INSTALL a new steering
returnability/sticky column column shaft. REFER to
steering shaft/coupling U- Section 211-04 .
joints
z Suspension z To continue the suspension
components diagnosis, REFER to Section
204-00 .
z Binding steering z INSTALL a new steering
column bearing(s) column. REFER to Section
211-04 .
z Binding dash boot z INSTALL a new dash boot
seal seal. REFER to Section 211-
04 .
z Steering gear turn z INSTALL new banjo
tube banjo bolt/dampers. REFER to
bolts/dampers Steering Gear Turn Tubes
Removal and Installation in
Section 211-02 .
z Steering gear z The steering gear cannot be
adjusted. INSTALL a new
steering gear as necessary.
z Steering system z Blockage in the z NOTE: Some noise during an
cold start noise power steering fluid extremely cold start (-12.2°C [-
reservoir filter 10°F]) is normal and should
screen or return improve as the steering system
ports caused by warms up (usually within 60
power steering fluid seconds).
contamination z NOTE: It may be necessary to
remove the power steering fluid
reservoir to flush contamination
trapped in the reservoir
filter/screen or to remove
blockage in the return ports.
CHECK the power steering fluid

reservoir filter/screen or return
ports for contaminants or
blockage. FLUSH the power
steering system as necessary.
REFER to Power Steering
z Air in the steering z CHECK for leaks in the system.
hydraulic system REFER to Power Steering Leak
(aerated fluid) Test Component Test. PURGE
the air from the system. REFER
to Power Steering System
Purging in this section.
z Steering grunt or z Air in the steering z CHECK for leaks in the system.
shudder — occurs hydraulic system REFER to Power Steering Leak
when turning into or (aerated fluid) Test Component Test. PURGE
out of a turn at low the air from the system. REFER
speeds to Power Steering System
(temperature Purging in this section.
sensitive)
z Steering gear or z GO to Steering Gear
power steering Grunt/Shudder Component Test
hoses in this section.
z Steering system z Air in the steering z NOTE: Some amount of clonk
clonk — hydraulic hydraulic system noise is considered acceptable.
knocking sound (aerated fluid) If in doubt of the acceptability,
compare to another vehicle.
CHECK for leaks in the system.

REFER to Power Steering Leak
Test Component Test. PURGE
the air from the system. REFER
to Power Steering System
Purging in this section.
z Power steering z Low fluid and/or air z CHECK for leaks in the system.
pump moan — loud in the steering REFER to Power Steering Leak
humming noise hydraulic system Test Component Test. PURGE
occurs when the (aerated fluid) the air from the system. REFER
steering wheel is to Power Steering System
rotated to the stop Purging in this section. If a
position. Produces a pump moan still exists,
120-600 Hz INSTALL a new power steering
frequency that pump. REFER to Section 211-
changes with rpm 02 .
z Blockage in the z NOTE: It may be necessary to
power steering fluid remove the power steering fluid
reservoir reservoir to flush contamination
filter/screen or trapped in the reservoir
return ports caused filter/screen or to remove
by power steering blockage in the return ports.
fluid contamination

z Power steering z INSPECT the power steering
line/hose grounded lines/hoses. REPAIR as
to chassis necessary.
z Power steering z CHECK bolts, brackets and
pump brackets bracket alignment. TIGHTEN
loose or misaligned bolts to specification. REPAIR
or INSTALL new brackets as
211-02 .
z Steering gear z INSPECT the isolators for wear
isolators or damage. REPAIR as
necessary.
z Steering gear clunk z Steering gear z INSPECT the steering gear for
— occurs only while loose mounting bolts. TIGHTEN
cornering over a to specification as necessary.
bump (can be REFER to Section 211-02 .
temperature
sensitive)
z Feedback (rattle, z Steering column z INSTALL a new steering column
chuckle or knocking shaft/coupling shaft. REFER to Section 211-
noise in the steering joints damaged or 04 .
gear) — roughness worn
is felt in the steering
wheel when the
vehicle is driven
over rough surfaces
z Loose, damaged or z INSPECT and INSTALL new
worn tie-rod ends tie-rod ends as necessary. GO
to Steering Linkage Component
Test in this section.
z Steering gear z TIGHTEN the bolts to
insulators or specification or INSTALL new
mounting bolts bolts as necessary. REFER to
loose or damaged Section 211-02 .
z Steering column z TIGHTEN the bolts to
shaft/coupling bolts specification. REFER to Section
are loose 211-04 .
z Steering column z REPAIR or INSTALL a new
damaged or worn steering column as necessary.
z Power steering hiss z Steering column z REPAIR or INSTALL a new
or whistle shaft/coupling-to- steering column shaft as
steering gear is necessary. REFER to Section
binding or 211-04 .
misaligned
z Grounded or loose z REPAIR as necessary.
steering column
boot at the dash
panel
z Damaged or worn z REPAIR or INSTALL a new
steering gear input steering gear as necessary.
shaft and valve REFER to Section 211-02 .
z Restricted power z GO to Pinpoint Test A .
steering
lines/hoses
z Steering column z Loose bolts or z TIGHTEN the bolts to
rattle attaching brackets specification.
z Loose, worn or z LUBRICATE bearings or
insufficiently INSTALL new steering column
lubricated column bearings or steering column as
bearings necessary. REFER to Section
211-04 .
z Steering shaft z INSTALL new insulators.
insulators damaged REFER to Section 211-04 .
or worn
z Steering column z INSPECT the rubber spider
shaft/coupling coupling for damage. INSTALL
compressed or a new intermediate/flexible
extended shaft. REFER to Section 211-
04 .
z Steering gear z Incorrect power z If incorrect power steering fluid
squeak steering fluid in is suspected, FLUSH the power
system steering system. REFER to
Power Steering System
Flushing in this section. If noise
persists after system flush,
INSTALL a new steering gear.
z Steering gear z NOTE: Use the chassis ears to
rotary seal verify that the steering gear is
the source of the noise. It may
be necessary to replicate the
customer operating conditions
(fluid temperature, turning rate
of steering wheel) to get the
squeak to reoccur.
INSTALL a new steering gear

Section 211-02 .
z Stone shield (if z MAKE SURE that the stone
equipped) shield is correctly installed and
that it is not making contact with
the steering shaft.
REPOSITION stone shield or
INSTALL a new stone shield as
necessary.
z Steering column z Loose or z TIGHTEN or ALIGN the steering
squeak, cracks or misaligned steering column shrouds.
grinds column shrouds
z Steering wheel z REPOSITION the steering
rubbing against column shrouds.
steering column
shrouds
z Steering column z Steering column z VERIFY that the noise is
ticking or creaking lower bearing coming from the lower bearing
noise and INSTALL a new bearing as
necessary. REFER to
Disassembly and Assembly —
Steering Column in Section
211-04 .
z Power steering z Blockage in the z NOTE: It may be necessary to
pump noisy power steering fluid remove the power steering fluid
fluid contamination
z Power steering z INSTALL a new power steering
pump pump as necessary. REFER to
Section 211-02 .
z Power steering z Power steering z Acceptable condition.
pump noise fluid flow into the
(steering wheel bypass valve of the
turned fully to pump valve
stop/lock) housing, with fluid
temperature below
54°C (130°F)
z Power steering z Aerated fluid z CHECK for a leak in the system.
pump whine noise REFER to Power Steering Fluid
Leak Test Component Test.
PURGE the air from the system.
System Purging in this section.
z Blockage in the z NOTE: It may be necessary to
power steering fluid remove the power steering fluid
fluid contamination
z Damaged power z INSTALL a new power steering
steering pump pump as necessary. REFER to
Section 211-02 .
z High speed shake z Worn or damaged z GO to Steering Linkage
or shimmy — occurs steering linkage Component Test in this section.
at high speeds components
Pinpoint Tests
Pinpoint Test A: Steering Has a Lack of Assist or Inconsistent Assist
NOTE: Hard steering or lack of assist is experienced when the steering wheel effort is higher than normal.
Hard steering can remain constant through the full turn, occur near the end of a turn or differ right to left.

z Power steering fluid contamination
z Steering gear
z Power steering hoses
PINPOINT TEST A: STEERING HAS A LACK OF ASSIST OR INCONSISTENT ASSIST — RWD

VEHICLES

A1 CHECK FOR POWER STEERING FLUID
CONTAMINATION
z Check the power steering fluid for contamination. Yes
z Is the power steering fluid free of any GO to A2 .
contamination?
No
FLUSH the power steering system.
REFER to Power Steering System
Flushing in this section. TEST the
If the assist concern is still present, GO

to A2 .
A2 CHECK THE STEERING ASSIST WITH THE ENGINE
SPEED RAISED
z NOTICE: Do not hold the steering wheel at the Yes
stops for an extended amount of time. Damage to INSTALL a new power steering pump.
the power steering pump may occur. REFER to Section 211-02 .
z Set the engine speed to 2,100 rpm and turn the
steering wheel fully to the left and right. No
z Is steering assist fully restored to normal with the GO to A3 .
engine speed raised?
A3 CHECK FOR A CHANGE IN ASSIST ON LEFT AND
RIGHT TURNS
z With the engine running at idle, turn the steering Yes
wheel fully to the left and to the right. INSTALL a new power steering gear.
z Does the steering assist change when turning REFER to Section 211-02 .
from right to left?
No
GO to A4 .
A4 CHECK THE STEERING LINES AND HOSES FOR
RESTRICTIONS
z Inspect the steering lines and hoses for damage, Yes
kinks or restrictions. GO to A5 .
z Are the steering lines and hoses free from any
damage, kinks and/or restrictions? No
INSTALL new lines and/or hoses as
necessary. TEST the system for normal
operation.
A5 MONITOR THE ENGINE SPEED CHANGES
Yes
NOTICE: Do not hold the steering wheel at the
INSTALL a new power steering gear.
stops for an extended amount of time. Damage to
the power steering pump may occur.
NOTE: Make sure that the vehicle is on a flat dry No
surface, all accessories are in the OFF position and INSTALL a new power steering pump.
that the steering system is at normal operating REFER to Section 211-02 .
temperature.
z Connect the scan tool.
z Start the engine.
z With the engine running at idle, raise the power
steering fluid temperature to 74°-80°C (165°-176°F)
by rotating the steering wheel fully to the left and to
the right several time.
DataLogger — PCM.
z Monitor the Engine Revolutions Per Minute (RPM)
PID while turning the steering wheel quickly to the left
stop position and then to the right stop position.
z Note the engine rpm during the turns.
z Does the engine speed change (even temporarily)
by more than 30 rpm when turning the steering
wheel?
Pinpoint Test B: Excessive Steering Wheel Play

z Steering linkage
z Steering gear
PINPOINT TEST B: EXCESSIVE STEERING WHEEL PLAY

B1 CHECK THE STEERING LINKAGE
z Carry out the Steering Linkage Yes

Component Test in this section. GO to B2 .
z Is the steering linkage OK?
No
INSTALL new steering linkage components as
necessary. REFER to Section 211-02 .
B2 CHECK THE STEERING COLUMN
SHAFT
z Inspect the steering column shaft U- Yes
joints and fasteners for looseness. INSTALL a new steering gear as necessary. REFER to
z Are the U-joints and fasteners Section 211-02 .
OK?
No
TIGHTEN the steering column shaft fasteners or
INSTALL a new steering column shaft. REFER to
Section 211-04 .
Pinpoint Test C: Steering System Drift/Pull/Wander

z Steering gear
z Steering gear mounts
z Steering column shaft U-joints
PINPOINT TEST C: STEERING SYSTEM DRIFT/PULL/WANDER

C1 CHECK THE STEERING COLUMN SHAFT
z NOTE: Be sure to keep the clockspring centered Yes
when disconnecting the intermediate shaft. Refer to GO to C2 .
Section 501-20B .
z Check the steering column and shaft for grounding. No
z Disconnect the steering column shaft at the steering INSTALL new steering column shaft as
column. necessary. REFER to Section 211-04 .
z Inspect the steering column shaft U-joints for
looseness or wear.
z Are the steering column shaft U-joints OK?
C2 CHECK THE STEERING GEAR MOUNTING
z Check the steering gear mounts for looseness or Yes
wear. GO to C3 .
z Are the steering gear mounts OK?
No
INSTALL a new steering gear as
C3 CHECK THE STEERING GEAR
z Carry out the Steering Gear Valve Component Test in Yes
this section. REFER to Section 204-00 to diagnose
z Is the steering gear valve OK? suspension system drift/pull/wander.
No
INSTALL a new steering gear as
Component Tests
Power Steering Fluid Leak Test
NOTE: This test should only be carried out if a leak in the system has not been detected during a thorough
visual inspection. Refer to Inspection and Verification.
1. Remove the power steering pump reservoir cap and check the power steering fluid level. If
necessary, add the specified power steering fluid.
2. Tightly install the Power Steering Evacuation Cap onto the reservoir and connect the Vacuum Pump
Kit to the Evacuation Cap.
3. Using the Vacuum Pump Kit, apply 68-85 kPa (20-25 in-Hg) of vacuum to the power steering system.
4. Observe the vacuum gauge for 30 seconds. If the vacuum gauge reading drops more than 3 kPa
(0.88 in-Hg), a leak is present.
5. Remove the Vacuum Pump Kit.
6. Start the engine and insert the Dial Thermometer into the Evacuation Cap.
7. NOTICE: Do not hold the steering wheel at the stops for an extended amount of time. Damage
to the power steering pump may occur.
With the engine at idle, raise the power steering fluid temperature to 74-80°C (165-176°F) by rotating
the steering wheel fully to the left and right several times.
8. Stop the engine and visually inspect the system for leaks.
z If a leak is evident, repair as necessary.
z If a leak is not evident, add the specified UV fluorescent tracer dye to the power steering fluid.
Use 14.78 ml (1/2 oz) of dye solution for every 1.89L (2 qt) of power steering fluid.
9. Start the engine.
10. NOTICE: Do not hold the steering wheel at the stops for an extended amount of time. Damage
to the power steering pump may occur.
With the engine at idle, raise the power steering fluid temperature to 74-80°C (165-176°F) by rotating
the steering wheel fully to the left and right several times.
11. Stop the engine and inspect the system for traces of UV dye using the 100W/12 Volt DC UV Lamp.
Repair as necessary.
Steering Gear Valve Test

z Raise the vehicle until the front wheels are off the ground.
2. NOTE: Do not hold the steering wheel while carrying out this step.
Start the engine.

z If the steering wheel rotates in either direction (with no hand input), install a new steering gear.
Steering Gear Grunt/Shudder Test
1. Place a Dial Thermometer in the power steering fluid reservoir.
2. With the engine cold, start the engine and set engine idle speed to 1,200 rpm.
3. NOTICE: Do not hold the steering wheel against the stops for an extended amount of time.
Rotate the steering wheel to the RH stop, then turn the steering wheel 90 degrees back from that
position. Slowly turn the steering wheel back and forth approximately one-twelfth of a full turn.
4. Turn the steering wheel another 90 degrees. Slowly turn the steering wheel back and forth
approximately one-twelfth of a full turn.
5. Repeat the test with the power steering fluid at different temperatures until the temperature reaches
74-80°C (165-176°F).
6. If a light grunt is heard or a low (50-200 Hz) shudder is present, this is a normal steering system
condition.
7. If a loud grunt is heard, or a strong shudder is felt, purge the power steering system. Refer to Power
Steering System Purging in this section. If a loud grunt or strong shudder still exists, check the power
steering lines/hoses for restrictions or damage and repair as necessary. Refer to Section 211-02 . If
the lines/hoses are OK, install a new steering gear. Refer to Section 211-02 .
Steering Linkage Test
2. Using hand force only, check the inner and outer tie rods for vertical and lateral movement in the tie-
rod ball studs/sockets.
z If there is any lateral or vertical movement in the tie-rod ball studs/sockets (inner or outer), a
new tie-rod must be installed. Refer to the appropriate section in Group 211 for the procedure.

(HPAS)
GENERAL PROCEDURES 10/25/2013
Power Steering System Filling
Special Tool(s)
211-265
Fill Adapter Manifold, Power

Steering
211-327
Vacuum Pump Kit

416-D002 (D95L-7559-A) or
equivalent
Material
Item Specification
(Canada)
Item Description
1 Power steering fluid reservoir
2 Control valve (vacuum side)
3 Control valve (fluid container side)
4 Fluid container
1. NOTICE: If the air is not purged from the power steering system correctly, premature power
steering pump failure may result. The condition can occur on pre-delivery vehicles with
evidence of aerated fluid or on vehicles that have had steering component repairs.
Remove the power steering fluid reservoir cap.
2. Install the Power Steering Evacuation Cap, Power Steering Fill Adapter Manifold and Vacuum Pump
Kit as shown in the illustration.
3. NOTE: The Power Steering Fill Adapter Manifold control valves are in the OPEN position when the
points of the handles face the center of the Power Steering Fill Adapter Manifold.
Close the Power Steering Fill Adapter Manifold control valve (fluid side).
4. Open the Power Steering Fill Adapter Manifold control valve (vacuum side).
6. Observe the Vacuum Pump Kit gauge for 30 seconds.
7. If the Vacuum Pump Kit gauge reading drops more than 3 kPa (0.88 in-Hg), correct any leaks in the
power steering system or the Power Steering Evacuation Cap, Power Steering Fill Adapter Manifold
and Vacuum Pump Kit before proceeding.
8. NOTE: The Vacuum Pump Kit gauge reading will drop slightly during this step.
Slowly open the Power Steering Fill Adapter Manifold control valve (fluid side) until power steering
fluid completely fills the hose and then close the control valve.
10. Close the Power Steering Fill Adapter Manifold control valve (vacuum side).
11. Slowly open the Power Steering Fill Adapter Manifold control valve (fluid side).
12. Once power steering fluid enters the fluid reservoir and reaches the minimum fluid level indicator line
on the reservoir, close the Power Steering Fill Adapter Manifold control valve (fluid side).
13. Remove the Power Steering Evacuation Cap, Power Steering Fill Adapter Manifold and Vacuum
Pump Kit.
14. Install the reservoir cap.
NOTE: There will be a slight drop in the power steering fluid level in the reservoir when the engine is
started.
Start the engine and turn the steering wheel from stop-to-stop.
16. Turn the ignition switch to the OFF position.
17. NOTE: Do not overfill the reservoir.
Remove the reservoir cap and fill the reservoir with the specified fluid.
18. Install the reservoir cap.

(HPAS)
Power Steering System Flushing
Material
Item Specification
(Canada)
NOTICE: Do not mix fluid types. Any mixture or any unapproved fluid may lead to seal deterioration
and leaks. A leak may ultimately cause loss of fluid, which may result in a loss of power steering
assist.
1. Remove the power steering fluid reservoir cap.
2. Using a suitable suction device, remove the power steering fluid from the reservoir.
3. Release the clamp and disconnect the return hose from the reservoir.
z Remove the clamp from the hose and allow the remaining fluid to drain out of the reservoir.
4. Plug the power steering fluid reservoir inlet port.
5. Attach an extension hose to the return hose.
6. NOTE: Do not reuse the power steering fluid that has been flushed from the power steering system.
Place the open end of the extension hose into a suitable container.
7. If equipped with Hydro-Boost®, apply the brake pedal 4 times.
Fill the reservoir as needed with the specified fluid.
9. NOTICE: Do not allow the power steering pump to run completely dry of power steering fluid.
Start the engine while simultaneously turning the steering wheel to lock and then immediately turn the
ignition switch to the OFF position.
10. NOTE: Avoid turning the steering wheel without the engine running as this may cause air to be pulled
into the steering gear.
NOTE: Do not overfill the reservoir.
11. Repeat Steps 8 and 9, turning the steering wheel in the opposite direction each time, until the fluid
exiting the power steering fluid return hose is clean and clear of foreign material.
12. Remove the extension hose from the return hose.
13. Remove the plug from the fluid reservoir inlet port.
14. Install the clamp and connect the power steering return hose to the reservoir.
15. NOTE: It is necessary to correctly fill the power steering system to remove any trapped air and
completely fill the power steering system components.
If, after correctly filling the power steering system, there is power steering noise accompanied by
evidence of aerated fluid and there are no fluid leaks, it may be necessary to purge the power
steering system. For additional information, refer to Power Steering System Purging in this section.
Fill the power steering system. For additional information, refer to Power Steering System Filling in
this section.

(HPAS)
Power Steering System Purging
Special Tool(s)
211-265
Vacuum Pump Kit

416-D002 (D95L-7559-A) or
equivalent
Material
Item Specification
(Canada)
NOTICE: If the air is not purged from the power steering system correctly, premature power steering
pump failure may result. The condition may occur on pre-delivery vehicles with evidence of aerated
fluid or on vehicles that have had steering component repairs.
1. NOTE: A whine heard from the power steering pump can be caused by air in the system. The power
steering purge procedure must be carried out prior to any component repair for which power steering
noise complaints are accompanied by evidence of aerated fluid.
Remove the power steering reservoir cap. Check the fluid.
2. Raise the front wheels off the floor. Refer to the appropriate section in Group 100 for the procedure.
3. Tightly insert the Power Steering Evacuation Cap into the reservoir and connect the Vacuum Pump
Kit.
5. Using the Vacuum Pump Kit, apply vacuum and maintain the maximum vacuum of 68-85 kPa (20-25
in-Hg).
z If the Vacuum Pump Kit does not maintain vacuum, check the power steering system for leaks
before proceeding. For additional information, refer to Power Steering Fluid Leak Test in this
section.
6. If equipped with Hydro-Boost®, apply the brake pedal 4 times.
Cycle the steering wheel fully from stop-to-stop 10 times.
8. Stop the engine.
9. Release the vacuum and remove the Vacuum Pump Kit and the Power Steering Evacuation Cap.
12. Install the Power Steering Evacuation Cap and the Vacuum Pump Kit. Apply and maintain the
maximum vacuum of 68-85 kPa (20-25 in-Hg).
Cycle the steering wheel fully from stop-to-stop 10 times.
14. Stop the engine, release the vacuum and remove the Vacuum Pump Kit and the Power Steering
Evacuation Cap.
Fill the reservoir as needed with the specified fluid and install the reservoir cap.
16. Visually inspect the power steering system for leaks.
SECTION 211-02: Power Steering 2014 F-150 Workshop Manual

Material
Capacity
Premium Long-Life Grease ESA-M1C75- —
XG-1-C or XG-1-K (US); CXG-1-C B
(Canada)
Motorcraft® MERCON® LV MERCON® —
(Canada)
Inner tie rod 120 89 —
Outer tie-rod end jam nut 103 76 —
Outer tie-rod end nut 115 85 —
Power steering fluid reservoir stud bolt 8 — 71
Pressure line bracket-to-crossmember bolt 7 — 62
Pressure line clamp plate-to-pump bolt 25 18 —
Power steering pump bolts 25 18 —
Skid plate bolts (all except SVT Raptor) 25 18 —
Skid plate bolts (SVT Raptor) 48 35 —
Steering column shaft-to-steering gear bolt 30 22 —
Steering gear-to-crossmember bolts 440 325 —
Steering gear turn tube dampers 30 — 22
Steering gear turn tube fittings 20 — 177
Steering line clamp plate-to-steering gear bolt 23 17 —

Power Steering
Hydraulic Power Assist Steering (HPAS)
The hydraulic power steering system consists of the following components:

z Power steering fluid reservoir
z Power steering pressure and return lines/hoses
z Power steering fluid cooler
z Steering gear
z Inner tie rod
z Outer tie rod
The power steering system uses a vane-type pump to move the fluid from the reservoir to the steering gear
and through the rest of the steering hydraulic system. The power steering pump is mounted to the engine
and driven by the engine accessory drive belt. Power steering fluid flows into the pump from the reservoir.
The power steering fluid is then trapped between the pump vanes and moved to the high-pressure side of
the pump creating a flow of fluid. The restriction of this flow by the steering gear creates the pressure that
provides the steering assist. A combined pressure relief/flow valve is built into the pump to control the
maximum pressure and flow provided to the steering system. This action prevents damage to the system
and provides the correct level of assist during all engine speeds. While under pressure, the power steering
fluid flows through the high-pressure power steering line to the steering gear. The fluid exits the gear and
flows through the return line, cooler and finally to the reservoir. The reservoir slows the fluid, allows air to
escape and filters the fluid before returning it to the pump.
Electronic Power Assist Steering (EPAS)
The Electronic Power Assist Steering (EPAS) consists of the following components:
z Steering gear
z Outer tie rod
z Inner tie rod
The EPAS system utilizes a rack-and-pinion type steering gear. Power assist is provided by a motor that is
connected to the steering rack by a belt and a pulley and bearing assembly. The steering gear and
motor/module are serviced as an assembly. A new steering gear includes inner tie rods, however, the inner
and outer tie rods can also be serviced separately.

Power Steering
For vehicles equipped with Electronic Power Assist Steering (EPAS), refer to Section 211-00A . For vehicles
equipped with Hydraulic Power Assist Steering (HPAS), refer to Section 211-00B .

Inner Tie Rod
Special Tool(s)
Boot Clamp Pliers
205-D067 (D87P-1098-A) or
equivalent
Separator, Ball Joint Tool

204-592
Material
Item Specification
Premium Long-Life Grease ESA-M1C75-
XG-1-C or XG-1-K (US); CXG-1-C B
(Canada)

1 3280 Inner tie rod
2 — Inner bellows boot clamp (part of 3332 service kit)
3 — Steering gear bellows boot (part of 3332 service kit)
4 — Outer bellows boot clamp (part of 3332 service kit)
5 W712367 Tie-rod jam nut
6 W520215 Outer tie-rod end nut
7 3A130 Outer tie-rod end
Removal
NOTICE: The steering gear boots and clamps are designed to produce an airtight seal and protect
the internal components of the steering gear. If the seal is not airtight, the vacuum generated during
turning will draw water and foreign material into the gear, causing damage. Zip ties do not provide
an airtight seal and must not be used.
NOTICE: When servicing inner tie rods, a new bellows boot and clamps must be installed or a leak
may occur causing steering gear damage.
NOTICE: The inner tie-rod ball joint grease is not compatible with water. Water trapped in the grease
will damage the joint.
1. NOTICE: For vehicles equipped with Electronic Power Assist Steering (EPAS), disconnect the
negative battery cable anytime the steering linkage is being serviced or damage to the
steering gear internal power relay may occur resulting in steering gear replacement.
If equipped with Electronic Power Assist Steering (EPAS), disconnect the battery ground cable. For
02 .
3. Loosen the tie-rod jam nut.
4. Remove and discard the outer tie-rod end nut.
5. NOTICE: Use care when installing the Ball Joint Tool Separator or damage to the tie-rod end
boot may occur.
Using the Ball Joint Tool Separator, separate the outer tie-rod end from the wheel knuckle.
6. NOTE: Note the number of times the outer tie-rod ends turn for reference during assembly.
Remove the outer tie-rod end.
7. Remove the tie-rod jam nut from the inner tie rod.
8. NOTE: New bellows boot clamps must be installed.
Remove and discard the inner and outer bellows boot clamps.
9. Remove and discard the steering gear bellows boot.
10. NOTE: Place the steering gear at the center position. Use an appropriate-sized crowfoot wrench on
the flat of the rack gear to resist rotation and to prevent damage during removal and installation of the
inner tie rod.
NOTE: If repairing the RH side, it will be necessary to pull back the LH inner tie-rod boot to hold the
steering gear.
NOTE: An assistant may be needed for removal of the RH inner tie rod.
While holding the steering gear rack, use an appropriate-sized crowfoot wrench to remove the inner
tie rod.
11. Thoroughly clean and inspect all the parts to be reused. Install new parts as necessary.
Installation
1. NOTICE: Place the steering gear at the center position. Use an appropriate-sized crowfoot
wrench on the flat of the rack gear to resist rotation and to prevent damage during the
installation of the inner tie rod.
NOTE: An assistant may be needed for installation of the RH inner tie rod.
Using an appropriate-sized crowfoot wrench, install the inner tie rod.

2. NOTE: Apply the specified grease to the bellows boot groove on the inner tie rod.
NOTE: Make sure the steering gear bellows boot is positioned correctly over the steering gear
housing bead and the groove in the inner tie rod.
Install the new steering gear bellows boot.
3. Using the Boot Clamp Pliers, install a new inner bellows boot clamp.
4. NOTE: Make sure the end of the steering gear bellows is positioned between the 2 grooves on the
inner tie rod or an internal leak can result.
Install a new outer bellows boot clamp.
5. Thread the tie-rod jam nut onto the inner tie rod.
6. NOTE: Install the outer tie-rod end the same number of turns as recorded during the removal.
Install the outer tie-rod end.
7. NOTICE: Make sure that the tie-rod end boots are seated correctly on the tie-rod ends or
failure may occur.
Connect the outer tie-rod end to the wheel knuckle and install a new tie-rod end nut.
z Tighten the new nut to 115 Nm (85 lb-ft).
8. Tighten the tie-rod jam nut.

9. Check and if necessary, adjust the front toe. For additional information, refer to Section 204-00 .

Power Steering Fluid Cooler
1. The power steering fluid cooler is integral to the A/C condenser core. For additional information, refer
to Section 412-01 .

Power Steering Fluid Reservoir
Part
1 W710897 Power steering fluid reservoir stud bolt
2 3E764 Power steering fluid reservoir
3 3691 Power steering fluid reservoir-to-pump supply hose
4 3A713 Power steering fluid cooler-to-power steering fluid
reservoir hose
5 — Wiring harness retainer (part of 14A067)
1. NOTICE: While repairing the power steering system, care should be taken to prevent the entry
of foreign materials or failure of the power steering components may result.
Using a suitable suction device, remove the power steering fluid from the fluid reservoir.
2. Detach the wiring harness retainer from the power steering fluid reservoir stud bolt and position the
wiring harness aside.
3. Release the clamp and disconnect the power steering fluid reservoir-to-pump supply hose.
4. Release the clamp and disconnect the power steering fluid cooler-to-power steering fluid reservoir
hose.
5. Remove the power steering fluid reservoir stud bolt and the power steering fluid reservoir.
7. Fill the power steering system. For additional information, refer to Section 211-00B .

Power Steering Pump to Steering Gear Pressure Line

1 W706681 Pressure line bracket-to-crossmember bolt
2 3A719 Pressure line
3 W712679 Steering line clamp plate-to-steering gear bolt

4 3A713C Return line
5 3F886 Return line O-ring seal (also part of 3A713C)
6 3B602 Back-up O-ring seal
7 3F886 Pressure line-to-gear O-ring seal (also part of 3A719)
8 W714824 Pressure line clamp plate-to-pump bolt
9 3F887 Pressure line-to-pump O-ring seal
NOTICE: While repairing the power steering system, care should be taken to prevent the entry of
foreign material or failure of the power steering components may result.
02 .
2. Detach the wiring harness retainer from the pressure line.
3. Remove the pressure line clamp plate-to-pump bolt and disconnect the pressure line from the pump.
4. Remove the pressure line bracket-to-crossmember bolt.

5. Remove the steering line clamp plate-to-steering gear bolt, disconnect the lines from the steering
gear and remove the pressure line.
z To install, tighten the steering line clamp plate-to-steering gear bolt to 23 Nm (17 lb-ft).

Power Steering Pump
Part
1 3691 Power steering pump supply hose
2 W715068 Power steering pump bolt (3 required)
3 W714824 Pressure line clamp plate-to-pump bolt
5 3F887 Pressure line-to-pump O-ring seal (also part of
3A719)
6 3A674 Power steering pump and pulley assembly
02 .
2. Using a suitable suction device, remove the power steering fluid from the fluid reservoir.
3. Release the clamp and disconnect the supply hose.
4. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt from the
power steering pump pulley.
5. Remove and discard the pressure line clamp plate-to-pump bolt.

z Disconnect the pressure line from the pump.
6. Remove the 3 power steering pump bolts and the power steering pump.

Steering Gear — Electronic Power Assist Steering (EPAS)
Special Tool(s)
204-592
Part
1 N808684 Steering column shaft-to-steering gear bolt
2 3C662 Steering column shaft
3 W520215 Outer tie-rod end nut (2 required)
4 W713954 Steering gear-to-crossmember bolt
5 W715436 Steering gear-to-crossmember bolt
6 3504 Steering gear
7 — Steering gear wiring harness retainers (4 required)
(part of 3F720)
8 — Steering gear electrical connectors (2 required) (part
of 3F720 )
1. If installing a new steering gear, connect the scan tool and upload the module configuration
information from the Power Steering Control Module (PSCM). For additional information, refer to
Section 418-01 .
2. NOTICE: Disconnect the negative battery cable anytime the steering gear is being serviced or
damage to the steering gear internal power relay may occur resulting in steering gear
replacement.
Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
02 .
4. NOTICE: Do not allow the steering column shaft to rotate while disconnected from the gear or
damage to the clockspring may occur. If there is evidence that the steering column shaft has
rotated, remove and recenter the clockspring. For additional information, refer to Section 501-
20B .
Use a suitable holding device to hold the steering wheel in the straight-ahead position.
5. Remove the front wheels and tires. For additional information, refer to Section 204-04 .
6. Disconnect the 2 steering gear electrical connectors, the 4 wiring harness retainers and position the
wiring harness aside.
7. If equipped, remove the skid plate bolts and the skid plate.
8. Remove and discard the outer tie-rod end nuts.

boot may occur.
Using the Ball Joint Tool Separator, disconnect the tie-rod ends from the wheel knuckles.
20B .
Remove and discard the steering column shaft-to-steering gear bolt and disconnect the steering
column shaft from the steering gear.
11. Remove and discard the 2 steering gear-to-crossmember bolts and remove the steering gear.
12. NOTICE: Make sure the tie-rod end boots are seated correctly on the tie-rod ends or tie-rod
end failure may occur.
13. When installing a new steering gear, it must be configured (using vehicle as-built data or module
configuration information retrieved earlier in this procedure). For additional information on
configuration, refer to Programmable Module Installation (PMI) in Section 418-01 .
14. Check and, if necessary, adjust the front toe. For additional information, refer to Section 204-00 .

Steering Gear — Hydraulic Power Assist Steering (HPAS)
Special Tool(s)
204-592

1 W712679 Steering line clamp plate-to-steering gear bolt
2 3A713C Return line
3 3F886 O-ring seals (2 required)
4 3B602 Back-up O-ring seal
6 N808684 Steering column shaft-to-steering gear bolt
7 W520215 Outer tie-rod end nut (2 required)
8 W713954 Steering gear-to-crossmember bolt (2 required)
9 3504 Steering gear
02 .
20B .
Use a suitable holding device and hold the steering wheel in the straight-ahead position.
3. Remove the front wheels and tires. For additional information, refer to Section 204-04 .
z To install (all except SVT Raptor), tighten to 25 Nm (18 lb-ft).
z To install (SVT Raptor), tighten to 48 Nm (35 lb-ft).
5. Remove and discard the outer tie-rod end nuts.

boot may occur.
Using the Ball Joint Tool Separator, disconnect the tie-rod ends from the wheel knuckles.
20B .
Remove and discard the steering column shaft-to-steering gear bolt and disconnect the steering
column shaft from the steering gear.
8. NOTICE: Install new O-ring seals any time the lines are disconnected from the steering gear or
a fluid leak may occur.
Remove the steering line clamp plate-to-steering gear bolt, and disconnect the power steering lines.
z Discard the O-ring seals.
z To install, tighten the steering line clamp plate-to-steering gear bolt to 23 Nm (17 lb-ft).
9. Remove and discard the 2 steering gear-to-crossmember bolts and remove the steering gear.
10. NOTICE: Make sure the tie-rod end boots are seated correctly on the tie-rod ends or tie-rod
end failure may occur.
12. Check and, if necessary, adjust the front toe. For additional information, refer to Section 204-00 .

Steering Gear to Fluid Cooler Return Hose — From Gear
Removal
NOTE: Service the return hose from the gear with the return hose to the cooler.
NOTE: Removal steps in this procedure may include installation details.
02 .

4. On both sides.
5.
Installation

Steering Gear to Fluid Cooler Return Hose — To Cooler
Removal
NOTE: Removal steps in this procedure may include installation details.
1. On both sides.
3.
Installation

Steering Gear Turn Tubes

1 00815 Steering gear turn tube damper seal (2 required)
2 3E651 Steering gear turn tube damper (2 required)
3 3A717 Steering gear (right) turn tube
4 3A714 Steering gear (left) turn tube
02 .
z To install (all except SVT Raptor), tighten to 25 Nm (18 lb-ft).
z To install (SVT Raptor), tighten to 48 Nm (35 lb-ft).
3. Disconnect the 4 steering gear turn tube fittings and remove the 2 turn tubes.
z To install, tighten the fittings to 20 Nm (177 lb-in).
4. If necessary, remove the steering gear turn tube dampers.
z Inspect the O-ring seals and replace as necessary.

SECTION 211-04: Steering Column 2014 F-150 Workshop Manual

Material
Instant Gel Adhesive WSK-M2G402-A4 —
TA-19
Lower steering column shaft-to-steering gear bolt 30 22 —
Lower steering column shaft-to-upper steering column shaft bolt 48 35 —
Steering column bolts 28 21 —
Steering column motor screws 6 — 53
Steering column motor trunnion nut bracket screws 7 — 62
Steering column nuts 30 22 —
Steering column shaft dash seal bolts 12 — 106
Steering column shroud screws 2 — 18
Steering wheel bolt 48 35 —
Upper steering column shaft-to-steering column bolt 28 21 —

Steering Column
The steering column consists of the following:
z Steering wheel
z Steering column
z Upper and lower steering column shafts
z Steering column control switch — located on the LH side of the SCCM just below the multifunction
switch and can be serviced separately from the module. The steering column control switch and the
brake pedal control switch are located in the same position. On vehicles equipped with both features,
the 2 switches are combined into a single switch assembly. For additional information, refer to
Section 206-06 .
z Steering column tilt motor (if equipped) — located on the steering column and can be serviced
separately from the column. For additional information, refer to Steering Column Motor — Tilt in this
section.
z Steering column telescopic motor (if equipped) — located on the steering column and can be
serviced separately from the column. For additional information, refer to Steering Column Motor —
Telescopic in this section.
The steering column is the mechanical linkage between the steering wheel and the steering gear. The
steering wheel is mounted to a shaft, which passes through the center of the steering column. The shaft is
centered by bearings within the steering column. The steering column shaft then connects the steering
column to the steering gear. The upper and lower steering column shaft connections utilize U-joint type
couplings.
Manual Tilt/Telescope Steering Column (if equipped)
The manual tilt/telescope function of the steering column is controlled by a mechanical lever on the left side
of the steering column to lock and unlock the steering column. When the lever is pulled down, the steering
column can be adjusted up or down and in or out to the desired position(s). While holding the steering wheel
in the desired position, pulling the lever up to the original position locks the steering column.
Power Adjustable Tilt/Telescope Steering Column (if equipped)
The power tilt and telescope function of the steering column is controlled by the steering column control
switch, the memory SET switch or the Remote Keyless Entry (RKE) transmitter. The steering column control
switch is a 4-position, normally open, momentary contact switch located on the steering column below the
multifunction switch. The steering column control switch moves the adjustable steering column in 4
directions:
z Forward/In (away from the driver)

z Rearward/Out (toward the driver)
z Up
z Down

Steering Column
Special Tool(s)
Flex Probe Kit

Test Light
SGT 27000 or equivalent 250-300
mA incandescent bulb test lamp

Power Adjustable Tilt/Telescope Steering Column
The power adjustable tilt/telescope steering column is controlled by the steering column control switch and 2
electric motors that are powered by the Steering Column Control Module (SCCM). The steering column
control switch is a 4-position, momentary-contact switch. When the steering column control switch is moved
to any of the 4 positions, it sends a signal to the SCCM to tilt the steering column up or down or telescope
the steering column forward or rearward.
The SCCM continuously monitors the steering column tilt and telescoping motors and circuits for faults. If a
fault is detected, the SCCM is capable of setting DTCs.
Tilt/Telescoping Motor Sensors
The SCCM receives digital signals from Hall-effect type rotation sensors that are integral to the tilt and
telescoping motors. The SCCM uses these signals to calculate the location of the steering column in relation
to the full forward/rearward and full up/down positions. The SCCM also uses these signals to store and
recall memory positions, carry out the easy entry/exit operations and to make sure the tilt and telescoping
motors do not stall against the steering column end of travel in the forward/rearward or up/down directions.
Both the tilt and telescopic motors can be serviced separately from the steering column.
Jog Mode
If the SCCM loses the signal from either of the motor sensors, the affected steering column motor operates
in jog mode. Jog mode allows limited operation of the affected steering column motor using only the steering
column control switch. When the steering column control switch is operated in jog mode, the steering
column moves in the desired direction for one second, then stops. The steering column control switch must
be released, then pressed again in order to move the steering column for an additional second. Jog mode is
an indication that there is a tilt or telescoping motor sensor fault. If the adjustable steering column is
operating in jog mode, a DTC can set in the SCCM .
Memory Position Programming and Recall
The SCCM monitors steering column position using Hall-effect sensors that are integral to the tilt and
telescoping motors. When a memory position is recalled through either the memory SET switch or the
Remote Keyless Entry (RKE) transmitter, the SCCM monitors the Hall-effect sensors and stops sending
voltage to the steering column motors once the commanded memory position is reached. If the SCCM
receives a steering column switch input during a memory position recall function, the module stops the
memory recall and responds to the new steering column switch position input.
When the RKE transmitter is activated, a message is sent over the Medium Speed Controller Area Network
(MS-CAN) to the Driver Seat Module (DSM). When the memory SET switch is pressed, the DSM senses
continuity to ground on the switch circuit. When the DSM receives either the MS-CAN message or the
ground input through the switch circuit, it sends a message over the MS-CAN to the Body Control Module
(BCM). The BCM acts as a gateway module, relaying the MS-CAN message that was received from the
DSM to the SCCM over the High Speed Controller Area Network (HS-CAN). The SCCM then sends voltage
over the appropriate circuit to the steering column tilt or telescoping motor to adjust the steering column
position.
For information on setting and recalling a memory position, refer to the Owner's Literature or Memory
Position Programming in Section 501-10 .
Easy Entry/Exit
The easy entry/exit function moves the steering column to the full inward and upward position when the
selector lever is in the PARK position and the ignition switch indicates the ignition key has been removed
from the ignition lock cylinder. The SCCM receives an ignition status message over the High Speed
Controller Area Network (HS-CAN). When the ignition status message indicates the ignition key has been
removed from the lock cylinder, the SCCM commands the steering column to the full upward/forward
position. The SCCM cancels this operation if a valid input is received from the steering column control switch
or memory position switch.
The SCCM records the current steering column position before powering the steering column for an easy
exit operation. This recorded position returns the steering column to this position on the next easy entry
operation. During easy entry operation, the steering column is returned to the position previous to the easy
exit operation.
The easy entry/exit feature can be activated or deactivated using the message center. Refer to driver
controls in the Owner's Literature for additional instructions for using the message center.
Power Tilt Steering Column Hard Stop/Soft Stop
A hard stop occurs when the power column physically reaches the end of travel and cannot go any further. A
soft stop occurs when the power column stops before physically reaching the end of travel. The hard stop is
set by steering column design and cannot be changed or adjusted. The soft stop is set by the SCCM . To
prevent unnecessary stress on the power column and motors, the SCCM sets 4 soft stop positions, one for
tilt up, one for tilt down, one for telescope out and one for telescope in. The SCCM uses a preset distance
from the hard stop to determine where the soft stop occurs.
The soft stops must be relearned by the SCCM whenever a new steering column or SCCM is installed.
3. Visually inspect for obstructions preventing column movement.

z Steering column control switch z Wiring, terminals or connectors
z Adjustable steering column tilt motor z Steering Column Control Module (SCCM)
z Adjustable steering column telescope motor
z Steering column assembly


z refer to Section 418-00 , The PCM Does Not Respond To The Scan Tool, to diagnose no

418-00 .
9. Carry out the self-test diagnostics for the SCCM .
10. If the DTCs retrieved are related to the concern, go to Steering Column Control Module (SCCM) DTC
Chart. For all other SCCM DTCs, refer to the Master DTC Chart in Section 211-05 .
DTC Chart

B1298:09 Steering Column Adjust Up Switch: INSTALL a new steering column control switch. REFER
Component Failure to Brake Pedal Control Switch in Section 206-06 .
CLEAR the DTCs. VERIFY correct system operation.

If DTC B1298:09 returns, INSTALL a new Steering

Column Control Module (SCCM). REFER to Section
211-05 .

B1299:09 Steering Column Adjust Down Switch: INSTALL a new steering column control switch. REFER

If DTC B1299:09 returns, INSTALL a new SCCM .


B12A1:09 Steering Column Adjust Out Switch: INSTALL a new steering column control switch. REFER

If DTC B12A1:09 returns, INSTALL a new SCCM .


B12A2:09 Steering Column Adjust In Switch: INSTALL a new steering column control switch. REFER

If DTC B12A2:09 returns, INSTALL a new SCCM .


B1375:18 Steering Column Tilt Motor: Circuit GO to Pinpoint Test A .
B1375:19 Steering Column Tilt Motor: Circuit GO to Pinpoint Test A .
B1375:71 Steering Column Tilt Motor: Actuator GO to Pinpoint Test A .
Stuck
B137E:18 Steering Column Telescope Motor: GO to Pinpoint Test A .
Actuator Stuck
B1C33:11 Steering Column Tilt Feedback GO to Pinpoint Test C .
Signal: Circuit Short To Ground
B1C33:12 Steering Column Tilt Feedback GO to Pinpoint Test C .
Signal: Circuit Short To Battery
B1C35:11 Steering Column Telescope GO to Pinpoint Test C .
Feedback Signal: Circuit Short To
Ground
B1C35:12 Steering Column Telescope GO to Pinpoint Test C .
Feedback Signal: Circuit Short To
Battery
— All Other SCCM DTCs REFER to Section 211-05 .
Symptom Chart
Symptom Chart
z No communication with z Fuse z REFER to Section 418-
the Steering Column z Wiring, terminals or 00 to diagnose the no
Control Module (SCCM) connectors communication

z SCCM condition.
z The adjustable steering z Fuse z GO to Pinpoint Test A .
column is inoperative in z Wiring, terminals or
one or more directions connectors
— using the steering z Steering column
column control switch control switch
z Adjustable steering
column tilt motor
z Adjustable steering
column telescopic
motor
z SCCM
z The adjustable steering z Wiring, terminals or z GO to Pinpoint Test B .
column is inoperative in connectors
one or more directions z Memory SET switch
— using the memory z Driver Seat Module
SET switch buttons (DSM)
z SCCM
(BCM)
z The adjustable steering z Wiring, terminals or z GO to Pinpoint Test B .
column is inoperative in connectors
one or more directions z RKE transmitter
— using an Remote z DSM
Keyless Entry (RKE) z SCCM
transmitter z BCM
z The adjustable steering z Entry/exit feature is z GO to Pinpoint Test B .
column is inoperative in disabled in the
one or more directions message center
— using the easy z Wiring, terminals or
entry/exit feature connectors
z SCCM
z The adjustable steering z Wiring, terminals or z GO to Pinpoint Test C .
column operates in one connectors
second intervals when z Adjustable steering
using the steering column tilt motor
column control switch z Adjustable steering
(jog mode) column telescopic
motor
z SCCM
z Looseness felt in the z Loose tilt motor z TIGHTEN fasteners. For
steering wheel or tilt fastener(s) additional information,
mechanism z Loose steering column refer to Steering Column
assembly fastener(s) Motor — Tilt or Steering
Column Motor —
Telescopic .
z Wore internal steering z INSTALL a new steering
column component(s) column. For additional
or loose internal information, REFER to
fastener/fasteners Steering Column in this
z Steering column tilt section.
housing fastener(s)
Pinpoint Tests
Pinpoint Test A: The Adjustable Steering Column is Inoperative in One or More Directions — Using
the Steering Column Control Switch
Refer to Wiring Diagrams Cell 128 , Adjustable Steering Column for schematic and connector information.
Normal Operation
When the steering column control switch is activated, the Steering Column Control Module (SCCM) supplies
voltage and ground to the applicable steering column tilt or telescoping motor to move the steering column
to the desired position.

z Fuse
z Steering column control switch
z Adjustable steering column tilt motor
z Adjustable steering column telescopic motor
z SCCM
DTC Description Fault Trigger Conditions

z B1375:18 — Steering This DTC sets when the SCCM senses current flow to the adjustable
Column Tilt Motor: steering column tilt motor is below a preset limit while the steering column
Circuit Current Below control switch is activated. This may be caused by an open or high
Threshold resistance in the adjustable steering column tilt motor circuits.
Column Tilt Motor: steering column tilt motor is above a preset limit while the steering column
Circuit Current Above control switch is activated. This may be caused by a short to ground in
Threshold the adjustable steering column tilt motor circuits.
Column Tilt Motor: steering column tilt motor is within a specific range but above a preset
Actuator Stuck limit during self test.
z B137E:18 — Steering This DTC sets when the SCCM senses current flow to the adjustable
Column Telescope steering column telescope motor is below a preset limit while the steering
Motor: Current Below column control switch is activated. This may be caused by an open or
Threshold high resistance in the adjustable steering column telescope motor circuits.
Column Telescope steering column telescope motor is above a preset limit while the steering
Motor: Current Above column control switch is activated. This may be caused by a short to
Threshold ground in the adjustable steering column telescope motor circuits.
Column Telescope steering column telescope motor is within a specific range but above a
Motor: Actuator Stuck preset limit during on-demand self test.
PINPOINT TEST A: THE ADJUSTABLE STEERING COLUMN IS INOPERATIVE IN ONE OR MORE
DIRECTIONS — USING THE STEERING COLUMN CONTROL SWITCH
NOTE: If the adjustable steering column only operates in one second intervals when activating the steering
column control switch, GO to Pinpoint Test C .

A1 CHECK THE OPERATION OF THE ADJUSTABLE COLUMN
USING THE STEERING COLUMN CONTROL SWITCH
z Operate the adjustable steering column in all directions using Yes
the steering column control switch. GO to A4 .
z Does the steering column operate correctly in at least one
direction using the steering column control switch? No
If the steering column does not
move in any direction at all
using the steering column
switch, GO to A2 . If the
steering column moves in only
one second intervals (jog
mode) in one or more
directions using the steering
column switch, GO to Pinpoint
Test C .
A2 CHECK FOR VOLTAGE AT THE SCCM
z Ignition OFF. Yes
z Disconnect: SCCM C2414A. GO to A3 .
z Disconnect: SCCM C2414B.
z Measure the voltage between SCCM C2414A-10, circuit No
SBP23 (WH/RD), harness side and ground. VERIFY BCM fuses 23 (15A)
and 24 (15A) are OK. If OK,
If not OK, REFER to the Wiring

Diagrams manual to identify
the cause for the circuit short.

operation.
z Measure the voltage between SCCM C2414B-8, circuit SBP24

(VT/RD), harness side and ground.
z Are the voltages greater than 10 volts?

A3 CHECK THE SCCM GROUND CIRCUITS FOR AN OPEN
z Measure the resistance between SCCM C2414A-13, circuit Yes
GD133 (BK), harness side and ground. GO to A4 .
No
operation.
z Measure the resistance between SCCM C2414B-5, circuit

GD138 (BK/WH), harness side and ground.

A4 CHECK THE SCCM STEERING COLUMN ADJUST SWITCH
(STRCOL_ADJ) PID
z Connect: SCCM C2414A (if previously disconnected). Yes
z Connect: SCCM C2414B (if previously disconnected). GO to A5 .
z Ignition ON.
DataLogger — SCCM . INSTALL a new steering
z Monitor the STRCOL_ADJ PID while moving the steering column control switch. REFER
column control switch in all directions. to Brake Pedal Control Switch
z Do the PID values agree with the steering column control in Section 206-06 .
switch positions?
CLEAR the DTCs. VERIFY
correct system operation.
REPEAT the self-test
If the concern is still present,

INSTALL a new Steering
Column Control Module
(SCCM). REFER to Section
211-05 . TEST the system for
normal operation.
A5 CHECK THE ADJUSTABLE STEERING COLUMN MOTOR
z Ignition OFF. Yes
z Disconnect: SCCM C2414B. REPAIR the affected circuit(s).
z Disconnect: SCCM C2414C. TEST the system for normal
SCCM C2414B-1, circuit CPP22 (GY/BN), harness No
side. GO to A6 .
SCCM C2414B-2, circuit CPP04 (GY), harness side.
SCCM C2414B-7, circuit CPP02 (BN), harness side.

z Ignition OFF. Yes
z Measure the resistance between ground and: GO to A7 .
SCCM C2414B-1, circuit CPP22 (GY/BN), harness
side. No
SCCM C2414B-2, circuit CPP04 (GY), harness side. REPAIR the affected circuit(s).
SCCM C2414B-7, circuit CPP02 (BN), harness side. TEST the system for normal
operation.

z Disconnect: Adjustable Steering Column Tilt Motor C2600 or Yes
Adjustable Steering Column Telescope Motor C2601. For a tilt motor that is
z For an inoperative adjustable steering column tilt motor, inoperative/does not operate
measure the resistance between SCCM C2414B and correctly, GO to A8 . For a
adjustable steering column tilt motor C2600 using the following telescope motor that is
chart: inoperative/does not operate
correctly, GO to A9 .
Adjustable Steering Column Tilt
SCCM Circuit Motor No
C2414B- CPP02 C2600-2 CLEAR the DTCs. REPEAT
7 (BN) the self-test.
C2414B- CPP04 C2600-1
2 (GY)
z For an inoperative adjustable steering column telescope

motor, measure the resistance between SCCM C2414B and
adjustable steering column telescope motor C2601 using the
following chart:
Adjustable Steering Column

SCCM Circuit Telescope Motor
C2414B- CPP02 (BN) C2601-2
7
C2414B- CPP22 C2601-1
1 (GY/BN)

A8 CHECK THE SCCM OUTPUT TO THE ADJUSTABLE
STEERING COLUMN TILT MOTOR
z Ignition OFF. Yes

z Connect: SCCM C2414B. INSTALL a new adjustable
z Connect: SCCM C2414C. steering column tilt motor.
z NOTICE: The following step uses a test light to simulate REFER to Steering Column
normal circuit loads. Use only the test light recommended Motor — Tilt in this section.
in the Special Tools table at the beginning of this section. CLEAR the DTCs. TEST the
To avoid connector terminal damage, use the Flex Probe system for normal operation.
Kit for the test light probe connection to the vehicle. Do REPEAT the self test.
not use the test light probe directly on any connector.
z Connect a 12-volt incandescent test light between adjustable No
steering column tilt motor C2600-1, circuit CPP02 (BN), GO to A10 .
harness side and C2600-2, circuit CPP04 (GY), harness side.
z Ignition ON.
z NOTE: Because the steering column motor (Hall-effect
sensor) is disconnected, the SCCM only activates the output
for approximately 1 second each time the steering column
control switch is activated (jog mode).
z Activate the steering column control switch in both the UP and
DOWN positions (release the switch briefly between each
switch activation) while observing the test light.
z Does the test light momentarily illuminate when the
steering column control switch is activated in both UP
and DOWN positions?
A9 CHECK THE SCCM OUTPUT TO THE ADJUSTABLE
STEERING COLUMN TELESCOPE MOTOR
z Ignition OFF. Yes
z Connect: SCCM C2414B. INSTALL a new adjustable
z Connect: SCCM C2414C. steering column telescopic
z NOTICE: The following step uses a test light to simulate motor. REFER to Steering
normal circuit loads. Use only the test light recommended Column Motor — Telescopic in
in the Special Tools table at the beginning of this section. this section. CLEAR the DTCs.
To avoid connector terminal damage, use the Flex Probe TEST the system for normal
Kit for the test light probe connection to the vehicle. Do operation. REPEAT the self
not use the test light probe directly on any connector. test.
z Connect a 12-volt incandescent test light between adjustable
steering column telescope motor C2601-2, circuit CPP02 No
(BN), harness side and C2601-1, circuit CPP22 (GY/BN), GO to A10 .
harness side.
z Ignition ON.
z NOTE: Because the steering column motor (Hall-effect
sensor) is disconnected, the SCCM only activates the output
for approximately 1 second each time the steering column
control switch is activated (jog mode).
z Activate the steering column control switch in both the
FORWARD and REARWARD positions (release the switch
briefly between each switch activation) while observing the
test light.
z Does the test light momentarily illuminate when the
steering column control switch is activated in both
FORWARD and REARWARD positions?
A10 CHECK THE SCCM CONNECTORS
z Check the SCCM electrical connectors for: Yes
corrosion INSTALL a new SCCM .
damaged pins REFER to Section 211-05 .
pushed-out pins TEST the system for normal
z Connect: Reconnect all previously disconnected electrical operation.
connectors.
z Make sure the connectors are seated correctly then operate No
the system and verify the concern is still present. The system is operating
z Is the concern still present? correctly at this time. Concern
may have been caused by a
the self-test. TEST the system
Pinpoint Test B: The Adjustable Steering Column is Inoperative in One or More Directions — Using
the Memory SET Switch Buttons/Using an RKE Transmitter/Using the Easy Entry/Exit Feature
Normal Operation
When the desired memory position is selected using the memory SET switch or an Remote Keyless Entry
(RKE) transmitter, the Driver Seat Module (DSM) communicates the desired steering column position in a
message on the Medium Speed Controller Area Network (MS-CAN) to the Body Control Module (BCM). The
BCM acts as a gateway module, relaying the message to the Steering Column Control Module (SCCM) over
the High Speed Controller Area Network (HS-CAN). The SCCM monitors the position of the adjustable
steering column using Hall-effect type rotation sensors that are integral to the tilt and telescoping motors.
The sensors provide a digital signal used by the SCCM to calculate the position of the steering column in
relation to the full forward/rearward and full up/down positions. The SCCM uses these signals to store and
recall memory positions, carry out easy entry/exit operations and to make sure the tilt and telescope motors
do not stall against the steering column end of travel. If a tilt or telescope motor sensor DTC sets, the SCCM
does not recall a programmed memory position or automatically position the steering column during the
easy entry/exit operation. If a DTC sets for either sensor, the affected adjustable steering column motor
operates in jog mode. Jog mode allows limited operation of the affected steering column motor using only
the steering column control switch. When the steering column control switch is operated in jog mode, the
steering column moves in the desired direction for one second, then stops. The steering column control
switch must be released, then pressed again in order to move the steering column for an additional second.

z Entry/exit feature is disabled in the message center
z Memory SET switch
z RKE transmitter
z DSM
z BCM
z SCCM
PINPOINT TEST B: THE ADJUSTABLE STEERING COLUMN IS INOPERATIVE IN ONE OR MORE

DIRECTIONS — USING THE MEMORY SET SWITCH BUTTONS/USING AN RKE TRANSMITTER/USING
THE EASY ENTRY/EXIT FEATURE

B1 CHECK THE OPERATION OF THE
ADJUSTABLE COLUMN USING THE STEERING
COLUMN CONTROL SWITCH
z Operate the adjustable steering column in Yes
all directions using the steering column If the adjustable steering column is inoperative
control switch. using the easy entry/exit feature, GO to B2 . If the
z Does the steering column move for more adjustable steering column is inoperative using
than one second in each direction using the memory SET switch, GO to B3 . If the
the steering column control switch? adjustable steering column is inoperative using
an RKE transmitter, GO to B4 .
No
If the steering column does not move in any
direction at all using the steering column switch,
GO to Pinpoint Test A . If the steering column
moves in only one second intervals (jog mode) in
one or more directions using the steering column
switch, GO to Pinpoint Test C .
B2 VERIFY THE EASY ENTRY/EXIT FEATURE
IS ENABLED
z Verify the easy entry/exit feature is enabled Yes
using the message center. Refer to the GO to B5 .
Owner's Literature for additional instructions
for using the message center. No
z Does the message center indicate that TOGGLE the easy entry/exit feature on using the
the easy entry/exit feature is enabled? message center controls. TEST the system for
normal operation.
MEMORY SEATS, MEMORY MIRRORS AND

STEERING COLUMN USING THE MEMORY SET
SWITCH
z Check the operation of the seats, memory Yes
mirrors and steering column using the If only the adjustable steering column is
memory SET switch. Refer to the Owner's inoperative using the memory SET switch, GO to
Literature for additional instructions for B5 .
programming a memory position.
z Do the seats and mirrors operate No
properly using the memory SET switch? If the seats and mirrors are also inoperative using
the memory SET switch, REFER to Section 501-
10 .
MEMORY SEATS, MIRRORS AND STEERING
COLUMN USING AN RKE TRANSMITTER
z Check the operation of the seats, mirrors Yes
and steering column using an RKE If only the adjustable steering column is
transmitter. Refer to the Owner's Literature inoperative using an RKE transmitter, GO to B5 .
for additional instructions for programming a
memory position to an RKE transmitter. No
z Do the seats and mirrors operate If the seats and mirrors are also inoperative using
correctly using an RKE transmitter? an RKE transmitter, REFER to Section 501-10 .
B5 CHECK FOR DSM , BCM AND SCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the To diagnose the DSM DTCs, REFER to Section
scan tool: Self Test — DSM . 501-10 . To diagnose the BCM DTCs, REFER to
z Enter the following diagnostic mode on the Section 419-10 . To diagnose the SCCM DTCs,
scan tool: Self Test — BCM . REFER to Section 211-05 .
z Enter the following diagnostic mode on the
scan tool: Self-Test — SCCM . No
z Record all DTCs retrieved from the DSM , INSTALL a new SCCM . REFER to Section 211-
BCM and SCCM . 05 . TEST the system for normal operation.
z Are any symptom or communication
related DTCs present?
Pinpoint Test C: The Adjustable Steering Column Operates in One Second Intervals When Using the
Steering Column Control Switch (Jog Mode)
Normal Operation
The Steering Column Control Module (SCCM) monitors the position of the adjustable steering column using
of Hall-effect type rotation sensors that are integral to the tilt and telescoping motors. Both the adjustable
steering column tilt motor and telescope motor can be serviced separately from the steering column.
The SCCM sends a reference voltage along the sensor feed circuit through the Hall-effect sensor and back
to the SCCM through a shared signal return circuit. The sensors provide a digital signal used by the SCCM
to calculate the position of the steering column in relation to the full forward/rearward and full up/down
positions. The SCCM uses this signal to store and recall memory positions, to carry out the easy entry/exit
operations and to make sure the adjustable steering column tilt and telescope motors do not stall against the
steering column end of travel.
If an adjustable steering column tilt or telescope motor sensor DTC sets (or if either of the sensor circuits
become open), the SCCM does not recall a programmed memory position or automatically position the
steering column during the easy entry/exit operations. The affected steering column motor operates in jog
mode. Jog mode allows limited operation of the affected steering column motor using only the steering
column control switch. When the steering column control switch is operated in jog mode, the steering
column moves in the desired direction for one second, then stops regardless of the length of time the switch
is actually activated. The steering column control switch must be released, then activated again in order to
move the steering column for an additional second.
DTC Description Fault Trigger Conditions

z B1C33:11 — Steering Column This DTC sets when the SCCM senses the adjustable steering
Tilt Feedback Signal: Circuit column tilt motor feedback sensor signal is below 1.5 volts. This
Short To Ground may be caused by a short to ground in the sensor signal circuit.
Tilt Feedback Signal: Circuit column tilt motor feedback sensor signal is above 7 volts. This
Short To Battery may be caused by a short to voltage in the sensor signal circuit.
Telescope Feedback Signal: column telescope motor feedback sensor signal is below 1.5 volts.
Circuit Short To Ground This may be caused by a short to ground in the sensor signal
circuit.
Telescope Feedback Signal: column telescope motor feedback sensor signal is above 7 volts.
Circuit Short To Battery This may be caused by a short to voltage in the sensor signal
circuit.

z Adjustable steering column tilt motor
z Adjustable steering column telescopic motor
z SCCM
PINPOINT TEST C: THE ADJUSTABLE STEERING COLUMN OPERATES IN ONE SECOND

INTERVALS WHEN USING THE STEERING COLUMN CONTROL SWITCH (JOG MODE)

C1 CHECK THE TILT/TELESCOPE SENSOR
z Ignition OFF. Yes
z Disconnect: SCCM C2414C. REPAIR the affected circuit(s). CLEAR the
z Disconnect: Adjustable Steering Column Tilt DTCs. REPEAT the self-test. TEST the
Motor C2600. system for normal operation.
z Disconnect: Adjustable Steering Column
Telescope Motor C2601. No
z Ignition ON. GO to C2 .
harness side.
SCCM C2414C-4, circuit VPP08 (WH),
harness side.
SCCM C2414C-5, circuit VPP17
(VT/BN), harness side.

z Ignition OFF. Yes
z Measure the resistance between ground and: GO to C3 .
harness side. No
SCCM C2414C-4, circuit VPP08 (WH), REPAIR the affected circuit(s). CLEAR the
harness side. DTCs. REPEAT the self-test. TEST the
SCCM C2414C-5, circuit VPP17 system for normal operation.
(VT/BN), harness side.

z Measure the resistance between SCCM Yes
C2414C-4, circuit VPP08 (WH), harness side GO to C4 .
and SCCM C2414C-5, circuit VPP17 (VT/BN),
harness side. No
REPAIR the affected circuit(s). CLEAR the

z Measure the resistance between SCCM Yes
C2414C, harness side and adjustable steering GO to C5 .
column tilt motor C2600; and between SCCM
C2414C, harness side and adjustable steering No
column telescope motor C2601, harness side REPAIR the affected circuit(s). CLEAR the
using the following chart: DTCs. REPEAT the self-test. TEST the
Adjustable Steering
Column
SCCM Circuit Tilt/Telescope Motor
C2414C- RPP06 C2600-3
3 (GN)
C2414C- RPP06 C2601-3
3 (GN)
C2414C- VPP08 C2600-4
4 (WH)
C2414C- VPP17 C2601-4
5 (VT/BN)

C5 CHECK THE SCCM CONNECTOR
z Check SCCM connector C2414C for: Yes
corrosion If the adjustable steering column does not
damaged pins operate correctly when the steering column
pushed-out pins control switch is in the UP/DOWN (tilt) position
z Connect: SCCM C2414C. (s), INSTALL a new adjustable steering
z Connect: Adjustable Steering Column Tilt column tilt motor. REFER to Steering Column
Motor C2600. Motor — Tilt in this section. CLEAR the DTCs.

z Connect: Adjustable Steering Column REPEAT the self-test. If the concern is still
Telescope Motor C2601. present, INSTALL a new SCCM . REFER to
z Ignition ON. Section 211-05 . TEST the system for normal
z Make sure the connectors are seated correctly operation. If the adjustable steering column
then operate the system and verify the concern does not operate correctly when the steering
is still present. column control switch is in the
z Is the concern still present? FORWARD/REARWARD (telescope) position
(s), INSTALL a new adjustable steering
column telescopic motor. REFER to Steering
Column Motor — Telescopic in this section.
CLEAR the DTCs. REPEAT the self-test. If the
concern is still present, INSTALL a new
SCCM . REFER to Section 211-05 . TEST the
No
The system is operating correctly at this time.
Concern may have been caused by a loose or
corroded connector. CLEAR the DTCs.
REPEAT the self-test. TEST the system for
normal operation.

Steering Wheel Wrap Bonding
Material
Item Specification
Instant Gel Adhesive WSK-M2G402-A4
TA-19
1. NOTE: If re-adhering leather to the front side of the steering wheel only, it will not be necessary to
remove the steering wheel. Steering wheel removal is necessary only when repairing loose leather on
the backside of the steering wheel.
If necessary remove the steering wheel. For additional information, refer to Steering Wheel in this
section.
2. Position the loose leather out of the way.
3. Apply the specificed adhesive evenly over the wheel spoke.
4. Position the loose leather back into the original position.
5. NOTE: The adhesive should be completely set after 5 minutes. Do not pull on the repair area.
Smooth the leather and tuck in for neat appearance.

z Apply pressure (for at least 30 seconds) until the leather is bonded to the wheel spoke.
6. If removed, Install the steering wheel. For additional information, refer to Steering Wheel in this
section.

Steering Column Motor — Telescopic
Part
1 3F797 Steering column motor (telescopic)
2 — Leadscrew housing (part of 3F797)
3 — Trunion nut capture bracket (part of 3C529)
4 — Trunion nut capture bracket screws (2 required) (part
of 3C529)
5 — Steering column motor screws (2 required) (part of
3C529)
6 — Trunion nut (part of 3F797)
Removal
1. Remove the steering column. For additional information, refer to Steering Column in this section.
2. Place the steering column upside down on a workbench.
3. Detach the electrical connector pin-type retainer from the steering column.
4. Remove the 2 steering column motor screws.
5. Remove the 2 steering column motor trunnion nut capture bracket screws and the trunnion nut
capture bracket.
6. Remove the steering column motor.
Installation
1. Apply grease (supplied with the motor) to the trunnion nut axles and the steering column motor
leadscrew housing holes.
2. NOTE: Install the trunnion nut with the axle O-ring facing inward towards the column.
NOTE: If necessary, make small alignment adjustments by pivoting the tilt bracket.
Rotate the pinion nut until the correct length is achieved to align the leadscrew housing with the
threaded holes in the support arm.
z Loosely install the 2 steering column motor screws.
3. Position the trunnion nut capture bracket and loosely install the 2 steering column motor trunnion nut
capture bracket screws.
4. Tighten the 2 steering column motor screws to 6 Nm (53 lb-in).
5. Tighten the 2 steering column motor trunnion nut capture bracket screws to 7 Nm (62 lb-in).
6. Attach the electrical connector pin-type retainer to the steering column.
7. Install the steering column. For additional information, refer to Steering Column in this section.

Steering Column Motor — Tilt
Part
1 — Leadscrew housing (part of 3F797)
2 — O-ring (part of 3F797)
3 — Trunion nut (part of 3F797)
4 — Trunion nut capture bracket (part of 3C529)
5 — Trunion nut capture bracket screws (2 required) (part
of 3C529)
6 — Steering column motor screws (2 required) (part of
3C529)
7 3F797 Steering column motor (tilt)
Removal
1. Remove the steering column. For additional information, refer to Steering Column in this section.
2. Place the steering column upside down on a workbench.
3. Detach the electrical connector pin-type retainer from the steering column.
4. Remove the 2 steering column motor screws.
5. Remove the 2 steering column motor trunnion nut capture bracket screws and the trunnion nut
capture bracket.
6. Remove the steering column motor.
Installation
1. Apply grease (supplied with the motor) to the trunnion nut axles and the steering column motor
leadscrew housing holes.
2. NOTE: Install the trunnion nut with the axle O-ring facing inward towards the column.
NOTE: If necessary, make small alignment adjustments by pivoting the tilt bracket.
Rotate the pinion nut until the correct length is achieved to align the leadscrew housing with the
threaded holes in the support arm.
z Loosely install the 2 steering column motor screws.
3. Position the trunnion nut capture bracket and loosely install the 2 steering column motor trunnion nut
capture bracket screws.
4. Tighten the 2 steering column motor screws to 6 Nm (53 lb-in).
5. Tighten the 2 steering column motor trunnion nut capture bracket screws to 7 Nm (62 lb-in).
6. Attach the electrical connector pin-type retainer to the steering column.
7. Install the steering column. For additional information, refer to Steering Column in this section.

Steering Column Shaft
Part
1 N808684 Lower steering column shaft-to-steering gear bolt
2 3B676 Lower steering column shaft
3 W710570 Lower steering column shaft-to-upper steering column
shaft bolt
4 W705132 Steering column shaft dash seal bolt (2 required)
5 3D677 Steering column shaft dash seal
6 3E751 Upper steering column shaft
7 W714409 Upper steering column shaft-to-steering column bolt
02 .
2. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
3. NOTICE: Do not allow the steering column to rotate while the steering column shaft is
disconnected or damage to the clockspring may result. If there is evidence that the steering
column shaft has rotated, remove and recenter the clockspring. For additional information,
refer to Section 501-20B .
Remove and discard the upper steering column shaft-to-steering column bolt and disconnect the
upper steering column shaft from the steering column.
4. Remove and discard the lower steering column shaft-to-upper steering column shaft bolt and
disconnect the lower steering column shaft from the upper steering column shaft.
5. Remove the 2 steering column shaft dash seal bolts, the steering column shaft dash seal and the
upper steering column shaft.
6. Remove and discard the lower steering column shaft-to-steering gear bolt and disconnect the lower
steering column shaft from the steering gear.
7.
and steering column shaft detachment or loss of steering control. Failure to follow this
instruction may result in serious injury to vehicle occupant(s).

Steering Column Shroud — Floor Shift

1 — Instrument cluster trim (part of 15044D70)
2 3530A Upper steering column shroud
3 3530B Lower steering column shroud
4 W710485 Lower steering column shroud screw (3 required)
1. Remove the 3 screws and the steering column opening trim panel.
2. Separate the instrument cluster trim from the upper steering column shroud.
3. Pull upward on the rearward portion of the upper steering column shroud to separate the clips from
the lower steering column shroud.
z Roll the upper steering column shroud upward on the hinge point and then pull straight
rearward to remove the upper shroud.
4. Remove the 3 screws and the lower steering column shroud.


Steering Column Shroud

1 W710485 Lower steering column shroud screw (3 required)
2 3530B Lower steering column shroud
3 3530A Upper steering column shroud
Removal
1. Remove the 3 screws and the steering column opening trim panel.
2. Place transmission selector lever in PARK.
3. Position the steering column in the full downward and rearward position.
4. Apply the parking brake.
5. With the ignition key in the ON position and the brake pedal pressed, shift the transmission selector
lever into DRIVE.
6. NOTICE: Use care when detaching the transmission selector lever boot clips from steering
column shrouds or damage to the selector lever boot may occur causing replacement of the
shift lever assembly. The transmission selector lever boot is not serviceable separately.
Position the selector lever boot aside.
1. Push forward on the selector lever boot at the area indicated and separate the boot from the
upper and lower steering column shrouds.
7. Pull upward on the rearward portion of the upper steering column shroud to separate the clips from
the lower steering column shroud.
z Roll the upper steering column shroud upward on the hinge point and then pull straight
rearward to remove the upper shroud.
8. Shift the shift lever to PARK and remove the ignition key.
9. Remove the 3 screws and the lower steering column shroud.
Installation
1. Position the lower steering column shroud and install the 3 screws.
2. Position the upper steering column shroud onto the lower steering column shroud and secure the
front clips.
3. NOTICE: Use care and follow the installation sequence when installing the selector lever boot
to the steering column shrouds or damage to the boot may occur causing replacement of the
selector lever assembly. The selector lever boot is not serviceable separately.
Install the selector lever boot in the sequence shown.

1. Slide the front of the selector lever boot into position.
2. Slide the bottom of the selector lever boot into position.
3. Slide the top of the selector lever boot into position and push down.
4. Push down on the back of the selector lever boot until selector lever boot is fully seated.
4. Place transmission selector lever in PARK.
5. Release the parking brake.
6. Position the steering column opening trim panel and install the 3 screws.

Steering Column
Power Column
Part
2 N808684 Upper steering column shaft-to-steering column bolt
3 N806423 Steering column nut (2 required)

4 W715057 Steering column bolt (2 required)
5 3C529 Steering column
6 — Steering column motor electrical connectors (2
required) (part of 14401)
7 — Steering Column Control Module (SCCM) electrical
connectors (3 required) (part of 14401)
8 — Passive Anti-Theft System (PATS) electrical connector
(part of 14401)
9 — Ignition switch electrical connector (part of 14401)
Manual Column
Part
1 W715057 Steering column bolt (2 required)
2 3C529 Steering column
3 N806423 Steering column nut (2 required)
4 W714409 Upper steering column shaft-to-steering column bolt
6 7E395 Selector lever cable (column shift only)
8 — Passive Anti-Theft System (PATS) electrical connector
(part of 14401)
All vehicles
1. Remove the steering column shrouds. For additional information, refer to Steering Column Shroud —
Floor Shift in this section.
2. Remove the steering wheel. For additional information, refer to Steering Wheel in this section.
3. Disconnect the following electrical connectors.

z Clockspring
z Passive Anti-Theft System (PATS) transceiver
z Ignition switch
z Steering Column Control Module (SCCM) (3 required)
z Key release interlock actuator (if equipped)
Vehicles with power column
4. Disconnect the 2 steering column motor electrical connectors.
Vehicles with column shift
5. Detach the shift lever cable from the steering column and the bracket.
6. Disconnect the overdrive cancel switch and the Brake Shift Interlock Actuator (BSIA) electrical
connectors.
All vehicles
7. Detach the wiring harness retainers from the steering column and position the wiring harness aside.
8.
and steering column shaft detachment or loss of steering control. Failure to follow this
instruction may result in serious injury to vehicle occupant(s).
Remove and discard the upper steering column shaft-to-steering column bolt and detach the upper
steering column shaft from the steering column.
9. Remove the 2 steering column nuts, the 2 steering column bolts and the steering column.
z To install, tighten the new steering column nuts to 30 Nm (22 lb-ft).
z To install, tighten the new steering column bolts to 28 Nm (21 lb-ft).
10. NOTICE: Make sure the steering column support is flush with the instrument panel and the tilt
lever (if equipped) is in the locked position before tightening the nuts and bolts or damage to
the steering column may occur.
NOTICE: Make sure the electrical wiring harness is routed correctly and secured to the
steering column or damage to the wires and/or connectors may occur.
Vehicles with power column
11. If a new power steering column has been installed, use the steering column control switch and set the
soft stops as follows.
1. Move the column rearward until it reaches the end of travel and hold the switch for 2 seconds
after the column has reached the end of travel.
2. Move the column in the same direction until it reaches the end of travel again and hold the
switch for 2 seconds after the motor has reached the end of travel. This clears any unintended
soft stops.
3. Move the column forward until it reaches the end of travel and hold the switch for 2 seconds
after the motor has reached the end of travel.
4. Move the column in the same direction until it reaches the end of travel and hold the switch for
2 seconds after the motor has reached the end of travel. This clears any unintended soft stops.
5. Repeat the sequence moving the column up and down.

Steering Wheel
Part
1 W709344 Steering wheel bolt
2 — Steering wheel switches electrical connector (part of
3600)
3 3600 Steering wheel
1. Remove the driver air bag module. For additional information, refer to Section 501-20B .
2. Turn the steering wheel to the straight-ahead position.
3. Remove and discard the steering wheel bolt.

4. Disconnect the steering wheel switches electrical connector from the clockspring.
5. Remove the steering wheel while routing the wires from the clockspring through the steering wheel.
6. Tape the clockspring center rotor to the outer housing to prevent it from rotating.
SECTION 211-05: Steering Column Switches 2014 F-150 Workshop Manual

Multifunction switch screws 2 18
Steering Column Control Module (SCCM) screws 2 18

Steering Column Switches
The steering column switches consist of the following components:

z Ignition switch
z Hazard flasher switch
z Multifunction switch
z Brake pedal control switch (if equipped)
z Steering column control switch (if equipped)
z Steering wheel switches (if equipped)
z Steering wheel rotation sensor (if equipped)
Steering Column Control Module (SCCM)
The SCCM acts as a central hub for the steering column switches and circuits. The hazard flasher switch,
multifunction switch, brake pedal control switch and steering column control switch are mounted directly to
the SCCM and can be serviced separately from the SCCM .

Steering Column Switches
Special Tool(s)
Backprobe Pins
POM 6411 or equivalent
Flex Probe Kit

NU105-R025D or equivalent


Ignition Switch
When the ignition lock cylinder is turned using the key, a mechanical connection positions the ignition switch
to the desired position. The available ignition switch positions are:
z OFF
z ACC
z RUN
z START
When placed in any position other than OFF, the ignition switch provides fused battery voltage inputs to the
Body Control Module (BCM). When placed in the START position, the ignition switch also provides fused
battery voltage input to the PCM. The ignition switch contains a key-in-ignition input that allows the BCM to
detect when the key has been inserted in the ignition to initiate the module wake up cycle. This information
is also used by the BCM for the brake shift interlock system. For information on the brake shift interlock
system, refer to Section 307-05 .
Key Removal Inhibit Solenoid
The key removal inhibit solenoid (also known as the key release interlock actuator) is an electronically
controlled solenoid that prevents the ignition lock cylinder from being turned to the OFF position unless the
gear selector lever is in the PARK position. The key removal inhibit solenoid is part of the ignition switch.
The Steering Column Control Module (SCCM) controls various systems and/or features:
z Wiper and washer system, refer to Section 501-16 .

z Exterior lighting, refer to Section 417-01 .
z Interior lighting, refer to Section 417-02 .
z Steering wheel audio controls (if equipped), refer to Refer to the appropriate section in Group 415 for
the procedure..
z Steering wheel message center controls (if equipped), refer to Section 413-01 .
z Cruise control, refer to Section 419-03 .
z Adjustable pedals, refer to Section 206-06 .
z Steering column control, refer to Section 211-04 .
The SCCM also provides a pass-through circuit path for various components and/or features:
z Steering wheel switch illumination

z Driver air bag module
z Horn
The multifunction switch, brake pedal control switch (if equipped), hazard flasher switch, steering column
control switch (if equipped), and LH/RH steering wheel switches (if equipped) provide inputs to the SCCM .
Based on inputs from the various switches, the SCCM communicates over the High Speed Controller Area
Network (HS-CAN) or the Local Interconnect Network (LIN) to control the supporting features.
Clockspring
The clockspring is mounted on the front of the SCCM and provides a continuous electrical connection
between the driver air bag and the Restraints Control Module (RCM) when the steering wheel is turned. For
information on the clockspring and other components of the Supplemental Restraint System (SRS), refer to
Section 501-20B .
Steering Wheel Rotation Sensor
The steering wheel rotation sensor is mounted on the front of the SCCM behind the clockspring and
provides steering wheel position information to the SCCM . This information is broadcast over the HS-CAN .
Multifunction Switch
The multifunction switch is mounted directly to the SCCM and controls the low/high-beam headlamps, flash-
to-pass, turn signals, windshield wiper and washer and front camera washer (if equipped), by transferring
the driver inputs to the SCCM . The high-beam headlamps, flash-to-pass and turn signals are communicated
from the SCCM over the HS-CAN . The windshield wiper and front camera washer signals (if equipped) are
communicated from the SCCM to the wiper motor internal module over the LIN . When the BCM receives
the correct signal from the SCCM , the BCM activates the required component.
The brake pedal control switch is mounted directly to the SCCM and controls the forward and rearward
movement of the accelerator and brake pedals. The brake pedal control switch functions when the ignition
switch is in the OFF, ACC or RUN positions. When the brake pedal control switch is pressed voltage is
connected through the SCCM to the adjustable pedals motor.
Hazard Flasher Switch
The hazard flasher switch is mounted directly to the SCCM and operates when the ignition switch is in any
position or when the key is removed. One press of the switch supplies a ground signal through the SCCM to
the BCM . When the ground signal is sensed by the BCM it turns the directional indicators ON. A second
press of the button releases the ground connection and turns the directional indicators OFF.
Steering Wheel Switches
The steering wheel switches are mounted directly to the steering wheel and wired to the SCCM . Depending
on what features the vehicle is equipped with, the SCCM sends messages via the HS-CAN to the PCM
(cruise control), Instrument Panel Cluster (IPC) (message center) and BCM (entertainment system). The
SCCM entertainment system messages are received by the BCM via HS-CAN and gatewayed over the
Medium Speed Controller Area Network (MS-CAN) where the messages are received by the applicable
entertainment system module(s).

z Multifunction switch z Battery Junction Box (BJB) fuse(s):
z Ignition switch 31 (15A)
z Key efforts 42 (5A)

z Steering column shrouds z Body Control Module (BCM) fuse(s):
23 (15A)
24 (15A)
28 (15A)
42 (5A)
z Instrument Panel Cluster (IPC)
z Passive Anti-Theft System (PATS) module


GO to Pinpoint Test A in this section to diagnose no power in all ignition switch positions
or GO to Pinpoint Test C to diagnose no power in RUN position.

418-00 .
z If the network test passes, retrieve and record continuous memory DTCs.
8. Carry out the self-test diagnostics for the BCM and the SCCM .
9. If the DTCs retrieved are related to the concern, refer to the Body Control Module (BCM) DTC Chart,
or the Steering Column Control Module (SCCM) DTC Chart. For all other DTCs, refer to Section 419-
10 .
DTC Charts

B1142:29 Ignition Status 1: Signal Invalid GO to Pinpoint Test E .

B1310:12 Run/Start Control: Circuit Short to Battery GO to Pinpoint Test F .
B1310:14 Run/Start Control: Circuit Short to Ground or GO to Pinpoint Test C .
Open
U300A:01 Ignition Switch: General Electrical Failure GO to Pinpoint Test A .
All other — REFER to the Master DTC Chart in Section
DTCs 419-10 .

B1007:09 High-Beam Headlamp REFER to Section 417-01 .
Switch: Component
Failure
B1008:09 Wiper Mode Switch: REFER to Section 501-16 .
Component Failure
B1051:09 Front Washer Switch: REFER to Section 501-16 .
Component Failure
B10A6:09 Main Light Switch: REFER to Section 417-01 .
Component Failure
B10AD:02 Rain Sensor: General REFER to Section 501-16 .
Signal Failure
B10AD:08 Rain Sensor: Bus REFER to Section 501-16 .
Signal / Message
Failure
B10AD:49 Rain Sensor: Internal REFER to Section 501-16 .
Electronic Failure
B10AD:55 Rain Sensor: Not CARRY OUT Programmable Module Installation (PMI) Using the
Configured Integrated Diagnostic System (IDS) When the Original Module is
NOT Available (using As-Built Data) on the SCCM . REFER to
Section 418-01 . RETRIEVE SCCM DTCs. If B10AD:55 returns,
INSTALL a new SCCM . REFER to Steering Column Control Module
(SCCM) in this section.
B1124:09 Lamp Fade Control: REFER to Section 417-01 .
Component Failure
B1131:02 Wiper Motor Module: REFER to Section 501-16 .
General Signal Failure
B1131:08 Wiper Motor Module: REFER to Section 501-16 .
Bus Signal / Message
Failure
B11D9:16 Vehicle Battery: Circuit GO to Pinpoint Test J .
Voltage Below
Threshold
B11D9:17 Vehicle Battery: Circuit GO to Pinpoint Test K .
Voltage Above
Threshold
B1298:09 Steering Column Adjust REFER to Section 211-04 .

Up Switch: Component
Failure
B1299:09 Steering Column Adjust REFER to Section 211-04 .
Down Switch:
Component Failure
B12A1:09 Steering Column Adjust REFER to Section 211-04 .
Out Switch: Component
Failure
B12A2:09 Steering Column Adjust REFER to Section 211-04 .
In Switch: Component
Failure
B12F7:09 Single Wipe Switch: REFER to Section 501-16 .
Component Failure
B1368:11 Adjustable Pedal REFER to Section 206-06 .
Position Feedback
Sensor: Circuit Short to
Ground
B1368:12 Adjustable Pedal REFER to Section 206-06 .
Position Feedback
Sensor: Circuit Short to
Battery
B1369:09 Pedal Adjustment REFER to Section 206-06 .
Switch: Component
Failure
B1375:18 Steering Column Tilt REFER to Section 211-04 .
Motor: Circuit Current
Below Threshold
Above Threshold
Motor: Actuator Stuck
B137D:18 Pedal Adjustment REFER to Section 206-06 .
Below Threshold
Above Threshold
Motor: Actuator Stuck
B137E:18 Steering Column REFER to Section 211-04 .
Telescope Motor:
Circuit Current Below
Threshold
Telescope Motor:
Circuit Current Above
Threshold
Telescope Motor:
Actuator Stuck
B137F:09 Steering Wheel Left REFER to Section 419-03 .
Switch Pack:
Component Failure
Switch Pack: Circuit
Short To Ground
Switch Pack: Circuit
Voltage Above
Threshold
B1380:09 Steering Wheel Right REFER to Refer to the appropriate section in Group 415 for the
Switch Pack: procedure..
Component Failure
Switch Pack: Circuit procedure..
Short to Ground
Switch Pack: Circuit procedure..
Voltage Above
Threshold
B1C33:11 Steering Column Tilt REFER to Section 211-04 .
Feedback Signal:
Circuit Short To Ground
B1C33:12 Steering Column Tilt REFER to Section 211-04 .
Feedback Signal:
Circuit Short To Battery
B1C35:11 Steering Column REFER to Section 211-04 .
Telescope Feedback
Signal: Circuit Short To
Ground
B1C35:12 Steering Column REFER to Section 211-04 .
Telescope Feedback
Signal: Circuit Short To
Battery
B1D36:09 Turn Indicator Switch: REFER to Section 417-01 .
Component Failure
C0051:09 Steering Wheel INSTALL a new steering wheel rotation sensor. REFER to Section
Position Sensor: 206-09 . CLEAR the DTCs. REPEAT the self-test.
Component Failure
C0051:16 Steering Wheel GO to Pinpoint Test I .
Position Sensor: Circuit
Voltage Below
Threshold
C0051:17 Steering Wheel GO to Pinpoint Test I .
Position Sensor: Circuit
Voltage Above
Threshold
U1000:00 Solid State Driver REPAIR all other SCCM DTCs before addressing this concern.
Protection Active-Driver CLEAR the DTCs and REPEAT the self test.
Disabled: No Sub Type

Information
U2100:00 Initial Configuration Not CARRY OUT Programmable Module Installation (PMI) Using the
Complete: No Sub Integrated Diagnostic System (IDS) When the Original Module is
Type Information NOT Available (using As-Built Data) on the SCCM . REFER to
Section 418-01 . RETRIEVE SCCM DTCs. If U2100:00 returns,
INSTALL a new SCCM . REFER to Steering Column Control Module
(SCCM) in this section.
U2101:00 Control Module This DTC sets if the steering wheel switches do not match the switch
Configuration function configuration data in the SCCM . CHECK the part numbers
Incompatible: No Sub in Ford Catalog Advantage™ or equivalent and CONFIRM the correct
Type Information SCCM and steering wheel control switches are installed to the
vehicle.
U3000:49 Control Module: INSTALL a new SCCM . REFER to Steering Column Control Module
Internal Electronic (SCCM) in this section. CLEAR the DTCs. REPEAT the self-test.
Failure
Symptom Chart
Symptom Chart
z No communication z Wiring, terminals z REFER to Section 418-00 .
with the Body Control or connectors
Module (BCM) z BCM
z No power in all z Fuse z GO to Pinpoint Test A .
ignition switch z Wiring, terminals
positions or connectors
z Ignition switch
z BCM
z No power in ACC z Fuse z GO to Pinpoint Test B .
z Wiring, terminals
or connectors
z Accessory delay
relay
z BCM
z No power in RUN z Fuse z GO to Pinpoint Test C .
z Wiring, terminals
or connectors
z Run/start relay
z Ignition switch
z BCM
z No power in START z Wiring, terminals z GO to Pinpoint Test D .
or connectors
z Ignition switch
z The ignition key z Wiring, terminals z GO to Pinpoint Test G .
cannot be returned to or connectors
the OFF position z Ignition lock
cylinder
z Key removal
inhibit solenoid
(part of the
ignition switch)
z Park range
switch (part of
the selector
lever)
z The ignition key can z Wiring, terminals z GO to Pinpoint Test H .
be turned to the OFF or connectors
position when the z Key release
selector lever is not interlock actuator
in PARK (part of the
ignition switch)
z Park range
switch (part of
the selector
lever)
z The ignition key is z Ignition key z REFER to Ignition Switch —
hard to turn z Ignition lock Mechanical Component Test in
cylinder this section.
z Ignition switch
rod
z Ignition switch
z The multifunction z Multifunction z CARRY OUT the SCCM self-test.
switch does not switch REFER to the Steering Column
operate correctly Control Module (SCCM) DTC
Chart to diagnose any DTCs
present. If no DTCs are present,
INSTALL a new multifunction
switch. REFER to Steering
Column Multifunction Switch in
this section.
z The wiper/washer z Wiper/washer z REFER to Section 501-16 .
switch does not switch
operate correctly
Pinpoint Tests
Pinpoint Test A: No Power in All Ignition Switch Positions
Normal Operation
The ignition switch receives fused battery voltage from the Body Control Module (BCM) permanent voltage
bus through fuse 28 (15A). In the ACC or ON position, voltage is sent to the BCM . In the START position,
voltage is sent to both the BCM and PCM.
When the ignition switch is cycled to the OFF/LOCK position from any other position, the BCM begins a
monitoring cycle. The monitoring cycle checks that the voltage supplied to the BCM from the ignition switch
through the RUN/ACC, RUN/START and START circuits is delivered correctly for each ignition switch
position.
z DTC U300A:01 (Ignition Switch: General Electric Failure) — the BCM continuously monitors the
ignition switch position. This DTC sets if the voltage inputs to the BCM do not match the pre-defined
configurations for each ignition switch position.

z Fuse
z Ignition switch
PINPOINT TEST A: NO POWER IN ALL IGNITION SWITCH POSITIONS

A1 CHECK THE IGNITION SWITCH
z Ignition OFF. Yes
z Disconnect: Ignition Switch C250 . GO to A2 .
z Carry out the Ignition Switch Component Test.
No
Refer to Wiring Diagrams Cell 149 for component INSTALL a new ignition switch. REFER to
testing. Ignition Switch in this section. CLEAR the
DTC. REPEAT the self-test. TEST the
z Is the ignition switch OK?
A2 CHECK FOR VOLTAGE TO THE IGNITION
SWITCH
z Measure the voltage between ignition switch C250- Yes
4, circuit SBP28 (GN/RD), harness side and GO to A5 .
ground.
No
VERIFY BCM fuse 28 (15A) is OK. If OK,
GO to A3 . If not OK, REFER to the Wiring
Diagrams manual to identify the possible
cause of the circuit short. CLEAR the
DTC. REPEAT the self-test. TEST the

A3 CHECK FOR VOLTAGE TO BCM
z Measure the voltage between BCM fuse 28 (15A), Yes
circuit SBP28 (GN/RD), and ground. GO to A4
No
VERIFY fusible links A and B are OK. If
OK, REPAIR circuit SDC04 (RD or GY). If
not OK, REFER to the Wiring Diagrams
manual to identify the possible cause of
the circuit short. CLEAR the DTC.
REPEAT the self-test. TEST the system


A4 CHECK FOR AN OPEN BETWEEN THE BCM AND
IGNITION SWITCH
z Disconnect: BCM C2280A . Yes
z Measure the resistance between BCM C2280A-6 GO to A6 .
and ignition switch C250-4, circuit SBP28 (GN/RD),
harness side. No
REPAIR circuit SBP28 (GN/RD) for an
open. CLEAR the DTCs. REPEAT the
self-test. TEST the system for normal
operation.

A5 CHECK THE IGNITION SWITCH OUTPUT
z Disconnect: BCM C2280B . Yes
z Measure the resistance between ignition switch GO to A6 .
C250, harness side and BCM C2280B, harness
side as follows: No
Ignition Switch Circuit BCM the DTC. REPEAT the self-test. TEST the
C250-6 CDC33 (VT/GN) C2280B-35
C250-1 CDC34 (WH/OG) C2280B-29
C250-7 CDC35 (BU/WH) C2280B-47

A6 CHECK FOR CORRECT BCM OPERATION
z Disconnect all BCM connectors. Yes
z Check the connectors for: INSTALL a new BCM . REFER to Section
corrosion 419-10 . CLEAR the DTCs. REPEAT the
damaged pins self-test. TEST the system for normal
z Connect all BCM connectors and make sure they
are seated correctly. No
z Connect: Ignition Switch C250 . The system is operating correctly at this
z Operate the system and verify the concern is still time. The concern may have been caused
present. by a loose or corroded connector. CLEAR
z Is the concern still present? the DTCs. REPEAT the self-test. TEST
Pinpoint Test B: No Power in ACC
Normal Operation
When in ACC mode, the Body Control Module (BCM) provides ground for the coil (control) side of the
run/acc relay located in the BCM . The run/acc relay is serviced with the BCM . The BCM also provides a
ground circuit for the coil side of the accessory delay relay located in the BCM . The accessory delay relay
can be serviced separately from the BCM .

z Fuse
z Accessory delay relay

z BCM
PINPOINT TEST B: NO POWER IN ACC

B1 CHECK FOR ACC VOLTAGE AT THE BCM
z Disconnect: BCM C2280B . Yes
z Ignition In ACC. GO to B3 .
z Measure the voltage between BCM C2280B-35, circuit
CDC33 (VT/GN), harness side and ground. No
GO to B2 .

B2 CHECK THE IGNITION ACC CIRCUIT FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: Ignition Switch C250 . INSTALL a new ignition switch.
z Measure the resistance between BCM C2280B-35, REFER to Ignition Switch in this
circuit CDC33 (VT/GN), harness side and ignition switch section. TEST the system for normal
C250-6, circuit CDC33 (VT/GN), harness side. operation.
No
REPAIR circuit CDC33 (VT/GN).
operation.

B3 CHECK THE ACCESSORY DELAY RELAY
z Ignition OFF. Yes
z Disconnect: Accessory Delay Relay . GO to B4 .
z Carry out the appropriate relay component test.
No
Refer to Wiring Diagrams Cell 149 for component INSTALL a new accessory delay
testing. relay. TEST the system for normal
operation.
z Does the relay pass the test?
B4 CHECK FOR POWER TO THE ACCESSORY DELAY
RELAY
z Measure the voltage between accessory delay relay Yes
cavity 3 and ground. GO to B5 .
No
GO to B6 .

B5 CHECK FOR POWER TO THE RUN/ACC RELAY
z Disconnect: BCM Fuse 10 (10A) . Yes
z Measure the voltage between BCM fuse 10 (10A), input GO to B7 .
side and ground.
No
GO to B6 .

B6 CHECK THE BCM BATTERY FEED CIRCUIT FOR AN
OPEN
z Disconnect: BCM C2280G . Yes
z Measure the voltage between BCM C2280G-1, circuit GO to B7 .

SDC04 (RD or GY), harness side and ground.
No
VERIFY fusible links A and B are
OK. If OK, REPAIR circuit SDC04
(RD or GY). If not OK, REFER to the
Wiring Diagrams manual to identify
the possible cause of the circuit
short. TEST the system for normal
operation.

B7 CHECK FOR CORRECT BCM OPERATION
z Check the connectors for: INSTALL a new BCM . REFER to
corrosion Section 419-10 . TEST the system
damaged pins for normal operation.
pushed-out pins
z Connect all BCM connectors and make sure they are No
seated correctly. The system is operating correctly at
z Connect: BCM Fuse 10 (10A) (if previously this time. The concern may have
disconnected) . been caused by a loose or corroded
z Operate the system and verify the concern is still connector. TEST the system for
present. normal operation.
Pinpoint Test C: No Power in RUN
Normal Operation
When the ignition switch is turned to the RUN position, a voltage signal is sent to the Body Control Module
(BCM). The BCM then activates the run/start relay and the run/acc relay, which distribute fused voltage to
various components. The run/acc relay is serviced as part of the BCM .
z DTC B1310:14 (Run/Start Control: Circuit Short to Ground or Open) — the BCM continuously
monitors the control side of the run/start relay. This DTC sets if the BCM detects an open or a short to
ground on the control circuit. The BCM uses a Field-Effect Transistor (FET) to control the run/start
relay. When this DTC sets, the control side of the run/start relay is disabled via the FET . Once the
condition that caused the DTC to set is repaired, the BCM must pass a self-test in order for the DTC
to clear and the system to resume normal operation.

z Fuse
z Ignition switch
z Run/start relay
z BCM
PINPOINT TEST C: NO POWER IN RUN

C1 REVIEW THE BCM DTCs
z Review the BCM DTCs retrieved during inspection and Yes
verification. GO to C6 .
z Is DTC B1310:14 present?
No
For all other BCM DTCs, GO to the
Body Control Module (BCM) DTC
Chart.
If no DTCs are present, GO to C2 .

C2 CHECK FOR RUN VOLTAGE AT THE BCM
z Ignition OFF. Yes
z Disconnect: BCM C2280B . GO to C4 .
z Ignition ON.
z Measure the voltage between BCM C2280B-29, circuit No
CDC34 (WH/OG), harness side and ground. GO to C3 .

C3 CHECK THE IGNITION RUN CIRCUIT FOR AN OPEN
z Ignition OFF. Yes
z Measure the resistance between BCM C2280B-29, REFER to Ignition Switch in this
circuit CDC34 (WH/OG), harness side and ignition section. CLEAR the DTCs. REPEAT
switch C250-1, circuit CDC34 (WH/OG), harness side. the self-test. TEST the system for
normal operation.
No
REPAIR open circuit CDC34
(WH/OG). TEST the system for normal
operation.

C4 CHECK THE RUN/START RELAY
z Ignition OFF. Yes
z Disconnect: Run/Start Relay . GO to C5 .
z Carry out the appropriate relay component test.
No
Refer to Wiring Diagrams Cell 149 for component INSTALL a new run/start relay.
testing. CLEAR the DTCs. REPEAT the self-
operation.
z Is the relay OK?
C5 CHECK THE VOLTAGE TO THE RUN/START RELAY
COIL
z Measure the voltage between run/start relay cavity 1, Yes
circuit SBB31 (WH/RD) and ground. GO to C6 .
No
VERIFY BJB fuse 31 (15A) is OK. If
OK, REPAIR circuit SBB31 (WH/RD).
If not OK, REFER to the Wiring
Diagrams manual to identify the
possible cause of the circuit short.
operation.

C6 CHECK THE RUN/START RELAY CONTROL CIRCUIT
FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: Run/Start Relay (if not previously GO to C7 .
disconnected) .
z Disconnect: BCM C2280F . No

z Measure the resistance between run/start relay cavity REPAIR circuit CDC55 (BN/VT) for an
2, circuit CDC55 (BN/VT) and BCM C2280F-18, circuit open. CARRY OUT a self-test
CDC55 (BN/VT), harness side. (required to clear certain DTCs).
CORRECT any unresolved DTCs.
CLEAR all DTCs. TEST the system for
normal operation.

C7 CHECK THE RUN/START RELAY CONTROL CIRCUIT
z Measure the resistance between BCM C2280F-18, Yes
circuit CDC55 (BN/VT), harness side and ground. GO to C8 .
No
REPAIR circuit CDC55 (BN/VT) for
short to ground. CARRY OUT a self-
test (required to clear certain DTCs).
CORRECT any unresolved DTCs.
CLEAR all DTCs. TEST the system for
normal operation.

C8 CHECK FOR CORRECT BCM OPERATION
z Check BCM C2280B and C2280F for: Yes
corrosion INSTALL a new BCM . REFER to
damaged pins Section 419-10 . REPEAT the self-
pushed-out pins test.
z Connect: BCM C2280B .
z Connect: BCM C2280F . No
z Connect: Run/Start Relay . The system is operating correctly at
z Make sure the connectors are seated correctly, then this time. The concern may have been
carry out a BCM self-test. caused by a loose or corroded
z Operate the system and verify the concern is still connector. CLEAR the DTCs.
present. REPEAT the self-test. TEST the
z Is the concern still present? system for normal operation.
Pinpoint Test D: No Power in START
Refer to Wiring Diagrams Cell 20 , Starting System for schematic and connector information.
Normal Operation
When the ignition switch is turned to the START position, a voltage signal is sent to the Body Control
Module (BCM) and the PCM. The BCM sends out a voltage signal to various modules to indicate a start
event and the PCM checks various inputs and bus messages in an effort to start the vehicle.

z Ignition switch
PINPOINT TEST D: NO POWER IN START

D1 CHECK THE IGNITION SWITCH
z Ignition OFF. Yes
z Disconnect: Ignition Switch C250 . REINSTALL the ignition
z Carry out the Ignition Switch Component Test. switch and CONNECT the
ignition switch connector
Refer to Wiring Diagrams Cell 149 for component testing. removed during the
component test. GO to D2 .
z Is the ignition switch OK? No
INSTALL a new ignition
switch. REFER to Ignition
Switch in this section. TEST
operation.
D2 CHECK THE START CIRCUIT TO THE BCM FOR VOLTAGE
z Ignition OFF. Yes
z Disconnect: BCM C2280B . GO to D3 .
z Measure the voltage between BCM C2280B-47, circuit CDC35
(BU/WH), harness side and ground, while holding the key in the No
START position. REPAIR circuit CDC35
(BU/WH) for an open. TEST
operation.

D3 CHECK THE START CIRCUIT TO THE PCM FOR VOLTAGE
z Ignition OFF. Yes
z Disconnect: PCM C1551B (3.5L), C175B (3.7L) or C1381B REFER to Section 303-06 to
(5.0L/6.2L) . diagnose the starting system.
z For 3.5L, measure the voltage between PCM C1551B-47, circuit TEST the system for normal
CDC35 (BU/WH), harness side and ground, while holding the operation.
key in the START position.
No
REPAIR circuit CDC35
(BU/WH) for an open. TEST
operation.
z For 3.7L, 5.0L and 6.2L, measure the voltage between PCM
C175B-16 or C1381B-16, circuit CDC35 (BU/WH), harness side
and ground, while holding the key in the START position.
Pinpoint Test E: DTC B1142:29
Normal Operation
Battery voltage is sent to the ignition switch from the Battery Junction Box (BJB) fuse 28 (15A). When placed
in ACC, RUN or START, the ignition switch sends fused battery voltage along 1 of 3 circuits to the Body
Control Module (BCM). Microprocessors in the BCM continuously monitor the ignition switch state.
z DTC B1142:29 (Ignition Status 1: Signal Invalid) — this DTC sets when the BCM does not receive a
valid ignition state signal during the BCM self-test.

z Ignition switch
z BCM
PINPOINT TEST E: DTC B1142:29

E1 CHECK THE IGNITION SWITCH
STATE (IGN_SW_STATE) PID
z Ignition ON. Yes
z Enter the following diagnostic GO to E5 .
mode on the scan tool:
DataLogger — BCM . No
z Monitor the IGN_SW_STATE GO to E2 .
PID while turning the ignition
switch through all 4 positions
(OFF, ACC, RUN and START).
z Does the PID match each
ignition switch position?
E2 CHECK THE ACC CIRCUIT FOR
AN OPEN OR SHORT TO VOLTAGE
z Ignition In ACC. Yes
PID with the ignition switch in
the ACC position. No
z Does the PID display "Acc"? If the PID displays "Off" or "Unknown", REPAIR circuit CDC33
(VT/GN) for an open. CLEAR the DTCs. REPEAT the self-
test. TEST the system for normal operation. If the PID
displays "Run" or "Start", REPAIR circuit CDC34 (WH/OG)
(RUN) or CDC35 (BU/WH) (START) for a short to voltage.
CLEAR the DTCs. REPEAT the self-test. TEST the system for
normal operation.
E3 CHECK THE RUN CIRCUIT FOR
AN OPEN OR SHORT TO VOLTAGE
z Ignition ON. Yes
PID with the ignition switch in
the RUN position. No
z Does the PID display "Run"? If the PID displays "Off" or "Unknown", REPAIR circuit CDC34
(WH/OG) for an open. CLEAR the DTCs. REPEAT the self-
displays "Acc" or "Start", REPAIR circuit CDC33 (VT/GN)
(ACC) or CDC35 (BU/WH) (START) for a short to voltage.
normal operation.
E4 CHECK THE START CIRCUIT
FOR AN OPEN OR SHORT TO
VOLTAGE
z Monitor the IGN_SW_STATE Yes
PID with the ignition switch in GO to E5 .
the START position.
z Does the PID display "Start"? No
If the PID displays "Off" or "Unknown", REPAIR circuit CDC35
(BU/WH) for an open. CLEAR the DTCs. REPEAT the self-
displays "Acc" or "Run", REPAIR circuit CDC33 (VT/GN)
(ACC) or CDC34 (WH/OG) (RUN) for a short to voltage.
normal operation.
E5 CHECK FOR CORRECT BCM
OPERATION
z Disconnect: All BCM Yes
Connectors . INSTALL a new BCM . REFER to Section 419-10 . REPEAT
z Check BCM connectors for: the self-test. TEST the system for normal operation.
corrosion
damaged pins No
pushed-out pins The system is operating correctly at this time. The concern
z Connect: All BCM Connectors . may have been caused by a loose or corroded connector.
z Make sure the connectors are CLEAR the DTCs. REPEAT the self-test. TEST the system for
seated correctly, then carry out normal operation.
a BCM self-test.
z Operate the system and verify
the concern is still present.
Pinpoint Test F: DTC B1310:12
Normal Operation
When the ignition is placed in RUN mode, the Body Control Module (BCM) module provides a ground for the
coil (control) side of the run/start relay located in the Battery Junction Box (BJB). The BCM monitors the
run/start relay control circuit and sets the applicable DTC if the circuit is open, shorted to ground or shorted
to voltage.
z DTC B1310:12 (Run/Start Control: Circuit Short to Battery) — this DTC sets if the BCM detects a
short to battery in the run/start relay control circuit during a BCM self-test or during normal operation.

z Run/start relay
z BCM
PINPOINT TEST F: DTC B1310:12

F1 CHECK THE RUN/START RELAY
z Disconnect: Run/Start Relay . Yes
z Carry out the appropriate relay component test. GO to F2 .
Refer to Wiring Diagrams Cell 149 for component testing. No

INSTALL a new run/start
relay. CARRY OUT a
z Is the relay OK? self-test (required to
clear certain DTCs).
CORRECT any
unresolved DTCs.
CLEAR all DTCs. TEST
operation.
F2 CHECK THE RUN/START RELAY CONTROL CIRCUIT FOR A

SHORT TO VOLTAGE
z Ignition ON. Yes
z Measure and record battery voltage. REPAIR circuit CDC55
(BN/VT) for a short to
voltage. CARRY OUT a
self-test (required to
clear certain DTCs).
CORRECT any
unresolved DTCs.
operation.
No
GO to F3 .
z NOTICE: This pinpoint test step directs testing circuits using a
back-probe method. Use the special back-probe tool specified
in the tool list in this section. Do not force test leads or other
probes into connectors. Adequate care must be exercised to
avoid connector terminal damage while ensuring that good
electrical contact is made with the circuit or terminal. Failure to
follow these instructions may cause damage to wiring,
terminals, or connectors and subsequent electrical faults
z Measure the voltage by backprobing between BCM C2280F-18,
circuit CDC55 (BN/VT), harness side and ground.
z Is the voltage equal to the recorded battery voltage?
F3 CHECK FOR CORRECT BCM OPERATION
z Disconnect: All BCM Connectors . Yes
z Check the connectors for: INSTALL a new BCM .
corrosion REFER to Section 419-
damaged pins 10 . CARRY OUT a self-
pushed-out pins test (required to clear
z Connect: All BCM Connectors . certain DTCs).
z Connect: Run/Start Relay . CORRECT any
z Make sure the connectors are seated correctly, then carry out a unresolved DTCs.
BCM self-test. CLEAR all DTCs. TEST
z Operate the system and verify the concern is still present. the system for normal
z Is the concern still present? operation.
No
corroded connector.
CARRY OUT a self-test
(required to clear certain
DTCs). CORRECT any
unresolved DTCs.
operation.
Pinpoint Test G: The Ignition Key Cannot Be Returned to the OFF/LOCK Position
Refer to Wiring Diagrams Cell 37 , Shift Interlock for schematic and connector information.
Normal Operation
The key removal inhibit solenoid (part of the ignition switch) receives battery voltage from the Body Control
Module (BCM) fuse 28 (15A). When the selector lever is moved out of the PARK position, the park range
switch (part of the selector lever) closes, providing a ground circuit to the key removal inhibit solenoid. The
key removal inhibit solenoid activates and prevents the ignition lock cylinder from being turned to the OFF
position and the key from being removed.

z Key removal inhibit solenoid (part of the ignition switch)
z Ignition lock cylinder
z Brake shift interlock solenoid
z Park range switch (part of the selector lever)
PINPOINT TEST G: THE IGNITION KEY CANNOT BE RETURNED TO THE OFF/LOCK POSITION

G1 CHECK FOR AN ENERGIZED KEY REMOVAL INHIBIT
SOLENOID
z Remove BCM fuse 28 (15A). Yes
z Attempt to turn the ignition lock cylinder to the RUN GO to G3 .
position and then back to the OFF/LOCK position and
remove the key. No
z Can the ignition lock cylinder be turned to the GO to G2 .
OFF/LOCK position and the key removed?
G2 CHECK THE IGNITION SWITCH FOR MECHANICAL
DAMAGE
z Remove the ignition switch. Refer to Ignition Switch in this Yes
section. INSTALL a new ignition switch.
z Attempt to turn the ignition lock cylinder to the OFF/LOCK REFER to Ignition Switch in this
position and remove the ignition key. section. TEST the system for
z Does the ignition lock cylinder turn to the OFF/LOCK normal operation.
position and the key removed?
No
INSTALL a new ignition lock
cylinder. REFER to Section 501-
14 . TEST the system for normal
operation.
G3 CHECK THE KEY REMOVAL INHIBIT SOLENOID
z Select PARK. Yes
z Measure the resistance between ignition switch C250-3, REFER to Ignition Switch in this
circuit CDC41 (WH/BN), harness side and ground. section. TEST the system for
normal operation.
No
Vehicles with column shift, GO to
G4 .
Vehicles with floor shift, GO to G5 .

G4 ISOLATE THE BRAKE SHIFT INTERLOCK SOLENOID
z Disconnect: Brake Shift Interlock Solenoid C2008 . Yes
z Measure the resistance between ignition switch C250-3, INSTALL a new brake shift interlock
circuit CDC41 (WH/BN), harness side and ground. solenoid. REFER to Section 307-
05 . TEST the system for normal
operation.
No
REPAIR circuit CDC41 (WH/BN) for
a short to ground. TEST the system

G5 ISOLATE THE SHORT TO GROUND IN THE KEY
REMOVAL INHIBIT SOLENOID CIRCUIT
z Disconnect: Floor Shifter C3245 . Yes
z Measure the resistance between ignition switch C250-3, GO to G6 .
circuit CDC41 (WH/BN), harness side and ground.
No
a short to ground. TEST the system

G6 CHECK THE PARK DETECT SWITCH
z Measure the resistance between the selector lever Yes
C3245-2, component side and selector lever C3245-5, CHECK the selector lever cable
component side with and without the selector lever in the adjustment. REFER to Section 307-
PARK range and the selector lever button released. 05 . INSPECT the selector lever,
selector lever knob, and selector
lever cable for damage. INSTALL

new components as necessary.
REFER to Section 307-05 . TEST
No
INSTALL a new selector lever.
z Is the resistance greater than 10,000 ohms with the

selector lever in PARK and less than 5 ohms with the
selector lever in REVERSE, NEUTRAL and DRIVE?
Pinpoint Test H: The Ignition Key Can Be Turned to the OFF/LOCK Position When the Selector Lever
is Not In PARK
Normal Operation
The key removal inhibit solenoid (part of the ignition switch) receives battery voltage from Body Control
Module (BCM) fuse 28 (15A). When the selector lever is moved out of the PARK position, the park range
switch (part of the selector lever) closes, providing a ground circuit to the key removal inhibit solenoid. The
key removal inhibit solenoid activates and prevents the ignition lock cylinder from being turned to the
OFF/LOCK position and the key from being removed.

z Key release interlock actuator (part of the ignition switch)
z Park range switch (part of the selector lever)
PINPOINT TEST H: THE IGNITION KEY CAN BE TURNED TO THE OFF/LOCK POSITION WHEN THE
SELECTOR LEVER IS NOT IN PARK

H1 CHECK THE KEY INHIBIT SOLENOID CIRCUIT FOR
GROUND
z Disconnect: Ignition Switch C250 . Yes
z Select DRIVE. INSTALL a new ignition switch.
z Measure the resistance between ignition switch C250-3, REFER to Ignition Switch in this
circuit CDC41 (WH/BN), harness side and ground. section. TEST the system for
normal operation.
No
Vehicles with column shift, GO to
H2 .
Vehicles with floor shift, GO to H3 .

H2 CHECK THE KEY INHIBIT SOLENOID CIRCUIT FOR AN
OPEN (COLUMN SHIFT)
z Disconnect: Brake Shift Interlock Solenoid C2008 . Yes
z Measure the resistance between ignition switch C250-3, INSTALL a new brake shift interlock
circuit CDC41 (WH/BN), harness side and brake shift solenoid. REFER to Section 307-
interlock solenoid C2008-3, circuit CDC41 (WH/BN), 05 . TEST the system for normal
harness side. operation.
No
an open. TEST the system for
normal operation.

H3 CHECK THE KEY INHIBIT SOLENOID CIRCUIT FOR AN
OPEN (FLOOR SHIFT)
z Disconnect: Floor Shifter C3245 . Yes
z Measure the resistance between ignition switch C250-3, GO to H4 .
circuit CDC41 (WH/BN), harness side and floor shifter
C3245-1, circuit CDC41 (WH/BN), harness side. No
normal operation.

H4 CHECK THE FLOOR SHIFTER GROUND CIRCUIT FOR
AN OPEN
z Measure the resistance between floor shifter C3245-5, Yes
circuit GD138 (BK/WH), harness side and ground. GO to H5 .
No
REPAIR circuit GD138 (BK/WH) for
normal operation.

H5 CHECK THE PARK DETECT SWITCH
z Measure the resistance between the selector lever Yes
C3245-2, component side and selector lever C3245-5, CHECK the selector lever cable
component side with and without the selector lever in the adjustment. REFER to Section 307-
PARK range and the selector lever button released. 05 . INSPECT the selector lever,
selector lever knob, and selector
lever cable for damage. INSTALL
No
INSTALL a new selector lever.
z Is the resistance greater than 10,000 ohms with the

selector lever in PARK and less than 5 ohms with the
selector lever in REVERSE, NEUTRAL and DRIVE?
Pinpoint Test I: DTCs C0051:16 And C0051:17
Normal Operation
The Steering Column Control Module (SCCM) continuously monitors the voltage supplied to the steering
wheel rotation sensor (also known as the steering wheel position sensor). If voltage outside of defined limits
is detected by the SCCM , the applicable DTC sets.
z DTC C0051:16 (Steering Wheel Position Sensor: Circuit Voltage Below Threshold) — If the SCCM
detects voltage to the steering wheel rotation sensor below 10 volts this DTC sets.
z DTC C0051:17 (Steering Wheel Position Sensor: Circuit Voltage Above Threshold) — If the SCCM
detects voltage to the steering wheel rotation sensor above 15.5 volts this DTC sets.

z Steering wheel rotation sensor
PINPOINT TEST I: DTCs C0051:16 AND C0051:17

I1 CHECK THE SCCM DTCs
z Review the SCCM DTCs Yes
retrieved and recorded during DIAGNOSE DTCs B119D:16 and B119D:17 before
Inspection and Verification. diagnosing DTCs C0051:16 or C0051:17.
z Is DTC B119D:16 and/or
B119D:17 present? For DTC B119D:16, GO to Pinpoint Test J .
For DTC B119D:17, GO to Pinpoint Test K .
No
GO to I2 .
I2 CHECK THE STEERING WHEEL
ANGLE SENSOR STATUS
(SW_ANG_SENS) PID
z Enter the following diagnostic Yes
mode on the scan tool: The condition that caused the DTC to set is not present at this
DataLogger — SCCM . time. CLEAR the DTCs. DRIVE the vehicle for more than 1
z Monitor the SW_ANG_SENS minute at a speed greater than 32 km/h (20 mph) and make at
PID. least one left turn and one right turn. REPEAT the self-test. If
z Does the PID display the DTC(s) does not return, RETURN the vehicle to the
CORRECT? customer. If the DTC(s) return, GO to I3 .
No
If the PID displays FAULT, INSTALL a new steering wheel
rotation sensor. REFER to Section 206-09 . REPEAT the self-
test. TEST the system for normal operation.
If the PID displays PSCM NOT INITIALIZED, GO to I3 .

I3 CHECK FOR CORRECT SCCM
OPERATION
z Ignition OFF. Yes
z Disconnect: All SCCM INSTALL a new SCCM . REFER to Steering Column Control
Connectors . Module (SCCM) in this section. CLEAR the DTCs. TEST the
z Check the SCCM connectors system for normal operation.
for:
corrosion No
damaged pins The system is operating correctly at this time. Concern may
pushed-out pins have been caused by a loose or corroded connector. CLEAR
z Connect: All SCCM the DTCs. REPEAT the self-test. TEST the system for normal
Connectors . operation.
z Make sure the SCCM
connectors are seated
correctly, then operate the
system and verify the concern
is still present.
Pinpoint Test J: DTC B119D:16
Normal Operation
The Steering Column Control Module (SCCM) continuously monitors input voltage for correct operation. If
voltage outside of defined limits is detected by the SCCM , the applicable DTC sets.
z DTC B119D:16 (Vehicle Battery: Circuit Below Threshold) — This DTC sets in continuous memory if
the SCCM detects battery voltage below 8 volts on the battery voltage supply circuit.

z Fuses
z Charging system
z Vehicle battery
z SCCM
NOTE: DTC B119D:16 can set if the vehicle battery has been discharged. The vehicle battery may become
discharged due to excessive load(s) on the charging system from aftermarket accessories or if the battery
has been left unattended with the accessories on.
PINPOINT TEST J: DTC B119D:16

J1 VERIFY THE SCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan GO to J2 .
tool: Self Test — SCCM .
z Clear the DTCs and repeat the self-test. No
z Is DTC B119D:16 still present? The system is operating normally at this
time. The DTC may have been set
previously during battery charging or while
jump starting the vehicle. CLEAR the
J2 CHECK FOR CHARGING SYSTEM DTCs IN THE
PCM
z Enter the following diagnostic mode on the scan Yes
tool: Self Test — PCM . REFER to Section 414-00 to diagnose the
z Retrieve and record all continuous memory DTCs charging system DTCs.
from the PCM.
z Are any charging system DTCs present in the No
PCM? GO to J3 .
J3 CHECK THE BATTERY CONDITION AND STATE
OF CHARGE
z Ignition OFF. Yes
z Refer to Section 414-01 and carry out pinpoint test GO to J4 .

A: Battery Condition Test.
z Is the battery OK and fully charged? No
REFER to Section 414-00 to diagnose the
charging system.
J4 CHECK THE SCCM VOLTAGE SUPPLY
z Measure and record battery voltage. Yes
GO to J5 .
No
VERIFY BCM fuses 23 (15A) and 24
(15A) are OK. If OK, REPAIR the affected
circuit(s). If not OK, REFER to the Wiring
Diagrams manual to identify the possible
causes of the circuit short. CLEAR the
z Disconnect: SCCM C2414A .

z Disconnect: SCCM C2414B .
SCCM C2414A-10, SBP23 (WH/RD),
harness side.
SCCM C2414B-8, SBP24 (VT/RD), harness
side.
z Are the voltages within 0.2 volt of the recorded

battery voltage?
J5 CHECK THE SCCM GROUND CIRCUIT
z Disconnect the battery negative cable. Refer to Yes
Section 414-01 . CONNECT the battery negative cable. GO
z Measure the resistance between ground and: to J6 .
SCCM C2414A-13, GD133 (BK), harness
side. No
SCCM C2414B-5, GD138 (BK/WH), harness REPAIR the affected circuit(s). CONNECT
side. the negative battery cable. CLEAR the

J6 CHECK FOR CORRECT SCCM OPERATION
z Disconnect: All SCCM Connectors . Yes
z Check the SCCM connectors for: INSTALL a new SCCM . REFER to
corrosion Steering Column Control Module (SCCM)
damaged pins in this section. CLEAR the DTCs.
pushed-out pins REPEAT the self-test. TEST the system
z Connect: All SCCM Connectors . for normal operation.
z Make sure the SCCM connectors are seated
correctly, then operate the system and verify the No
concern is still present. The system is operating correctly at this
z Is the concern still present? time. Concern may have been caused by
a loose or corroded connector. CLEAR the
Pinpoint Test K: DTC B119D:17
Normal Operation
The Steering Column Control Module (SCCM) continuously monitors input voltage for correct operation. If
voltage outside of defined limits is detected by the SCCM , the applicable DTC sets.
z DTC B119D:17 (Vehicle Battery: Circuit Above Threshold) — This DTC sets in continuous memory if
the SCCM detects battery voltage above 19 volts on the battery voltage supply circuit.

z Charging system
z SCCM
NOTE: DTC B119D:17 can set if the vehicle has been recently jump started or the vehicle battery has been
recently charged.
PINPOINT TEST K: DTC B119D:17

K1 CHECK FOR HIGH BATTERY
VOLTAGE AND/OR CHARGING SYSTEM
DTC IN OTHER MODULES
z Ignition ON. Yes
z Enter the following diagnostic mode REFER to Section 414-00 to diagnose an overcharging
on the scan tool: Self Test — All condition.
CMDTCs .
z Retrieve and recorded all CMDTCs No
from all modules. GO to K2 .
z Are any high battery voltage
and/or charging system DTCs
present in other modules?
K2 CHECK THE BATTERY VOLTAGE
z Turn off all interior/exterior lights and Yes
accessories. REFER to Section 414-00 to diagnose an overcharging
z Start and run the engine at condition.
approximately 2,000 rpm for 3
minutes while monitoring the battery No
voltage. GO to K3 .
z Does the battery voltage rise to
16.5 volts or higher?
K3 RECHECK FOR SCCM DTC
B119D:17
z Turn the engine off. Yes
z Ignition ON. GO to K4 .
on the scan tool: Self Test — No
SCCM . The system is operating normally at this time. The DTC
z Clear the continuous memory DTCs may have been set previously during battery charging or
and repeat the self-test. while jump starting the vehicle. CLEAR the DTCs.
z Is DTC B119D:17 present in the REPEAT the self-test. TEST the system for normal
SCCM ? operation.
K4 CHECK FOR CORRECT SCCM
OPERATION
z Ignition OFF. Yes
z Disconnect: All SCCM Connectors . INSTALL a new SCCM . REFER to Steering Column
z Check the SCCM connectors for: Control Module (SCCM) in this section. CLEAR the
corrosion DTCs. REPEAT the self-test. TEST the system for
damaged pins normal operation.
pushed-out pins
z Connect: All SCCM Connectors . No
z Make sure the SCCM connectors are The system is operating correctly at this time. Concern
seated correctly, then operate the may have been caused by a loose or corroded
system and verify the concern is still connector. CLEAR the DTCs. REPEAT the self-test.
present. TEST the system for normal operation.
Component Tests
Ignition Switch — Mechanical
The following conditions can cause difficulty in operating the ignition switch and lock cylinder:
z Burrs on the lock cylinder key

z Insufficient lube on the lock cylinder
z Binding lock cylinder
z Burrs or foreign material around the rack and pinion actuator in the lock cylinder housing
z Insufficient lube on the actuator (Do not apply lubricant to the inside of the ignition switch.)
z Binding ignition switch
If the steering wheel lock is engaged with the wheels loaded against a curb, high effort is necessary to turn
the key from lock. Turn the steering wheel to either side of the lock to unload the system.
Carry out the following test to determine if the ignition switch and lock cylinder are operating correctly.
1. Inspect the ignition key for any burrs, damage or incorrect cut. Replace the ignition key as necessary.
2. NOTE: The steering wheel may be locked full left or full right. If the steering wheel is locked, it is
necessary to apply turning effort to the steering wheel in the direction of the lock while turning the
key.
Turn the key to the ACC position and then the RUN position.
z If the ignition key turns to the ACC and RUN position, continue with Step 3.
z If the ignition key does not turn to the ACC and RUN position, continue with Step 4.
3. NOTE: The ignition switch and lock cylinder should return from the START position back to the RUN
position without assistance.
Turn the ignition key to the START position and release the key.
z If the ignition switch and lock cylinder return from the START position back to the RUN position
without assistance, the ignition switch is operating correctly at this time.
z If the ignition switch and lock cylinder do not return from the START position back to the RUN
position without assistance, continue with Step 4.
4. Remove the ignition lock cylinder. Refer to Section 501-14 .
5. Rotate the ignition lock cylinder through all of the switch positions.
z If the lock cylinder operates correctly, continue with Step 6.
z If the lock cylinder does not operate correctly, install a new ignition lock cylinder. Refer to
Section 501-14 .
6. Check for binding or sticking ignition switch actuating rod, burrs around the rack-and-pinion actuator
in the ignition lock cylinder housing or insufficient lubrication.
z If there is sufficient lubrication and there are no burrs, binding or sticking conditions, install a
new ignition switch. Refer to Ignition Switch in this section.
z If there is insufficient lubrication, burrs, binding or sticking conditions, repair or lubricate as
necessary.

Ignition Switch
NOTE: Manual column shown, power column similar.

2 11572 Ignition switch
Manual and Power Columns
2. Disconnect the ignition switch electrical connector.
Manual Columns
3. Place the steering column tilt lever in the unlocked position.
Manual and Power Columns
4. Press the 2 locking tabs and remove the ignition switch.

Part
2 W715057 SCCM bolts (3 required)
3 3F791 SCCM
1. Remove the steering wheel rotation sensor. For additional information, refer to Section 206-09 .
2. Disconnect the 3 Steering Column Control Module (SCCM) electrical connectors.
3. Remove the 3 screws and the SCCM .


Steering Column Control Switch
1. NOTE: The steering column control switch and the brake pedal control switch are serviced as an
assembly.
For additional information, refer to Brake Pedal Control Switch in Section 206-06 .

Steering Column Multifunction Switch
NOTE: Steering wheel removed for clarity.

1 W705132 Multifunction switch screws (2 required)
2 13K359 Multifunction switch
2. If equipped, remove the steering column control switch. For additional information, refer to Steering
Column Control Switch in this section.
3. Turn the steering wheel 90 degrees to the left and remove the 2 screws and the multifunction switch.

Steering Wheel Switch
High Series
NOTE: RH shown, LH similar
Part
1 3600 Steering wheel
2 — Steering wheel control switch bezel (part of 3600)
3 9C888 RH steering wheel switch
4 — Steering wheel switch screw (2 required) (part of
3600)
5 — Steering wheel controls electrical connector (part of
3600)
Low Series
NOTE: RH shown, LH similar

1 9C888 RH steering wheel switch
2 — Electrical connector (part of 3600)
High and Low Series
1. Remove the driver air bag module. For additional information, refer to Section 501-20B .
Low Series
2. Using a suitable flat-bladed tool, detach the steering wheel switch from the steering wheel.
z Disconnect the electrical connector and remove the switch.
High Series
3. Remove the steering wheel switch bezel.

z Disconnect the steering wheel switch electrical connector.
4. Remove the 2 screws and the steering wheel switch.
High and Low Series
SECTION 303-00: Engine System — General Information 2014 F-150 Workshop Manual
Material
Capacity
Dye-Lite® Gasoline Engine Oil — —
Leak Detection Dye
164-R3700 (Rotunda)
High Temperature Retaining WSK- —
Compound M2G349-A9
Loctite® 620™/Permatex® 62050,
or equivalent; obtain locally
Motorcraft® SAE 5W-20 Premium WSS- —
Synthetic Blend Motor Oil (US); M2C930-A
Motorcraft® SAE 5W-20 Super
Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-
LSP12 (Canada); or equivalent
Threadlock 262 WSK- —
TA-26 M2G351-A6
Engine
NOTICE: When repairing engines, all parts must be contamination free. If contamination/foreign
material is present when repairing an engine, premature engine failure may occur.
NOTE: Specifications show the expected minimum or maximum condition. Refer to the appropriate section
NOTE: If a component fails to meet the specifications, it is necessary to refinish it or install a new
component. Wear limits are provided as an aid to determine if the component can be refinished. A new
component must be installed when any component fails to meet specifications and cannot be refinished.
NOTE: This section contains information, steps and procedures that may not be specific to this engine.
This section covers general procedures and diagnosis and testing of the engine system, except for exhaust
emission control devices, which are covered in the Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
The engine incorporates the following features: Refer to the appropriate section in Group 303 for the
procedure.
z Crankcase ventilation or breather system

z Exhaust emission control system
z Evaporative Emission (EVAP) control system
Some engines incorporate a fail-safe cooling system. Refer to the appropriate section in Group 303 for the
procedure.
The engine, fuel system, ignition system, emissions system and exhaust system all affect exhaust emission
levels and must be maintained according to the maintenance schedule. Refer to the scheduled Maintenance
Guide.
Correct engine identification is required to order parts. Refer to the appropriate section in Group 303 for the
procedure.
For complete vehicle and engine identification codes, refer to Section 100-01 .
Engine
Special Tool(s)
Fixture
100-002 (TOOL-4201-C) or
equivalent
EngineEAR
EngineEAR/ChassisEAR
Oil Pressure Gauge

303-088 (T73L-6600-A)
Vacuum/Pressure Tester

System (IDS)
Material
Item Specification
Dye-Lite® Gasoline Engine Oil Leak —
Detection Dye
164-R3700 (Rotunda)
Motorcraft® SAE 5W-20 Premium WSS-
LSP12 (Canada)
There are 2 diagnostic paths that can be followed depending on the type of engine concern. Carry out
Inspection and Verification — Engine Performance or Inspection and Verification — Engine NVH.
Inspection and Verification — Engine Performance
1. Verify the customer concern by operating the engine to duplicate the condition.
2. Visually inspect for obvious signs of mechanical damage. Refer to the following chart.

Mechanical
z Engine coolant leaks
z Engine oil leaks
z Fuel leaks
z Damaged or severely worn parts
z Loose mounting bolts, studs and nuts
3. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.



418-00 .
(CMDTCs).
8. Clear the CMDTCs and carry out the self-test diagnostics for the PCM.
9. If the DTCs retrieved are related to the concern, refer to Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Engine Performance .
Inspection and Verification — Engine NVH
1. Engine NVH symptoms should be identified using the diagnostic tools and techniques that are
available. For a list of these techniques, tools, an explanation of their uses and a glossary of common
terms, refer to Section 100-04 .
2. Verify the customer concern by operating the engine to duplicate the condition.
3. Inspect the engine for installation of an aftermarket oil filter. Review oil and filter maintenance history
to make sure that the vehicle has not gone beyond the standard Ford recommended oil change
interval.
4. Check the engine oil level and check the oil for contamination. Low engine oil level or contaminated
oil are common causes of engine noise. If the oil is contaminated, the source of the contamination
must be identified and repaired as necessary.

Mechanical
z Loose mounting bolts, studs and nuts
z Damaged or leaking powertrain mounts
z Damaged or disconnected vacuum hoses
z Damaged or disconnected air intake components
z Obstruction of cooling fan
z Obstruction of Front End Accessory Drive (FEAD)
6. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.



418-00 .
12. If the DTCs retrieved are related to the concern, refer to Section 419-10 .
13. If no DTCs related to the concern are retrieved, continue the inspection and verification if a noise
concern is related to the engine. For vibration concerns and noise concerns such as powertrain
mounts, air intake system and starter GO to Symptom Chart - Engine NVH .
In some cases, a noise may be a normal characteristic of that engine type. In other cases the noise may
require further investigation. Comparing the noise to a similar year/model vehicle equipped with the same
engine will aid in determining if the noise is normal or abnormal.
Once a customer concern has been identified as an abnormal engine noise, it is critical to determine the
location of the specific noise. Use the EngineEAR/ChassisEAR or stethoscope (the noise will always be
louder closer to the noise source) to isolate the location of the noise to one of the following areas.
z Upper end of engine

z Lower end of engine
z Front of engine
z Rear of engine
Upper end engine noise
Common sources of upper end engine noise (ticking, knocking or rattle) include the fuel injectors, camshaft
phaser sprocket(s), camshaft(s) and valve train. Upper end engine noise can be determined using the
EngineEAR/ChassisEAR or stethoscope on the valve cover bolts. If the noise is loudest from the valve cover
bolts, then the noise is upper end. The EngineEAR/ChassisEAR or stethoscope can be used to further
isolate the noise to the specific cylinder bank and cylinder. Removal of the valve covers will be required to
pinpoint the source of the noise.
z Fuel Injector Noise

A common source of an engine ticking noise can be related to the fuel injector(s). This is
normal engine noise that can be verified by listening to another vehicle. If the injector noise is
excessive or irregular, use the EngineEAR/ChassisEAR or stethoscope to isolate the noise to
a specific fuel injector.
z Valve Train
Lash adjusters/valve tappets can make an engine ticking or tapping noise noticeable at any
engine rpm or temperature and is audible through the wheel well or an open hood. However,
with the hood down, lash adjuster/valve tappet noise can be heard as a light tapping noise
through the wheel well and is considered normal. The EngineEAR/ChassisEAR or stethoscope
can be used to further isolate the noise to the specific cylinder bank and cylinder, some
disassembly of the engine may be required to inspect for damage or wear.
Lower end engine noise
A common source of lower end engine noise (ticking or knocking) include the crankshaft, connecting rod(s)
and bearings. Lower end noises can be determined by using the oil pan or cylinder block lug bosses. If the
noise is loudest from these areas then the noise is lower end. If an engine noise is isolated to the lower end,
some disassembly of the engine may be required to inspect for damage or wear.
Front of engine noise
A common source of noise from the front of the engine (squeal, chirp, whine or hoot) is the Front End
Accessory Drive (FEAD) components. To isolate FEAD noise, carry out the Engine Accessory Test, refer to
Section 100-04 .
Some other noises from the front of the engine (ticking, tapping or rattle) may be internal to the engine. Use
the EngineEAR/ChassisEAR or stethoscope on the engine front cover to determine if the noise is internal to
the engine. Removal of the engine front cover may be necessary to inspect internal engine components.
Rear of engine noise
A common source of noise from the rear of the engine (knocking) is the flywheel/flexplate. Inspection of the
flywheel/flexplate will be necessary.
14. After the noise is localized, note the characteristics of the noise, including type of noise, frequency
and conditions when the noise occurs and GO to Symptom Chart - Engine NVH .
Symptom Chart — Engine Performance
Symptom Chart — Engine Performance

z Difficult z Inoperative or z INSPECT the starting system for
starting damaged ignition damage. INSTALL new components
system as necessary. Refer to the
z Air or vacuum leak appropriate section in Group 303 for
z Inoperative or the procedure. REFER to the
damaged fuel Powertrain Control/Emissions
system Diagnosis (PC/ED) manual.
z Inoperative or
damaged starting
system
z Damaged charging z REFER to Section 414-00 .
system/battery
z Low oil pressure z CARRY OUT the oil pressure test.
z Burnt valve z INSPECT the valve(s) and valve seat
(s) for damage. INSTALL new
the appropriate section in Group 303
for the procedure.
z Worn piston z INSPECT the piston(s) for damage.
INSTALL new components as
procedure.
z Worn piston rings z INSPECT the piston ring(s) for
damage. INSTALL new components
as necessary. Refer to the
appropriate section in Group 303 for
the procedure.
z Worn cylinder z INSPECT the cylinder block for

the procedure.
z Damaged head z INSPECT the cylinder head gasket(s)
gasket for damage. INSTALL new
for the procedure.
z Damaged cooling z INSPECT the cooling system for
system damage. INSTALL new components
the procedure.
z Poor idling z Vacuum leaks z Refer to the appropriate section in
z Malfunctioning or Group 303 for the procedure. REFER
damaged ignition to the Vehicle Communication
system Module (VCM) and Integrated
z Malfunctioning or Diagnostic System (IDS) software
damaged fuel with appropriate hardware, or
system equivalent scan tool.
z Damaged hydraulic z INSPECT the hydraulic lash adjuster
lash adjuster — 5.0L (s) for damage. INSTALL new
(4V) engine only components as necessary. Refer to
for the procedure.
z Damaged rocker z INSPECT the rocker arm ahsft
arm and/or shaft — assemblies for damage. INSTALL
6.2L (2V) engine new components as necessary. Refer
only to the appropriate section in Group
z Incorrect valve-to- z INSPECT the valve(s) and cylinder
seat contact head(s) for damage. INSTALL new
for the procedure.
gasket for damage. INSTALL new
for the procedure.
z Worn or damaged z INSPECT the engine support bracket
engine support (s) for damage. INSTALL new
bracket(s) components as necessary. Refer to
for the procedure.
z Worn or damaged z INSPECT the engine support
engine support insulator(s) for damage. INSTALL
insulator(s) new components as necessary. Refer
to the appropriate section in Group
z Worn or damaged z INSPECT the transmission insulator
transmission and retainer for damage. INSTALL
insulator and new components as necessary. Refer

retainer to the appropriate section in Group
z Abnormal z Inoperative or z INSPECT each system for damage.
combustion damaged fuel INSTALL new components as
system necessary. Refer to the appropriate
z Air or vacuum leaks section in Group 303 for the
z EGR system fault procedure. REFER to the Powertrain
z Inoperative or Control/Emissions Diagnosis (PC/ED)
damaged cooling manual.
system (if equipped,
fail-safe cooling
invoked)
z Inoperative or
damaged ignition
system
z Malfunctioning or z INSPECT the air intake system for
damaged air intake damage. INSTALL new components
system as necessary. Refer to the
the procedure.
z Damaged hydraulic z INSPECT the hydraulic lash adjuster
lash adjuster(s) — (s) for damage. INSTALL new
5.0L (4V) engine components as necessary. Refer to
only the appropriate section in Group 303
for the procedure.
z Damaged rocker z INSPECT the rocker arm(s) for
arm(s) — 6.2L (2V) damage. INSTALL new components
engine only as necessary. Refer to the
the procedure.
z Burnt or sticking z INSPECT the valve(s) and valve seat
valve (s) for damage. INSTALL new
for the procedure.
z Weak or broken z INSPECT the valve spring(s) for
valve spring damage. INSTALL new components
the procedure.
z Carbon z ELIMINATE carbon buildup.
accumulation in
combustion
chamber
z Excessive oil z Leaking oil z REPAIR oil leakage.
consumption
z Malfunctioning PCV z INSPECT the PCV system for
system damage. Refer to the appropriate
procedure. REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED)
manual.
z Worn valve stem z INSPECT the valve(s) and valve stem
seal seal(s) for damage. INSTALL new

for the procedure.
z Worn valve stem or z INSPECT the valve(s) and cylinder
valve guide head(s) for damage. INSTALL new
for the procedure.
z Sticking piston rings z INSPECT the piston(s) and cylinder
block for damage. INSTALL new
for the procedure.
z Worn piston ring z INSPECT the piston(s) for damage.
groove INSTALL new components as
procedure.
z Worn piston or z INSPECT the piston(s) and cylinder
cylinder block for damage. INSTALL new
for the procedure.
z Insufficient z Inoperative or z REFER to the Powertrain
power damaged ignition Control/Emissions Diagnosis (PC/ED)
system manual.
z Air intake system
blockage
z Lubrication system
blockage
z Inoperative or
damaged fuel
system
z Oil level too high z DRAIN oil to correct level.
z Incorrect engine oil z INSTALL correct specification engine
oil.
z Excessive z INSPECT the accessory drive system
accessory drive belt for damage. INSTALL new
loading components as necessary. Refer to
for the procedure.
z Inoperative or z INSPECT the cooling system for
damaged cooling damage. INSTALL new components
system (if equipped, as necessary. Refer to the
fail-safe cooling appropriate section in Group 303 for
invoked) the procedure.
z Damaged or z INSPECT the exhaust system for flow
plugged exhaust and damage. INSTALL new
system components as necessary. REFER to
Section 309-00 .
z Incorrect tire size z REFER to Section 204-00 .
z Dragging brakes z REFER to Section 206-00 .
z Slipping z Refer to the appropriate section in

transmission Group 307 for the procedure.
z Incorrect valve z ADJUST valve clearance. Refer to
clearance — 3.5L the appropriate section in Group 303
GTDI and 3.7L for the procedure.. TEST the system
engines only for normal operation after the repair.
z Worn or damaged z INSTALL a new valve tappet. TEST
valve tappet — 3.5L the system for normal operation after
GTDI and 3.7L the repair.
engines only
z Malfunctioning z INSPECT the hydraulic lash adjuster
hydraulic lash for wear or damage. INSTALL new
adjuster — 5.0L components as necessary. Refer to
(2V) engine only the appropriate section in Group 303
for the procedure.
z Damaged rocker z INSPECT the rocker arm ahsft
arm and/or shaft — assemblies for damage. INSTALL
6.2L (2V) engine new components as necessary. Refer
only to the appropriate section in Group
z Compression z INSPECT the valve, valve seat and
leakage at valve cylinder head for damage. INSTALL
seat new components as necessary. Refer
z Seized valve stem z INSPECT the valve for wear or
the procedure.
z Damaged valve z INSTALL a new cylinder head
guide assembly. TEST the system for
z Compression normal operation after the repair.
leakage at valve
seat
z Seized valve stem
z Weak or broken z INSPECT the valve spring. INSTALL
valve spring new components as necessary. Refer
z Worn or damaged z INSPECT the camshaft for wear or
camshaft damage. INSTALL new components
the procedure.
gasket(s) for damage. INSTALL new
for the procedure.
z Cracked or distorted z INSPECT the cylinder head(s) for
cylinder head(s) damage. INSTALL new components
the procedure.
z Damaged, worn or z INSPECT the piston ring(s) for

sticking piston ring damage. INSTALL new components
(s) as necessary. Refer to the
the procedure.
z Worn or damaged z INSPECT the piston for damage.
piston INSTALL new components as
procedure.
z Oil in coolant z Leaking head z INSTALL a new head gasket. Refer
gasket to the appropriate section in Group
z Leaking oil cooler z INSPECT the oil filter adapter and
seal for damage. INSTALL new
for the procedure.
z Leaking oil filter z INSPECT the oil filter adapter and
adapter gasket for damage. INSTALL new
for the procedure.
z Damaged cylinder z INSPECT the engine components for
head damage. INSTALL new components
the procedure.
z Damaged cylinder z INSPECT the engine components for
block damage. INSTALL new components
the procedure.
z Oil in coolant z Leaking head z INSPECT the engine components.
gasket INSTALL new engine components as
z Damaged cylinder necessary. Refer to the appropriate
block section in Group 303 for the
z Damaged cylinder procedure. TEST the system for
head normal operation after the repair.
z Coolant in oil z Leaking head z INSPECT the engine components for
gasket damage. INSTALL new components
z Leaking oil cooler (if as necessary. Refer to the
equipped) appropriate section in Group 303 for
z Leaking oil filter the procedure.
adapter
z Damaged cylinder
head
z Damaged cylinder
block
Symptom Chart — Engine NVH
Symptom Chart — Engine NVH
refer to Section 100-04 . Since it is possible that any one of multiple systems may be the
cause of the symptom, it may be necessary to use a process of elimination type of
diagnostic approach to pinpoint the responsible system. If this is not the causal system
for the symptom, refer back to Section 100-04 for the next likely system and continue
diagnosis.
z Drone type noise z Powertrain mount(s) z CARRY OUT the
Powertrain/Drivetrain Mount
Neutralizing procedure in this
section.
z Drumming noise — z Engine vibration z CARRY OUT the
occurs inside the excites the body Powertrain/Drivetrain Mount
vehicle during idle resonances Neutralizing procedure in this
or high idle, hot or inducing interior section.
cold. Very low- noise
frequency drumming
is very rpm
dependent
z Engine drumming z Powertrain mount(s) z CARRY OUT the
noise — Powertrain/Drivetrain Mount
accompanied by Neutralizing procedure in this
vibration section.
z Rattle — occurs at z Powertrain mount(s) z CHECK the powertrain mounts
idle or at light for damage. INSTALL new
acceleration from a mounts as necessary. For
stop engine, Refer to the
303 for the procedure. For
automatic transmission, Refer
to the appropriate section in
z Whine/moan type z Powertrain mount(s) z CHECK the powertrain mounts
noise — pitch for damage. INSTALL new
increases or mounts as necessary. For
changes with engine, Refer to the
vehicle speed appropriate section in Group
z Clunk — occurs z Powertrain mounts z CHECK the
when shifting from powertrain/drivetrain mounts
PARK or between for damage. INSTALL new
REVERSE and mounts as necessary. For
DRIVE engine, Refer to the
z Idle speed is too z CHECK for the correct idle
high speed.
z Accessory drive z Accessory drive z CARRY OUT the engine cold

bearing hoot — idler or tensioner soak procedure. REFER to
occurs at idle or pulley bearing is Section 100-04 .
high idle in cold experiencing z PLACE the EngineEAR probe
temperatures of stick/slip between directly on the idler/tensioner
approximately +4°C ball bearings and center post or bolt to verify
(+40°F) or colder at the bearing race which bearing is making the
the first start of the noise. INSTALL new parts as
day necessary. Refer to the
z Accessory drive belt z Defective/worn or z CARRY OUT the Engine
noise, squeal or incorrect accessory Accessory Test. REFER to
chirping drive belt Section 100-04 . INSPECT
z Misaligned pulley(s) components and INSTALL new
z Pulley runout parts as necessary. Refer to
z Damaged or worn the appropriate section in
accessory drive Group 303 for the procedure.
component or idler
z Fluid contamination
of the accessory
drive belt or pulleys
z Damaged or worn
accessory drive belt
tensioner
z Damaged pulley
grooves
z Clunking noise z Coolant pump has z CHECK the coolant pump for
excessive end play excessive end play. INSPECT
or imbalance the coolant pump for imbalance
with the drive belt off. INSTALL
a new coolant pump as
z Whine or moaning z Air intake system z CHECK the air cleaner and
noise ducts for correct fit. INSPECT
the air intake system for leaks
or damage. REPAIR as
necessary.Refer to the
z Whistling noise — z Air intake system z CHECK the air intake ducts, Air
normally Cleaner (ACL), Throttle Body
accompanied with (TB) and vacuum hoses for
poor idle condition leaks and correct fit. REPAIR
or ADJUST as necessary.Refer
z Hissing noise — z Vacuum leak noise z USE the EngineEAR to locate
occurs during idle or the source. SCAN the air intake
high idle that is system from the inlet to each
apparent with the cylinder intake port. DISCARD
hood open the leaking parts, and INSTALL
a new component.
z Vehicles with a z Acceptable condition. Some
plastic intake plastic manifolds exhibit this

manifold noise, which is the effect of the
plastic manifold.
z Grinding noise — z Incorrect starter z INSPECT the starter motor for
occurs during motor mounting correct mounting. REPAIR as
engine cranking necessary. Refer to the
z Starter motor z CHECK the starter motor.
INSTALL a new starter motor
z Incorrect starter z INSPECT the starter motor
motor drive drive for wear or damage.
engagement INSTALL a new starter motor
z INSPECT the flywheel/flexplate
for wear or damage. INSTALL
a new flywheel/flexplate as
z Engine noise, front z Damaged or z CHECK for obvious signs of
of engine — separated damage or wobble during
knocking noise from crankshaft operation. INSTALL new as
lower front of engine pulley/damper necessary. Refer to the
z Engine noise, front z Timing drive z REMOVE the accessory drive
of engine — ticking, components belt. Refer to the appropriate
tapping or rattling section in Group 303 for the
noise from the front procedure.
of the engine z USE the EngineEAR to isolate
the noise to the engine front
cover.
z REMOVE the engine front
cover and INSPECT the timing
drive components. INSTALL
new parts as necessary. Refer
z Engine noise, upper z Fuel rail clip z CHECK for loose or damaged
end — ticking noise fuel rail clip(s). REPAIR as
near the fuel rail and necessary. Refer to the
intake manifold appropriate section in Group
z Fuel injector z USE the EngineEAR to isolate
the noisy injector(s). INSTALL
new injector(s) as necessary.
z Engine noise, upper z Valve train noise z CARRY OUT the Valve Train
end — ticking, (bled down Analysis Component Test in

knocking or rattle lifter/lash this section. INSTALL new
noise that occurs adjuster/valve parts as necessary. Refer to
during idle or high tappet) the appropriate section in
idle during the first Group 303 for the procedure.
cold start of the day
and may disappear
as the engine
warms
z Engine noise, upper z Worn or damaged z REMOVE the spark plugs.
end — occurs spark plugs INSPECT and INSTALL new
mostly with a warm as necessary. Refer to the
engine at appropriate section in Group
light/medium 303 for the procedure.
acceleration
z Carbon z INSPECT the cylinder using a
accumulation in Bore scope. ELIMINATE
combustion carbon buildup.
chamber
z Engine noise, upper z Low oil level z CHECK the oil level. FILL as
end — rattling noise necessary.
from the valve train.
Worse when the
engine is cold
z Worn valve train z CARRY OUT the Valve Train
components Analysis Component Test in
this section. INSTALL new
parts as necessary. Refer to
the appropriate section in
z Worn valve guides z CARRY OUT the Valve Guide
Inner Diameter procedure in
this section.
z Excessive runout of z CARRY OUT the Valve Seat
the valve seats on Inspection procedure in this
the valve face section.
z Engine noise, upper z Gasoline octane too z VERIFY with customer the type
end — pinging noise low of gasoline used. CORRECT
as necessary.
z Knock Sensor (KS) z CHECK the KS . INSTALL a
operation new KS as necessary. Refer to
the appropriate section in
z Incorrect spark z REFER to the Powertrain
timing Control/Emissions Diagnosis
(PC/ED) manual.
z High operating z INSPECT the cooling system
temperature for leaks. CHECK the coolant
level. REFILL as necessary.
CHECK the coolant for the
correct mix ratio. DRAIN and
REFILL as needed. VERIFY
the engine operating
temperature is within
specifications. REPAIR as

z Spark plug z CHECK the spark plugs.
spark plugs as necessary.
z Catalytic converter z Acceptable noise.
z Engine noise, upper z Low oil level z CHECK the oil level. FILL as
end — knocking or necessary.
ticking noise, occurs
mostly with a warm
engine at idle
z Thin or diluted oil z INSPECT the oil for
contamination. If the oil is
contaminated, CHECK for the
source. REPAIR as necessary.
CHANGE the oil and filter.
z Damaged or z INSPECT the oil filter.
incorrect oil filter INSTALL a new oil filter as
necessary.
z Low oil pressure z CARRY OUT the oil pressure
test.
z Engine noise, lower z Oil pump z USE the EngineEAR to verify
end — ticking or the oil pump as the source of
knocking noise near the noise at low rpm. REPAIR
the oil filter adapter as necessary. Refer to the
z Engine noise, lower z Excessive z CARRY OUT the Piston To
end — light clearance between Cylinder Bore Clearance
knocking noise, also the piston and the procedure in this section.
described as piston cylinder wall
slap. Noise is most
noticeable when the
engine is cold with
light to medium
acceleration. The
noise disappears as
the engine warms
z Engine noise, lower z Excessive z CARRY OUT the Piston Pin
end — light double clearance between Bore Diameter procedure and
knock or sharp rap the piston and the the Piston Pin Diameter
sound. Occurs piston pin procedure in this section.
mostly with a warm
engine at idle or low
speeds in drive.
Increases in relation
to engine load.
Associated with a
poor lubrication
history
z Excessive z CARRY OUT the Connecting
clearance between Rod Bushing Diameter

the piston pin and procedure and the Piston Pin
the connecting rod Diameter procedure in this
bore section.
z Engine noise, lower z Excessive z CARRY OUT the Connecting
end — light clearance between Rod Bearing Journal-to-
knocking noise. The the connecting rod Bearing Clearance procedure
noise is most bearings and the in this section.
noticeable when the crankshaft
engine is warm. The
noise tends to
decrease when the
vehicle is coasting
or in NEUTRAL
z Engine noise, lower z Worn or damaged z CARRY OUT the Crankshaft
end — deep crankshaft main Main Bearing Journal-to-
knocking noise. The bearings Bearing Clearance procedure
noise is most in this section.
noticeable when the
engine is warm, at
lower rpm and
under a light load
and then at float
z Engine noise, rear z Damaged z CARRY OUT the Flexplate
of engine — flywheel/flexplate Inspection procedure in this
knocking noise at section.
rear of engine
z Engine vibration — z Excessive z CARRY OUT the Engine
vibration felt at all crankshaft pulley Accessory Test. INSTALL a
times runout new crankshaft pulley as
z Damaged or worn z CARRY OUT the Engine
accessory Accessory Test. REPAIR or
component INSTALL a new component as
necessary.
z Engine vibration — z Cylinder misfire z Using the scan tool, CARRY
at idle, a low- OUT the cylinder power
frequency vibration balance and the relative
(5-20 Hz) or mild compression test. REPAIR as
shake that is felt necessary. Refer to the
through the appropriate section in Group
seat/floorpan 303 for the procedure.
z Engine or torque z VERIFY the torque converter to
converter out of crankshaft pilot clearance is
balance correct. REPAIR as necessary.
RE-INDEX the torque converter
on the flexplate by 120 degrees
for a 3-bolt converter or 180
degrees for a 4-bolt converter.
z Engine vibration — z Powertrain mount(s) z CHECK the powertrain mounts
is felt with increases for damage. INSTALL new
and decreases in mounts as necessary. For

engine rpm engine, Refer to the
z Engine or z INSPECT the
transmission powertrain/drivetrain for correct
contacting the clearances. REPAIR as
chassis necessary.
z Engine vibration — z Engine out-of- z CARRY OUT the Neutral
increases intensity balance Engine Run-Up (NERU) Test.
as the engine rpm is REFER to Section 100-04 .
increased ROTATE the torque converter,
120 degrees for 3-bolt or 180
degrees for 4-bolt. INSPECT
the torque converter pilot outer
diameter to crankshaft pilot
inner diameter. REPAIR as
z Engine vibration — z Combustion z CHECK the ignition system.
mostly at instability INSTALL new components as
coast/neutral coast. necessary. Refer to the
Condition improves appropriate section in Group
with vehicle 303 for the procedure.
acceleration
z Engine vibration or z Worn or damaged z INSPECT the spark plugs for
shudder — occurs spark plugs cracks, high resistance or
with light to medium broken insulators. INSTALL a
acceleration above new spark plug(s) as
56 km/h (35 mph) necessary. Refer to the
z Plugged fuel injector z INSTALL a new fuel injector as
z Contaminated fuel z INSPECT the fuel for
contamination. DRAIN the fuel
system and refill.
Pinpoint Tests
Pinpoint Test A: Low Oil Pressure
Normal Operation
Oil is drawn into the oil pump through the oil pump screen and pickup tube in the sump of the oil pan. Oil is
pumped through the oil filter and then enters the main gallery where it is distributed to the crankshaft main
journals, piston oil coolers and to both cylinder heads. From the main journals, the oil is routed through
cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled leakage through
the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the
cylinder walls as well as the entire connecting rod, piston and piston ring assembly. The cylinder heads are
fed from a drilling into the supply passage feeding the main gallery. Main gallery pressure is sent through
Variable Camshaft Timing (VCT) circuit and reduced as it enters the cylinder head galleries through fixed
serviceable orifices, located at the upper part of the feed passages. It is this reduced pressure in the cylinder
head galleries which feed the camshaft journals, rocker arm shafts or hydraulic lash adjusters and the
primary and/or secondary timing chain tensioners. The camshaft lobe, roller followers, rocker arms and
valve tappets are lubricated by splash created through valve train operation.

z Excessive crankshaft end play
z Excessive main bearing clearance
z Excessive connecting rod bearing clearance
z Excessive camshaft bearing cap clearance
z Loose oil galley plugs
z Loose timing chain tensioner bolts
z Oil pump screen and pickup tube
z Restricted oil flow passages
z Worn or damaged oil pump
z Damaged piston oil coolers
PINPOINT TEST A: LOW OIL PRESSURE

A1 CHECK THE CRANKSHAFT END PLAY
z Check the crankshaft end play. Refer to Crankshaft End Yes
Play in this section. GO to A2 .
z Is the crankshaft end play within specification?
No
REPAIR as necessary. Refer to the
the procedure.
A2 VERIFY THE CAMSHAFT BEARING CAPS ARE NOT
DAMAGED AND TIGHT
z Check that the camshaft bearing caps are not damaged Yes
and the bolts are properly tightened. Refer to the REPAIR as necessary. Refer to the
Specification chart in the appropriate engine section. appropriate section in Group 303 for
z Are the camshaft bearing caps loose or damaged? the procedure.
No
GO to A3 .
A3 CHECK CAMSHAFT JOURNAL-TO-BEARING
CLEARANCE
z Check the camshaft journal-to-bearing clearance. Refer Yes
to the Specification chart in the appropriate engine GO to A4 .
section.
z Is camshaft journal-to-bearing clearance within No
specification? REPAIR as necessary. Refer to the

the procedure.
A4 CHECK FOR RESTRICTED OIL FLOW
z Verify the oil supply and return passages are not Yes
plugged and clean of debris. Refer to the oil flow chart in REPAIR as necessary. Refer to the
the appropriate engine section. appropriate section in Group 303 for
z Is oil flow restricted? the procedure.
No
GO to A5 .
A5 CHECK THE TIMING CHAIN TENSIONERS FOR
DAMAGE AND VERIFY THE BOLTS ARE TIGHT
z Check that the timing chain tensioners are not damaged Yes
or the bolts are loose. Refer to the Specification chart in REPAIR as necessary. Refer to the
the appropriate engine section. appropriate section in Group 303 for
z Are the timing chain tensioners damaged or bolts the procedure.
loose?
No
GO to A6 .
A6 CHECK THE OIL PUMP PICKUP TUBE AND SCREEN
FOR DAMAGE
z Check that the oil pump pickup tube and screen is not Yes
plugged, cracked or that the bolts are loose. Refer to the REPAIR as necessary. Refer to the
Specification chart in the appropriate engine section. appropriate section in Group 303 for
z Is the oil pump screen and pickup tube damaged or the procedure.
loose?
No
GO to A7 .
A7 CHECK THE OIL PUMP FOR DAMAGE
z Verify the oil pump is not damaged. Yes
z Is oil pump damaged? REPAIR as necessary. Refer to the
the procedure.
No
GO to A8 .
A8 CHECK CRANKSHAFT MAIN BEARING JOURNAL-TO-
BEARING CLEARANCE
z Check the crankshaft main bearing journal-to-bearing Yes
clearance. Refer to the Specification chart in the GO to A9 .
appropriate engine section.
z Is crankshaft main bearing journal-to-bearing No
clearance within specification? REPAIR as necessary. Refer to the
the procedure.
A9 CHECK CONNECTING ROD BEARING JOURNAL-TO-
BEARING CLEARANCE
z Check the connecting rod bearing journal-to-bearing Yes
clearance. Refer to the Specification chart in the The concern may have been caused
appropriate engine section. by debris or an incorrect assembly.
z Is connecting rod bearing journal-to-bearing REPEAT the oil pressure test.
clearance within specification?
No
REPAIR as necessary. Refer to the

the procedure.
Component Tests
The following component tests are used to diagnose engine concerns.
Engine Oil Leaks
NOTICE: If an overnight drive is done, the fan air or road air blast may cause erroneous readings.
NOTE: When diagnosing engine oil leaks, the source and location of the leak must be positively identified
prior to repair.
Prior to carrying out this procedure, clean the cylinder block, cylinder heads, valve covers, oil pan and
flywheel with a suitable solvent to remove all traces of oil.
Engine Oil Leaks — Fluorescent Oil Additive Method
Use the 12 Volt Master UV Diagnostic Inspection Kit to carry out the following procedure for oil leak
diagnosis.
1. Add 29.6 ml (1 oz) of gasoline engine oil dye to a minimum of 0.47L (1/2 qt) and a maximum of 0.95L
(1 qt) engine oil and fill through the engine oil fill. If the oil is not premixed, the gasoline engine oil dye
will not have enough time to reach the crankcase, oil galleries and seal surfaces during this particular
15 minute test. The gasoline engine oil dye must be mixed with oil and added through the oil fill.
Check the level on the oil level indicator to determine what amount of oil to premix. If it is in the middle
of the crosshatch area or below the full mark, use 0.95L (1 qt). If it is at the full mark, use 0.47L (1/2
qt).
2. Run the engine for 15 minutes. Stop the engine and inspect all seal and gasket areas for leaks using
the UV Diagnostic Inspection Kit. A clear bright yellow or orange area will identify the leak. For
extremely small leaks, several hours may be required for the leak to appear.
3. At the end of test, make sure the oil level is within the upper and lower oil indicator marks. Remove oil
as necessary if it registers above the full mark.
Leakage Points — Underhood
Examine the following areas for oil leakage:
z Valve cover gaskets

z Cylinder head gaskets
z Oil cooler, if equipped
z Oil filter adapter
z Engine front cover
z Oil filter adapter and filter body
z Oil level indicator tube connection
z Engine Oil Pressure (EOP) sensor
z Oil passage end plugs
Leakage Points — Under Engine, With Vehicle on Hoist
z Oil pan gaskets

z Oil pan sealer
z Engine front cover gasket
z Crankshaft front seal
z Crankshaft rear oil seal
z Oil filter adapter and filter body
z Oil cooler, if equipped
Leakage Points — With Transmission and Flywheel Removed
z Crankshaft rear seal

z Crankshaft rear seal retainer
z Flexplate mounting bolt holes (with flexplate installed)
Oil leaks at crimped seams in sheet metal parts and cracks in cast or stamped parts can be detected when
using the Gasoline Engine Oil Dye method.
Compression Test — Compression Gauge Check
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level and that the
battery is correctly charged. Operate the vehicle until the engine is at normal operating temperature.
Turn the ignition switch to the OFF position, then remove all the spark plugs.
2. Set the throttle plates in the wide-open position.
3. Install a compression gauge in the No. 1 cylinder.
4. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, and
using the auxiliary starter switch, crank the engine a minimum of 5 compression strokes and record
the highest reading. Note the approximate number of compression strokes required to obtain the
highest reading.
5. Repeat the test on each cylinder, cranking the engine approximately the same number of
compression strokes.
Compression Test — Test Results
The indicated compression pressures are considered within specification if the lowest reading cylinder is at
least 75% of the highest reading. Refer to the Compression Pressure Limit Chart.
Compression Test — 3.5L Gasoline Turbocharged Direct Injection (GTDI) Engine Only
Compression Pressure Limit Chart — 3.7L, 5.0L (4V) and 6.2L (2V) Engines
If one or more cylinders reads low, squirt approximately one tablespoon of engine oil on top of the pistons in
the low-reading cylinders. Repeat the compression pressure check on these cylinders.
Compression Test — Interpreting Compression Readings
1. If compression improves considerably, piston rings are faulty.
2. If compression does not improve, valves are sticking or seating incorrectly.
3. If 2 adjacent cylinders indicate low compression pressures and squirting oil on each piston does not
increase compression, the head gasket may be leaking between cylinders. Engine oil or coolant in
cylinders could result from this condition.
Use the Compression Pressure Limit Chart when checking cylinder compression so that the lowest
reading is within 75% of the highest reading.
Cylinder Leakage Detection
When a cylinder produces a low reading, use of a cylinder leakage tester will be helpful in pinpointing the
exact cause.
The leakage tester is inserted in the spark plug hole, the piston is brought up to Top Dead Center (TDC) on
the compression stroke, and compressed air is admitted.
Once the combustion chamber is pressurized, the leakage tester gauge will read the percentage of leakage.
Leakage exceeding 20% is excessive.
While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve
will be heard in the Throttle Body (TB). A leak at the exhaust valve can be heard at the tail pipe. Leakage
past the piston rings will be audible at the PCV connection. If air is passing through a blown head gasket to
an adjacent cylinder, the noise will be evident at the spark plug hole of the cylinder into which the air is
leaking. Cracks in the cylinder block or gasket leakage into the cooling system may be detected by a stream
of bubbles in the radiator.
Excessive Engine Oil Consumption
Nearly all engines consume oil, which is essential for normal lubrication of the cylinder bore walls and
pistons and rings. Determining the level of oil consumption may require testing by recording how much oil is
being added over a given set of miles.
Customer driving habits greatly influence oil consumption. Mileage accumulated during towing or heavy
loading generates extra heat. Frequent short trips, stop-and-go type traffic or extensive idling, prevent the
engine from reaching normal operating temperature. This prevents component clearances from reaching
specified operating ranges.
The following diagnostic procedure may be utilized to determine internal oil consumption. Make sure that the
concern is related to internal oil consumption, and not external leakage, which also consumes oil. Verify
there are no leaks before carrying out the test. Once verified, the rate of internal oil consumption can be
tested.
A new engine may require extra oil in the early stages of operation. Internal piston-to-bore clearances and
sealing characteristics improve as the engine breaks in. Engines are designed for close tolerances and do
not require break-in oils or additives. Use the oil specified in the Owner's Literature. Ambient temperatures
may determine the oil viscosity specification. Verify that the correct oil is being used for the vehicle in the
geographic region in which it is driven.
Basic Pre-checks
1. For persistent complaints of oil consumption, interview the customer to determine the oil consumption
characteristics. If possible, determine the brand and grade of oil currently in the oil pan. Look at the oil
filter or oil-change station tags to determine if Ford-recommended maintenance schedules have been
followed. Make sure that the oil has been changed at the specified mileage intervals. If vehicle
mileage is past the first recommended drain interval, the OEM production filter should have been
changed.
2. Ask how the most current mileage was accumulated. That is, determine whether the vehicle was
driven under the following conditions:

z Extended idling or curbside engine operation
z Stop-and-go traffic or taxi operation
z Towing a trailer or vehicle loaded heavily
z Frequent short trips (engine not up to normal operating temperature)
z Excessive throttling or high engine-rpm driving
3. Verify that there are no external leaks. If necessary, review the diagnostic procedure under Engine Oil
Leaks in the Diagnosis and Testing portion of this section.
4. Inspect the crankcase ventilation system for:

z disconnected hoses at the valve cover or TB .
z loose or missing valve cover fill cap.
z missing or incorrectly seated engine oil level indicator.
z incorrect or dirty PCV valve.
z a PCV valve grommet unseated in the valve cover (if so equipped).
5. Inspect for signs of sludge. Sludge affects PCV performance and can plug or restrict cylinder head
drainback wells. It can also increase oil pressure by restricting passages and reducing the drainback
capability of piston oil control rings.
6. Inspect the air filter for dirt, sludge or damage. A hole in the filter element will allow unfiltered air to
bypass into the air induction system. This can cause premature internal wear (engine dusting),
allowing oil to escape past rings, pistons, valves and guides.
7. If the engine is hot or was recently shut down, wait at least 5 minutes to allow the oil to drain back.
Ask the customer if this requirement has been followed. Adding oil without this wait period can cause
an overfill condition, leading to excessive oil consumption and foaming which may cause engine
damage.
8. Make sure the oil level indicator (dipstick) is correctly and fully seated in the indicator tube. Remove
the oil level indicator and record the oil level.
Detailed Pre-checks
1. Check the thermostat opening temperature to make sure that the cooling system is operating at the
specified temperature. If it is low, internal engine parts are not running at specified internal operating
clearances.
2. Verify the spark plugs are not oil saturated. Oil leaking into one or more cylinders will appear as an oil
soaked condition on the plug. If a plug is saturated, a compression check may be necessary at the
conclusion of the oil consumption test.
Oil Consumption Test
Once all of the previous conditions are met, carry out an oil consumption test.
1. Drain the engine oil and remove the oil filter. Install a new manufacturer-specified oil filter. Make sure
the vehicle is positioned on a level surface. Refill the oil pan to a level 1 liter (1 quart) less than the
specified fill level, using manufacturer-specified oil.
2. Run the engine for 3 minutes (if hot) or 10 minutes (if cold). Allow for a minimum 5-minute drainback
period and then record the oil level shown on the oil level indicator. Place a mark on the backside of
the oil level indicator noting the oil level location.
3. Add the final 1 L (1 qt) to complete the normal oil fill. Restart the engine and allow it to idle for 2
minutes. Shut the engine down.
4. After a 5-minute drainback period, record the location of the oil level again. Mark the oil level indicator
with the new oil level location. (Note: Both marks should be very close to the MIN-MAX upper and
lower limits or the upper and lower holes on the oil level indicator. These marks will exactly measure
the engine's use of oil, with a one quart differential between the new marks.) Demonstrate to the
customer that the factory-calibrated marks on the oil level indicator are where the oil should fall after
an oil change with the specified fill amount. Explain however, that this may vary slightly between MIN-
MAX or the upper and lower holes on the oil level indicator.
5. Record the vehicle mileage.
6. Advise the customer that oil level indicator readings must be taken every 320 km (200 mi) or weekly,
using the revised marks as drawn. Remind the customer that the engine needs a minimum 5-minute
drainback for an accurate reading and that the oil level indicator must be firmly seated in the tube
prior to taking the reading.
7. When the subsequent indicator readings demonstrate a full quart (liter) has been used, record the
vehicle mileage. The mileage driven between the 2 readings should not be less than 4,800 km (3,000
miles). The drive cycle the vehicle has been operated under must be considered when making this
calculation. It may be necessary to have the customer bring the vehicle in for a periodic oil level
indicator reading to closely monitor oil usage.
Post Checks, Evaluation and Corrective Action
1. If test results indicate excessive oil consumption, carry out a cylinder compression test. The cylinder
compression test should be carried out with a fully charged battery and all spark plugs removed. See
the Compression Test Chart in this section for pressure range limits.
2. Compression should be consistent across all cylinders. Refer to the Compression Testing portion of
this section. If compression tested within the specifications found in this section, the excessive oil
consumption may be due to wear on the valve guides, valves or valve seals.
3. A cylinder leak detection test can be carried out using a cylinder leakage tester. This can help identify
valves, piston rings, or worn valve guides/valve stems, inoperative valve stem seals or other related
areas as the source of oil consumption.
NOTE: An oil-soaked appearance on the porcelain tips of the spark plugs also indicates excessive oil use. A
typical engine with normal oil consumption will exhibit a light tan to brown appearance. See Spark Plug
Analysis in this section for details. A single or adjoining, multiple cylinder leak can be traced by viewing the
tips.
4. If an internal engine part is isolated as the root cause, determine if the repair will exceed cost limits
and proceed with a repair strategy as required.
5. Once corrective action to engine is complete and verifying that all pre-check items were eliminated in
the original diagnosis, repeat the Oil Consumption Test as described above and verify consumption
results.
Intake Manifold Vacuum Test
Bring the engine to normal operating temperature. Connect the Vacuum/Pressure Tester to the intake
manifold. Run the engine at the specified idle speed.
The vacuum gauge should read between 51-74 kPa (15-22 in-Hg) depending upon the engine condition and
the altitude at which the test is performed. Subtract 4.0193 kPa (1 in-Hg) from the specified reading for every
304.8 m (1,000 ft) of elevation above sea level.
The reading should be steady. If necessary, adjust the gauge damper control (where used) if the needle is
fluttering rapidly. Adjust the damper until the needle moves easily without excessive flutter.
Intake Manifold Vacuum Test — Interpreting Vacuum Gauge Readings
A careful study of the vacuum gauge reading while the engine is idling will help pinpoint trouble areas.
Always conduct other appropriate tests before arriving at a final diagnostic decision. Vacuum gauge
readings, although helpful, must be interpreted carefully.
Most vacuum gauges have a normal band indicated on the gauge face.
The following are potential gauge readings. Some are normal; others should be investigated further.
1. NORMAL READING: Needle between 51-74 kPa (15-22 in-Hg) and holding steady.
2. NORMAL READING DURING RAPID ACCELERATION AND DECELERATION: When the engine is
rapidly accelerated (dotted needle), the needle will drop to a low reading (not to zero). When the
throttle is suddenly released, the needle will snap back up to a higher than normal figure.
3. NORMAL FOR HIGH-LIFT CAMSHAFT WITH LARGE OVERLAP: The needle will register as low as
51 kPa (15 in-Hg), but will be relatively steady. Some oscillation is normal.
4. WORN RINGS OR DILUTED OIL: When the engine is accelerated (dotted needle), the needle drops
to 0 kPa (0 in-Hg). Upon deceleration, the needle runs slightly above 74 kPa (22 in-Hg).
5. STICKING VALVES: When the needle (dotted) remains steady at a normal vacuum, but occasionally
flicks (sharp, fast movement) down and back about 13 kPa (4 in-Hg), one or more valves may be
sticking.
6. BURNED OR WARPED VALVES: A regular, evenly-spaced, downscale flicking of the needle

indicates one or more burned or warped valves. Insufficient hydraulic lash adjuster or hydraulic lash
adjuster clearance will also cause this reaction.
7. POOR VALVE SEATING: A small but regular downscale flicking can mean one or more valves are
not seating.
8. WORN VALVE GUIDES: When the needle oscillates over about a 13 kPa (4 in-Hg) range at idle
speed, the valve guides could be worn. As engine speed increases, the needle will become steady if
guides are responsible.
9. WEAK VALVE SPRINGS: When the needle oscillation becomes more violent as engine rpm is
increased, weak valve springs are indicated. The reading at idle could be relatively steady.
10. LATE VALVE TIMING: A steady but low reading could be caused by late valve timing.
11. IGNITION TIMING RETARDING: Retarded ignition timing will produce a steady, but somewhat low,
reading.
12. INSUFFICIENT SPARK PLUG GAP: When spark plugs are gapped too close, a regular, small
pulsation of the needle can occur.
13. INTAKE LEAK: A low, steady reading can be caused by an intake manifold or throttle body gasket
leak.
14. BLOWN HEAD GASKET: A regular drop of fair magnitude can be caused by a blown head gasket or
warped cylinder head-to-cylinder block surface.
15. RESTRICTED EXHAUST SYSTEM: When the engine is first started and is idled, the reading may be
normal, but as the engine rpm is increased, the back pressure caused by a clogged muffler, kinked
tail pipe or other concerns will cause the needle to slowly drop to 0 kPa (0 in-Hg). The needle then
may slowly rise. Excessive exhaust clogging will cause the needle to drop to a low point even if the
engine is only idling.
16. When vacuum leaks are indicated, search out and correct the cause. Excess air leaking into the
system will upset the fuel mixture and cause concerns such as rough idle, missing on acceleration or
burned valves. If the leak exists in an accessory unit such as the power brake booster, the unit will
not function correctly. Always fix vacuum leaks.
Oil Pressure Test
NOTICE: Inspect the engine for installation of an aftermarket oil filter. Review oil and filter
maintenance history to make sure that the vehicle has not gone beyond the standard Ford
recommended oil change intervals. Check the engine oil level and check the oil for contamination. If
the oil is contaminated, engine damage can occur. The source of the contamination must be
identified and repaired as necessary.
1. Disconnect and remove the Engine Oil Pressure (EOP) switch from the engine. Refer to the
appropriate section in Group 303 for the procedure.
2. Connect the Oil Pressure Gauge to the oil pressure port.
3. Run the engine until normal operating temperature is reached.
4. With the engine at idle record the gauge reading.
5. The oil pressure should be within specifications; refer to the specifications in the appropriate engine
section.
6. If the pressure is not within specification, GO to Pinpoint Test A .
Valve Train Analysis — 3.5L Gasoline Turbocharged Direct Injection (GTDI) and 3.7L
The following component tests are used to diagnose valve train concerns.
Valve Train Analysis — Engine Off, Valve Cover Removed
Check for damaged or severely worn parts and correct assembly. Make sure correct parts are used with the
static engine analysis as follows.
Valve Train Analysis — Camshafts and Valve Tappets
z Check for broken or damaged parts.

z Check for loose mounting bolts on camshaft caps.
z Check for worn or damaged valve tappets.
Valve Train Analysis — Valve Springs, Valve Tappets Removed
Valve Train Analysis — Valve Spring Retainer and Valve Spring Retainer Keys, Valve Tappets
Removed
z Check for correct seating of the valve spring retainer key on the valve stem and in valve spring
retainer.
z Check for correct seating on the valve stem.
Valve Train Analysis — Valves and Cylinder Head, Valve Tappets Removed
z Check for plugged oil drain-back holes.

z Check for worn or damaged valve tips.
z Check for missing or damaged valve stem seals or guide-mounted valve stem seal.
z Check for missing or worn valve spring seats.
Valve Train Analysis — Camshaft Lobe Lift
Check the lift of each camshaft lobe in consecutive order and make a note of the readings.
1. Remove the spark plugs. Refer to Section 303-07A for 3.5L GTDI , or Section 303-07B for 3.7L.
2. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of the dial indicator is on top of
the camshaft lobe and on the same plane as the valve tappet.
3. Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retainer bolt.
Rotate the crankshaft until the base circle of the camshaft lobe is reached.
4. Zero the dial indicator. Continue to rotate the crankshaft until the high-lift point of the camshaft lobe is
in the fully-raised position (highest indicator reading).
5. To check the accuracy of the original dial indicator reading, continue to rotate crankshaft until the
base circle is reached. The dial indicator reading should be zero. If zero reading is not obtained,
repeat Steps 1 through 6.
6. If the lift on any lobe is below specified service limits, install a new camshaft and camshaft valve
tappets.
7. Install the spark plugs. Refer to Section 303-07B .
Valve Train Analysis — 5.0L (4V)
Valve Train Analysis — Engine Off — Valve Cover Removed
Valve Train Analysis — Engine Off, Camshaft Roller Followers and Hydraulic Lash Adjusters,
Overhead Camshaft
z Check for plugged oil feed in the camshaft roller followers, hydraulic lash adjusters or cylinder heads.
Valve Train Analysis — Engine Off, Camshaft — Engines
Valve Train Analysis — Valve Springs
Valve Train Analysis — Engine Off, Valve Spring Retainer and Valve Spring Retainer Keys
retainer.
Valve Train Analysis — Engine Off, Valves and Cylinder Head
z Check for plugged oil drain back holes.

z Check for missing or damaged guide-mounted valve stem seal.
z Check for damaged hydraulic lash adjuster.
z Check installed valve spring height.
Static checks (engine off) are to be made on the engine prior to the dynamic procedure.
Valve Train Analysis — Engine Running, Valves and Cylinder Head

z Check for missing or damaged valve stem seals or guide mounted valve stem seals.
If insufficient oiling is suspected, check oil passages for blockage, then accelerate the engine to 1,200 rpm
with the transmission in NEUTRAL and the engine at normal operating temperature. Oil should spurt from
the rocker arm oil holes such that valve tips and camshaft roller followers are well oiled. With the valve
covers off, some oil splash may overshoot camshaft roller followers.
1. Remove the spark plugs. Refer to Section 303-07C for 5.0L (4V) engines.
2. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of indicator is on top of the
camshaft lobe.
4. Zero the Dial Indicator Gauge. Continue to rotate the crankshaft until the (1) high-lift point of the
camshaft lobe is in the fully-raised position (highest indicator reading).
5. To check the accuracy of the original indicator reading, continue to rotate crankshaft until the (2) base
circle is reached. The indicator reading should be zero. If zero reading is not obtained, repeat the
measurement.
6. If the lift on any lobe is below specified service limits, install a new camshaft and camshaft roller
followers.
7. Install the spark plugs. Refer to Section 303-07C for 5.0L (4V) engines.
Valve Train Analysis — 6.2L (2V)
Valve Train Analysis — Engine Off — Valve Cover Removed
Valve Train Analysis — Engine Off, Rocker Arm and Overhead Camshaft
z Check for loose mounting bolts on rocker arm shafts and camshaft carriers.
z Check for plugged oil feed in the rocker arm shafts and cylinder heads.
Valve Train Analysis — Engine Off, Camshaft
Valve Train Analysis — Valve Springs
Valve Train Analysis — Engine Off, Valve Spring Retainer and Valve Spring Retainer Keys
retainer.
Valve Train Analysis — Engine Off, Valves and Cylinder Head

z Check for missing or damaged guide-mounted valve stem seal.
z Check installed valve spring height.
z Check for plugged oil metering orifice in cylinder head oil reservoir (if equipped).
Static checks (engine off) are to be made on the engine prior to the dynamic procedure.
Valve Train Analysis — Engine Running, Valves and Cylinder Head

z Check for missing or damaged valve stem seals or guide mounted valve stem seals.
z Check for a plugged oil metering orifice in the cylinder head oil reservoir.
If insufficient oiling is suspected, check oil passages for blockage, then accelerate the engine to 1,200 rpm
with the transmission in NEUTRAL and the engine at normal operating temperature. Oil should spurt from
the rocker arm oil holes such that valve tips and camshaft roller followers are well oiled. With the valve
covers off, some oil splash may overshoot camshaft roller followers.
1. Remove the spark plugs. Refer to Section 303-07D .
2. Install the Dial Indicator Gauge with Holding Fixture so the rounded tip of indicator is on top of the
camshaft lobe.
4. Zero the Dial Indicator Gauge. Continue to rotate the crankshaft until the (1) high-lift point of the
camshaft lobe is in the fully-raised position (highest indicator reading).
5. To check the accuracy of the original indicator reading, continue to rotate crankshaft until the (2) base
circle is reached. The indicator reading should be zero. If zero reading is not obtained, repeat the
measurement.
6. If the lift on any lobe is below specified service limits, install a new camshaft and camshaft roller
followers.
7. Install the spark plugs. Refer to Section 303-07D .
Bearing Inspection
1. Inspect bearings for the following defects:

1. Cratering — fatigue failure
2. Spot polishing — incorrect seating
3. Imbedded dirty engine oil
4. Scratching — dirty engine oil
5. Base exposed — poor lubrication
6. Both edges worn — journal damaged
7. One edge worn — journal tapered or bearing not seated
Camshaft Bearing Journal Diameter
NOTE: Refer to the appropriate Section 303-01 for the specification.
1. Measure each camshaft journal diameter in 2 directions.
Camshaft End Play — OHC Engines
Special Tool(s)
Fixture
100-002 (TOOL-4201-C) or
equivalent
1. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
2. Position the camshaft to the rear of the cylinder head.
3. Zero the Dial Indicator Gauge.
4. Move the camshaft to the front of the cylinder head. Note and record the camshaft end play.
z If camshaft end play exceeds specifications, install a new camshaft and recheck end play.
z If camshaft end play exceeds specification after camshaft installation, install a new cylinder
head.
Camshaft Journal to Bearing Clearance — OHC Engines
1. NOTE: The camshaft journals must meet specifications before checking camshaft journal clearance.
Measure each camshaft bearing in 2 directions.

z Subtract the camshaft journal diameter from the camshaft bearing diameter.
Camshaft Lobe Lift
Special Tool(s)
Fixture
100-002 (TOOL-4201-C) or
equivalent
1. Use the Dial Indicator Gauge with Holding Fixture to measure camshaft intake/exhaust lobe lift.
z Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial
Indicator Gauge reading to figure the camshaft lobe lift.
Camshaft Runout
Special Tool(s)
Fixture
100-002 (TOOL-4201-C) or
equivalent
1. NOTE: Camshaft journals must be within specifications before checking runout.
Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft runout.
z Camshaft must be supported on the first and last camshaft bearing journal.
z Rotate the camshaft and subtract the lowest Dial Indicator Gauge reading from the highest Dial
Indicator Gauge reading.
Camshaft Surface Inspection
1. Inspect camshaft lobes for pitting or damage in the contact area. Minor pitting is acceptable outside
the contact area.
Connecting Rod Bearing Journal Taper and Out-of-Round
1. Measure the crankshaft connecting rod journal diameters in 2 directions perpendicular to one another
at each end of the connecting rod journal. The difference in the measurements from one end to the
other is the taper. Verify measurement is within the wear limit.
Connecting Rod Bearing Journal-to-Bearing Clearance
NOTE: The crankshaft connecting rod journals must be within specifications to check the connecting rod
bearing journal clearance.
1. Remove the connecting rod bearing cap.
2. Position a piece of Plastigage across the bearing surface.
3. NOTE: Do not turn the crankshaft during this step.
Install and tighten to specifications, then remove the connecting rod bearing cap.
4. Measure the Plastigage to get the connecting rod bearing journal clearance. The Plastigage should
be smooth and flat. A changing width indicates a tapered or damaged connecting rod or connecting
rod bearing.
Connecting Rod Bend
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. Using the Feeler Gauge Set, measure the connecting rod bend on a suitable alignment fixture. Follow
the instructions of the fixture manufacturer. Verify the bend measurement is within specification.
Connecting Rod Bushing Diameter
1. Use a telescoping gauge to determine the ID of the connecting rod bushing, if equipped.
2. Measure the telescoping gauge with a micrometer. Verify the diameter is within specification.
Connecting Rod Cleaning
NOTICE: Do not use a caustic cleaning solution or damage to connecting rods can occur.
1. NOTE: The connecting rod large end is a matched set. The connecting rod cap must be installed on
the original connecting rod in the original position. Do not reverse the cap. Parts are not
interchangeable.
Mark and separate the parts and clean with solvent. Clean the oil passages.
Connecting Rod Large End Bore
1. Tighten the bolts to specification, then measure the bore in 2 directions. The difference is the
connecting rod bore out-of-round. Verify the out-of-round is within specification.
Connecting Rod to Crankshaft Side Clearance
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. Using the Feeler Gauge Set, measure the clearance between the connecting rod and the crankshaft.
Verify the measurement is within specification.
Connecting Rod Twist
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. Using the Feeler Gauge Set, measure the connecting rod twist on a suitable alignment fixture. Follow
the instructions of the fixture manufacturer. Verify the measurement is within specification.
Core Plug Replacement
Special Tool(s)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
High Temperature Retaining WSK-M2G349-
Compound A9
Loctite® 620™/Permatex® 62050,
or equivalent; obtain locally
Threadlock 262 WSK-M2G351-
TA-26 A6
NOTICE: It is necessary to use High Temperature Retaining Compound Loctite® 620™/Permatex®

62050 or equivalent on all 3 valve modular engine cylinder head cup plugs. If not used, the cylinder
head cup plugs could leak or seep, causing serious engine damage.
NOTE: Use threadlock 262 on all other applications.
All core plugs
1. NOTE: Cylinder block core plug shown, cylinder head core plug similar.
Use the Slide Hammer and a freeze plug remover to remove the core plug.
2. NOTE: Oversize plugs are identified by the OS stamped in the flat located on the cup side of the plug.
Inspect the core plug bore for any damage that would interfere with the correct sealing of the plug. If
the core plug bore is damaged, bore for the next oversize plug.
Cup-type
3. NOTICE: Use care during this procedure so as not to disturb or distort the cup sealing
surface.
NOTE: When installed, the flanged edge must be below the chamfered edge of the bore to effectively
seal the bore.
Coat the cup-type core plug and bore lightly with sealant and install the core plug using a freeze plug
installer.
Expansion-type
4. NOTICE: Do not contact the crown when installing an expansion-type core plug. This could
expand the plug before seating and result in leakage.
Coat the expansion-type core plug and bore lightly with sealant and install the core plug using a
freeze plug installer.
Crankshaft End Play
Special Tool(s)
Fixture
100-002 (TOOL-4201-C) or
equivalent
2. Position the crankshaft to the rear of the cylinder block.
3. Zero the Dial Indicator Gauge.
4. Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
Crankshaft Main Bearing Journal Diameter
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions.
Crankshaft Main Bearing Journal Taper and Out-of-Round
1. Measure each of the crankshaft main bearing journal diameters in at least 2 directions at each end of
the main bearing journal.
Crankshaft Main Bearing Journal-to-Bearing Clearance
NOTE: Crankshaft main bearing journals must be within specifications before checking journal clearance.
1. Remove the crankshaft main bearing caps and crankshaft main bearing.
2. Lay a piece of Plastigage across the face of each crankshaft main bearing surface.
3. NOTE: Do not turn the crankshaft while carrying out this procedure.
Install and remove the crankshaft main bearing cap.
4. Verify the crankshaft journal clearance.
Cylinder Bore Cleaning
Material
Item Specification
LSP12 (Canada)
1. NOTICE: If these procedures are not followed, rusting of the cylinder bores may occur.
Clean the cylinder bores with soap or detergent and water.
2. Thoroughly rinse with clean water and wipe dry with a clean, lint-free cloth.
3. Use a clean, lint-free cloth and lubricate the cylinder bores.

z Use clean engine oil meeting Ford specification.
Cylinder Bore Out-of-Round
1. Measure the cylinder bore in 2 directions. The difference is the out-of-round.
Cylinder Bore Taper
1. Measure the cylinder bore at the top, middle and bottom of piston ring travel in 2 directions as
indicated. Verify the cylinder bore is within the wear limit. The difference indicates the cylinder bore
taper. If the cylinder bore taper does not meet specification, bore the cylinder to the next oversize
limit.
Cylinder Head Distortion
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, silicone sealant, oil and
coolant. The cylinder head surface must be clean and dry before running a flatness check.
NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002
in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the
Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from
end to end.
Using a Straightedge and a Feeler Gauge Set, inspect the cylinder head for flatness in the sequence
shown.
Exhaust Manifold Cleaning and Inspection
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. Clean the exhaust manifold using a suitable solvent. Use a plastic scraping tool to clean the gasket
sealing surfaces.
2. NOTE: New exhaust manifold gaskets, studs, nuts and/or bolts must be installed when an exhaust
manifold is serviced.
NOTE: Use a Straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002
in) per running foot of length, such as Snap-On® GA438A or equivalent. For example, if the
Straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from
end to end.
Using the Straightedge and a Feeler Gauge Set, check the exhaust manifold sealing surface for
warpage. If the warpage is greater than 0.76 mm (0.0299 in), install a new exhaust manifold.
Flexplate Inspection
1. Inspect the flexplate for:

1. any cracks.
2. worn ring gear teeth.
3. chipped or cracked ring gear teeth.
Flywheel Inspection
1. NOTE: The flywheel cannot be resurfaced, it must be replaced.
Inspect the flywheel for:

1. any cracks.
2. worn ring gear teeth.
3. chipped or cracked ring gear teeth.
4. scratches, nicks and discoloration.
Hydraulic Lash Adjuster Inspection
1. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the
camshaft lobes and valves for damage.
Piston Diameter
1. Measure the piston diameter 90 degrees from the piston pin and 35 mm (1.38 in) down from the top
of the piston at the uncoated skirt area point indicated.
Piston Inspection
Special Tool(s)
Scraper, Piston Ring Groove
303-D033 (D81L-6002-D) or
equivalent
NOTICE: Do not use a caustic cleaning solution or a wire brush to clean the pistons or damage can
occur.
1. Clean and inspect the (1) ring lands, (2) skirts, (3) pin bosses and the (4) tops of the pistons. If wear
marks, scores or glazing is found on the piston skirt, check for a bent or twisted connecting rod.
2. Use the Piston Ring Groove Scraper to clean the piston ring grooves.
z Make sure the oil ring holes are clean.
Piston Pin Bore Diameter
1. NOTE: Piston and piston pins are a matched set and should not be interchanged.
Measure the piston pin bore diameter in 2 directions on each side. Verify the diameter is within
specification.
Piston Pin Diameter
1. Measure the piston pin diameter in 2 directions at the points shown. Verify the diameter is within
specification.
Piston Ring End Gap
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
NOTICE: Use care when fitting piston rings to avoid possible damage to the piston ring or the
cylinder bore.
NOTE: Piston rings should not be transferred from one piston to another.
NOTE: The cylinder bore must be within specification for taper and out-of-round.
1. Use a piston without rings to push a piston ring in a cylinder to the bottom of ring travel.
2. Use the Feeler Gauge Set to measure the top piston ring end gap and the second piston ring end
gap.
Piston Ring-to-Groove Clearance
Special Tool(s)
Feeler Gauge Set
303-D027 (D81L-4201-A) or
equivalent
1. Inspect the piston for ring land damage or accelerated wear.
2. Using the Feeler Gauge Set, measure the piston ring-to-groove clearance.
Piston Selection
3.5L, 3.7L and 5.0L (4V) Engines
1. Engines are equipped with a single grade size piston.
6.2L (2V) Engines
NOTE: The cylinder bore must be within the specifications for taper and out-of-round before fitting a piston.
2. Select a piston size based on the cylinder bore.
3. NOTE: For precision fit, new pistons are divided into 3 categories within each size range based on
their relative position within the range. A paint spot or specific size grade on a new piston indicates
the position within the size range.
Choose the piston with the correct paint color or specific size grade.
z Refer to the appropriate section in Group 303 for the procedure.
Piston To Cylinder Bore Clearance
1. Subtract the piston diameter from the cylinder bore diameter to find the piston-to-cylinder bore
clearance.
Powertrain/Drivetrain Mount Neutralizing
NOTE: Refer to the appropriate section and procedure for special instructions on loosening and tightening
mount fasteners.
02 .
2. Loosen, but do not remove, the powertrain/drivetrain mount fasteners.
3. Lower the vehicle.
4. NOTICE: Do not twist or strain the powertrain/drivetrain mounts or damage to the mounts may
occur.
Start the vehicle and move it in forward 0.6-1.2 m (2-4 ft). Then move the vehicle in reverse the same
distance.
5. Raise and support the vehicle.
6. Tighten the powertrain/drivetrain mount fasteners.
7. Lower the vehicle.
8. Test the system for normal operation.
Roller Follower Inspection
1. Inspect the roller follower for flat spots or scoring. If any damage is found, inspect the camshaft lobes
and hydraulic lash adjuster for damage.
Spark Plug Inspection
1. Inspect the spark plug for a bridged gap.

z Check for deposit build-up closing the gap between the electrodes. Deposits are caused by oil
or carbon fouling.
z Install a new spark plug.
2. Check for oil fouling.

z Check for wet, black deposits on the insulator shell bore electrodes, caused by excessive oil
entering the combustion chamber through worn rings and pistons, excessive valve-to-guide
clearance or worn or loose bearings.
z Correct the oil leak concern.
3. Inspect for carbon fouling. Look for black, dry, fluffy carbon deposits on the insulator tips, exposed
shell surfaces and electrodes, caused by a spark plug with an incorrect heat range, dirty air cleaner,
too rich a fuel mixture or excessive idling.
z Install new spark plugs.
4. Inspect for normal burning.

z Check for light tan or gray deposits on the firing tip.
5. Inspect for pre-ignition, identified by melted electrodes and a possibly damaged insulator. Metallic
deposits on the insulator indicate engine damage. This may be caused by incorrect ignition timing,
wrong type of fuel or the unauthorized installation of a heli-coil insert in place of the spark plug
threads.
6. Inspect for overheating, identified by white or light gray spots and a bluish-burnt appearance of
electrodes. This is caused by engine overheating, wrong type of fuel, loose spark plugs, spark plugs
with an incorrect heat range, low fuel pump pressure or incorrect ignition timing.
7. Inspect for fused deposits, identified by melted or spotty deposits resembling bubbles or blisters.
These are caused by sudden acceleration.
z Install new spark plugs.
Sprockets
1. Inspect the sprockets for cracks and worn or chipped teeth.
Valve Guide Inner Diameter
1. NOTE: Valve guides tend to wear in an hourglass pattern. The ball gauge can be inserted into the
combustion chamber side of the valve guide, if necessary.
Use a ball gauge to determine the inside diameter of the valve guides in 2 directions at the top,
middle and bottom of the valve guide.
2. Measure the ball gauge with a micrometer.
3. If the valve guide is not within specifications, install a new cylinder head assembly.
Valve Inspection
1. Inspect the following valve areas:

1. The end of the stem for grooves or scoring.
2. The valve face and the edge for pits, grooves or scores.
3. The valve head for signs of burning, erosion, warpage and cracking.
4. The valve margin for wear.
Valve Seat Inspection
Valve and Seat Refacing Measurements
NOTE: After grinding valves or valve seats, check valve clearance.
1. Check the valve head and seat.

z Check valve angles.
z Check margin width.
z Be sure margin width is within specification.
2. Inspect for abnormalities on the valve face and seat. Install a new cylinder head assembly if
abnormalities are found.
Valve Seat Runout
1. Use a valve seat runout gauge to check valve seat runout.
Valve Seat Width
1. Measure the valve seat width. If necessary, grind the valve seat to specification.
z Measure the intake valve seat width.
z Measure the exhaust valve seat width.
z Recheck the valve spring installed length after the seats have been ground, and shim the valve
springs as necessary to achieve the correct installed spring length.
z Depending on the engine, check the valve lash. Refer to General Procedures in Section 303-
01.
Valve Spring Installed Length
1. Measure the installed length of each valve spring.
Valve Spring Squareness
1. Measure the out-of-square on each valve spring.

z Turn the valve spring and observe the space between the top of the valve spring and the
square.
Valve Spring Strength
Special Tool(s)
Pressure Gauge, Valve/Clutch
Spring
303-006 (TOOL-6513-DD) or
equivalent
1. Use the Valve/Clutch Spring Pressure Gauge to check the valve spring for correct strength at the
specified valve spring length.
Valve Stem Diameter
1. Measure the diameter of each intake and exhaust valve stem at the points shown. Verify the diameter
is within specification.
Valve Stem to Valve Guide Clearance
Special Tool(s)
Clearance Gauge, Valve Guide
303-004 (TOOL-6505-E) or
equivalent

Fixture
100-002 (TOOL-4201-C) or
equivalent
NOTE: The valve stem diameter must be within specifications before checking valve stem-to-valve guide
clearance.
1. NOTE: If necessary, use a magnetic base.
Install a Valve Guide Clearance Gauge on the valve stem and install a Dial Indicator Gauge with
Holding Fixture. Lower the valve until the clearance gauge contacts the upper surface of the valve
guide.
2. Move the Valve Guide Clearance Gauge toward the Dial Indicator Gauge with Holding Fixture and
zero the Dial Indicator Gauge. Move the Valve Guide Clearance Gauge away from the Dial Indicator
Gauge with Holding Fixture and note the reading. The reading will be DOUBLE the valve stem-to-
valve guide clearance.
Valve Tappet Inspection
OHC engines
1. Inspect the valve tappet for damage, especially in the indicated areas. If any damage is evident,
inspect the camshaft lobes and valves for damage. Replace components as necessary.
Push rod engines
SECTION 303-01A: Engine — 3.5L GTDI 2014 F-150 Workshop Manual

Material
Capacity
Motorcraft® Gasket Maker WSK- —
TA-16 M2G348-A5
Motorcraft® High Performance WSE- —
Engine RTV Silicone M4G323-A6
TA-357
ZC-31-A
Motorcraft® SAE 5W-30 WSS- 5.6L (6.0
Premium Synthetic Blend Motor M2C946-A qts.)
Oil (US); Motorcraft® SAE 5W- includes oil
30 Super Premium Motor Oil filter change
(Canada)
XO-5W30-QSP (US); CXO-
5W30-LSP12 (Canada)
Motorcraft® Orange WSS- —
Antifreeze/Coolant Concentrated M97B44-D
VC-3-B (US); CVC-3-B2

(Canada)
Motorcraft® Silicone Gasket — —
Remover
ZC-30
Motorcraft® Thread Sealant with WSK- —
PTFE M2G350-A2
TA-24
Motorcraft® Threadlock 262 WSK- —
TA-26 M2G351-A6
Item Specification
Engine
Displacement 3.5L Gasoline Turbocharged Direct Injection (GTDI) (214
CID)
No. cylinders 6
Bore/stroke 92.5/86.7 mm (3.641/3.413 in)
Fire order 1-4-2-5-3-6
Spark plug 12405
Spark plug gap 0.889 mm (0.035 in)
Oil pressure Minimum 30 psi @ 1,500 rpm with engine at normal
operating temperature
Compression ratio 10.0:1

Engine weight (without accessory drive 189.01 kg (416.7 lb)
components)
Cylinder Head and Valve Train
Cylinder head gasket surface flatness Flat within 0.08 mm (0.003 in) length end to end;
area 150 mm (5.9 in) x 150 mm (5.9 in) (or full width)
should be less than 0.05 mm (0.002 in)
Combustion chamber volume 55.84 cc (3.41 CI)
Valve tappet clearance — intake 0.15-0.25 mm (0.006-0.01 in)
Valve tappet clearance — exhaust 0.360-0.460 mm (0.0142-0.0181 in)
Engine must be at room temperature before measuring

Valve guide bore inner diameter 5.519-5.549 mm (0.217-0.218 in)
Valve stem diameter — intake 5.479-5.497 mm (0.2157-0.2164 in)
Valve stem diameter — exhaust 5.466-5.484 mm (0.2151-0.2159 in)
Valve stem-to-guide clearance — intake 0.022-0.070 mm (0.0008-0.0027 in)
Valve stem-to-guide clearance — exhaust 0.035-0.083 mm (0.0013-0.032 in)
Valve head diameter — intake 36.82-37.18 mm (1.44-1.46 in)
Valve head diameter — exhaust 30.82-31.18 mm (1.21-1.22 in)
Valve face runout 0.05 mm (0.0001 in)
Valve face angle 45.75-45.25 degrees
Valve seat width — intake 1.3-1.6 mm (0.051-0.063 in)
Valve seat width — exhaust 1.7-2.0 mm (0.067-0.079 in)
Valve seat runout 0.04 mm (0.0001 in) MAX
Valve seat angle 44.5-45.5 degrees
Valve spring free length (approx.) 55.16 mm (2.17 in)
Valve spring compression pressure (N @ spec. 465 N @ 28.0 mm (105 lb @ 1.10 in)
length)
Valve spring installed height 37.0 mm (1.45 in)
Valve spring installed height pressure (N @ 265 N @ 37.0 mm (60 lb @ 1.45 in)
spec. length)
Valve spring installed pressure — service limit 10% force loss @ specified height
Camshaft
Theoretical valve lift @ 0 lash 9.49 mm (0.373 in)
Lobe lift — intake 9.49 mm (0.373 in)
Lobe lift — exhaust 9.49 mm (0.373 in)
Allowable lobe lift loss 0.062 mm (0.0024 in)
Camshaft journal bore inside diameter — 1st 39.0375-39.0625 mm (1.537-1.538 in)
journal
Camshaft journal bore inside diameter — 25.9875-26.0125 mm (1.023-1.024 in)
intermediate journals
Camshaft bearing outside diameter — 1st 38.990-39.010 mm (1.535-1.536 in)

journal
Camshaft bearing outside diameter — 25.937-25.963 mm (1.021-1.022 in)
Camshaft journal-to-bearing clearance, 1st 0.0725 mm (0.0029 in) MAX
journal — service limit
Camshaft journal-to-bearing clearance, 0.0755 mm (0.0029 in) MAX
intermediate journals — service limit
Runout 0.040 mm (0.0015 in) MAX
End play — standard 0.032-0.170 mm (0.0012-0.0066 in)
End play — service limit 0.190 mm (0.00748 in) MAX
Cylinder Block
block main bore roundness 0.008 mm (0.003 in)
Cylinder bore diameter — grade 1 92.500-92.520 mm (3.641-3.642 in)
Cylinder bore roundness 0.013 mm (0.0005 in)
Cylinder bore taper 0.010 mm (0.0004 in) per 25.4 mm (1.000 in)
Main bearing bore inside diameter 72.400-72.424 mm (2.8503-2.8513 in)
Head gasket surface flatness Flat within 0.150 mm (0.005 in) overall
0.050 mm (0.001 in) per 150 mm (5.905 in) x 150 mm

(5.905 in);
0.025 mm (0.0009 in) per 25 mm (0.984 in) x 25 mm

(0.984 in)
Crankshaft
Main bearing journal diameter 67.5 mm (2.657 in)
Main bearing journal maximum taper 0.004 mm (0.00015 in)
Main bearing journal maximum out-of-round 0.006 mm (0.00023 in)
Main bearing journal-to-cylinder block clearance 0.026-0.041 mm (0.0010-0.0016 in)
Connecting rod journal diameter 55.983-56.003 mm (2.204-2.205 in)
Connecting rod journal maximum taper 0.004 mm (0.00015 in)
Connecting rod journal maximum out-of-round 0.006 mm (0.00023 in)
Crankshaft maximum end play 0.101-0.291 mm (0.0039-0.0114 in)
Piston and Connecting Rod
Piston diameter — single grade 92.476-92.490 mm (3.6407-3.6413 in)
Piston-to-cylinder bore clearance 0.010 to 0.044 mm (0.0003-0.0017 in)
Piston ring end gap — compression (top, gauge 0.17-0.27 mm (0.0067-0.0106 in)
diameter)
Piston ring end gap — compression (bottom, 0.30-0.55 mm (0.0118-0.0216 in)
gauge diameter)
Piston ring end gap — oil ring (steel rail, gauge 0.15-0.45 mm (0.0059-0.0177 in)
diameter)
Piston ring groove width — compression (top) 1.230-1.25 mm (0.0484-0.0492 in)
Piston ring groove width — compression 1.530-1.55 mm (0.0602-0.0610 in)

(bottom)
Piston ring groove width — oil ring 2.53-2.55 mm (0.0996-0.1003 in)
Piston ring width — upper compression ring 1.17-1.19 mm (0.0460-0.0468 in)
Piston ring width — lower compression ring 1.47-1.49 mm (0.0578-0.0586 in)
Piston ring-to-groove clearance (upper and 0.040-0.080 mm (0.0.0014-0.0031 in)
lower compression rings)
Piston pin bore diameter 23.004-23.008 mm (0.9056-0.9058 in)
Piston pin diameter 22.997-23.000 mm (0.9053-0.9055 in)
Piston pin length 2.343 in (59.512 mm)
Piston pin-to-piston fit 0.004-0.011 mm (0.00015-0.00043 in)
Piston-to-connecting rod clearance 3.3 mm (0.13 in)
Connecting rod-to-pin clearance — standard 0.007-0.022 mm (0.0002-0.0009 in)
Connecting rod pin bore diameter 23.007-23.019 mm (0.905-0.906 in)
Connecting rod length (center-to-center) 152.68 mm (6.01 in)
Connecting rod maximum allowed bend 0.038 mm (0.0014 in)
Connecting rod maximum allowed twist 0.050 mm (0.0019 in)
Connecting rod bearing bore diameter — grade 59.866-59.872 mm (2.3569-2.3571 in)
1
2
3
Connecting rod bearing-to-crankshaft clearance 0.020-0.054 mm (0.0007-0.0021 in)
Connecting rod side clearance (assembled to 0.175-0.425 mm (0.0068-0.0167 in)
crank) — standard
crank) — service limit
A/C compressor bolt 25 18 —
A/C compressor stud 9 — 80
A/C tube nut 15 — 133
Accessory drive belt tensioner bolts 25 18 —
Axle shaft housing carrier bushing bolt 115 85 —
Bellhousing-to-engine bolts and stud bolts 48 35 —
Bellhousing-to-oil pan bolts 48 35 —
Block coolant drain plug — RH a — — —
Block coolant drain plug — LH b — — —
Block oil gallery plug — LH c 48 35 —

Block oil gallery plug — rear c 85 63 —
Block oil gallery plug — RH c 32 24 —
Charge Air Cooler (CAC) tube bracket nuts 6 — 53
CAC tube clamps 5 — 44
CAC -to-Throttle Body (TB) pipe clamp 5 — 44
Camshaft bearing cap assembly bolts d — — —
Camshaft bearing cap bolts d — — —
Camshaft Position (CMP) sensor bolts (LH cylinder head) 10 — 89
CMP sensor bolts (RH valve cover) 7 — 62
CMP sensor heat shield bolt 10 — 89
CMP sensor heat shield nut 10 — 89
Catalytic converter-to-exhaust manifold nuts 45 35 —
Catalytic converter-to-intermediate pipe bolts d — — —
Connecting rod cap bolts d — — —
Coolant pump bolts d — — —

Coolant pump pulley bolts 24 18 —
Crankshaft rear seal retainer plate bolts d — — —
Crankshaft pulley bolt d — — —
Crankshaft Position (CKP) sensor bolt 10 — 89
CKP sensor heat shield bolt 10 — 89
CKP sensor heat shield nut 10 — 89
Crossmember brace nuts and bolts 90 66 —
d — — —
Cylinder head bolts
Cylinder head M6 bolt 10 — 89
Cylinder Head Temperature (CHT) sensor 11 — 97
Engine appearance cover bracket bolts 10 — 89
Engine coolant crossover assembly bolt d — — —
Engine front cover bolts d — — —
Engine support insulator bolts 175 129 —
Engine support insulator bracket bolts - LH side 63 46 —
Engine support insulator bracket bolts - RH side, standard payload package 63 46 —
Engine support insulator bracket bolts - RH side, heavy duty payload package 77 53 —
Engine support insulator nuts 175 129 —
Engine support insulator studs 30 22 —
Engine support insulator through bolts 350 258 —
Engine oil filter e — — —
Engine-to-bellhousing bolt 45 35 —
Engine Oil Pressure (EOP) switch d — — —

Evaporative Emission (EVAP) canister purge valve bolt 10 — 89
d — — —
Exhaust manifold nuts
Exhaust manifold studs 12 — 106
d — — —
Flexplate bolts
Fuel injection pump mounting plate bolt d — — —
Fuel rail bolts d — — —

Generator B+ terminal nut 17 — 150
Generator nut and bolt 48 35 —
Generator stud 8 — 71
Ground strap bolt 10 — 89
Ground stud bolt d — — —
Hood bolts 12 — 106
d — — —
High pressure fuel tube bracket bolt
High pressure fuel tube bracket nut 8 — 71
High pressure fuel tube flare nut d — — —
Ignition coil-on-plug bolts d — — —
Intake manifold bolts d — — —

Knock Sensor (KS) bolts 20 — 177
Lower front axle carrier mounting bushing bolt 115 85 —
Main bearing bolts d — — —
Main bearing side bolts d — — —
Main bearing cap support brace bolts d — — —
Oil cooler insert bolt 58 43 —
Oil filter adapter bolts d — — —
Oil pan bolts d — — —
Oil pan drain plug 27 20 —
Oil pump bolts 10 — 89
Oil pump screen and pickup tube bolts 10 — 89
Piston oil cool valves 4 — 35
Primary timing chain tensioner bolts 10 — 89
Radio ignition interference capacitor bolt 10 — 89
Spark plugs 15 — 133
Thermostat housing bolts d — — —
Timing chain gear bolts d — — —
Timing chain guide bolts 10 — 89
Timing chain guide pin f — — —

Timing chain tensioner arm guide pin f — — —
Torque converter nuts 44 32 —
Transmission cooler tube bracket bolt 12 — 106
Transmission cooler tube bracket nut 12 — 106
Transmission crossmember nuts 103 75 —
Turbocharger intake tube clamp 5 — 44
Turbocharger bracket-to-engine bolts 10 — 89
Turbocharger oil return tube assembly bolts g — — —
Turbocharger-to-mounting bracket bolt 28 — 21
Turbocharger-to-exhaust manifold bolts 32 24 —
Vacuum pump bolts d — — —
Wiring harness retainer stud bolt 10 — 89
Valve cover bolts and stud bolts d — — —
Valve train oil tube bolts d — — —
Variable Camshaft Timing (VCT) bolts d — — —
VCT oil control solenoid bolts d — — —
Wiring harness retainer stud bolt 10 — 89
a Tighten to 20 Nm (177 lb-in) plus an additional 180 degrees.
b Tighten to 10 Nm (89 lb-in) plus an additional 720 degrees
c
Discard original plug and O-ring seal. Install a new plug and O-ring seal to specified torque, no sealer or
lubricant required.
d Refer to the procedure in this section.
e
Tighten to 5 Nm (44 lb-in) plus an additional 180 degrees.
f 20 Nm (177 lb-in) plus an additional 60 degrees
g Refer to the assembly procedure in this section.

Engine
The 3.5L Gasoline Turbocharged Direct Injection (GTDI) (4V) is a V-6 engine with the following features:
z Dual overhead camshafts

z Four valves per cylinder
z GTDI
z A composite intake manifold
z Aluminum cylinder heads
z An aluminum, 60-degree V-cylinder block
z Twin independent Variable Camshaft Timing (VCT) system
z The electronic ignition system with 6 ignition coils
Engine Identification
For quick identification, refer to the safety certification decal.
z The decal is located on the LH front door lock face panel.
Engine Code Information Label
The engine code information label, located on the front side of the valve cover, contains the following:
Item Description
1 Engine part number
2 Engine plant (Cleveland)
3 Engine displacement
4 Engine configuration
5 Twin independent Variable Camshaft Timing (VCT)
6 Bar code
7 Bar code
8 Running number
9 Engine build date (DDMMYY)
10 Plant shift line
11 Derivative code
Engine Cylinder Identification
Exhaust Emission Control System
Operation and required maintenance of the exhaust emission control devices used on this engine is covered
in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
The GTDI is Pulse Width Modulated (PWM).
Fuel is metered directly into each combustion chamber. Fuel injectors pulse to follow engine firing order, in
accordance with engine demand.
The various sensors detect any changes in the operating conditions and send signals to the PCM. This
permits the PCM to control the opening duration (pulse width) of the fuel injectors and maintain optimum
exhaust emission control and engine performance for all operating conditions.
Valve Train
The valve train uses Direct Acting Mechanical Buckets (DAMB). The camshaft lobes are positioned directly
above mechanical buckets which are positioned on top of the valves.
Twin Independent Variable Camshaft Timing (VCT) System
The twin independent VCT system allows variable control of intake valve closing which optimizes
combustion at full load providing improved power and low speed torque (broadening the torque curve) which
enables variable valve overlap which provides better fuel economy and emissions and provides optimized
cold start operation with improved exhaust emissions.
PCV System
All engines are equipped with a closed-type PCV system recycling the crankcase vapors to the upper intake
manifold.
Lubrication System
The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the
crankshaft, connecting rod bearings, piston cooling jets, turbochargers, timing chain tensioners and VCT
solenoids. The flow of oil to the valve tappets and valve train is controlled by a restricting orifice located in
the cylinder head, front camshaft cap.
Oil Pump
The lubrication system is designed to provide optimum oil flow to critical components of the engine through
its entire operating range.
The heart of the system is a positive displacement internal gear oil pump.
Generically, this design is known as a gerotor pump, which operates as follows:
z The oil pump is mounted on the front face of the cylinder block.
z The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
z System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil
back to the inlet side of the oil pump.
z Oil pump displacement has been selected to provide adequate volume to make sure of correct oil
pressure both at hot idle and maximum speed.
z The relief valve calibration protects the system from excessive pressure during high-viscosity
conditions.
z The relief valve is designed to provide adequate connecting rod bearing lubrication under high-
temperature and high-speed conditions.
Cooling System
The engine cooling system includes the following:
z Radiator
z Belt driven coolant pump
z Electric fan assembly(s)
z Degas bottle (aids in maintaining the correct volume of engine coolant)
z Coolant thermostat
z Coolant hoses
The channel cover plate is located under the engine front cover mounted to the cylinder block. It contains a
timing chain idler and press-in-place gaskets separating engine coolant and engine oil. A weep hole is
provided on the front left side of the engine behind the generator. If oil or coolant is leaking from the weep
hole, then a gasket has failed and must be replaced.

Engine
For basic engine mechanical concerns, refer to Section 303-00 . For driveability concerns, refer to the
Powertrain Control/Emissions Diagnosis (PC/ED) manual.

Valve Clearance Check
1. Remove the valve covers. For additional information, refer to Valve Cover — LH and Valve Cover —
RH in this section.
2. NOTE: Engine must be at room temperature before measuring. The valve clearance must be
measured with the camshaft at base circle. The engine will have to be rotated with the crankshaft
pulley bolt to bring each valve to base circle.
Use a feeler gauge to measure the clearance of each valve and record its location. A midrange
clearance is the most desirable:
z Intake: 0.15-0.25 mm (0.006-0.01 in)
z Exhaust: 0.360-0.460 mm (0.0142-0.0181 in)
3. NOTE: The number on the valve tappet reflects the thickness of the valve tappet. For example, a
tappet with the number 3.310 has the thickness of 3.31 mm (0.13 in).
If any of the valve clearances are out of specification, select new tappets using this formula: tappet
thickness = measured clearance + the base tappet thickness - most desirable thickness.
Select the tappets and mark the installation location.
4. If required, install the new selected valve tappets in the marked locations. For additional information,
refer to Valve Tappets in this section.

REMOVAL Procedure revision date: 10/25/2013
Engine
Special Tool(s)
Bar, Engine Spreader
303-1454
Lifting Bracket, Engine

303-F047 (014-00073) or
equivalent
Lift Eye, Right Front

303-1566
2,200# Floor Crane, Fold Away

300-OTC1819E or equivalent
Retainer, Torque Converter

307-346 (T97T-7902-A) or
equivalent
working on or near any fuel-related component. Highly flammable mixtures are always present and
may be ignited. Failure to follow these instructions may result in serious personal injury.
components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel
system remains under high pressure, even when the engine is not running. Failure to follow this
02 .
2. NOTE: Index-mark the hood hinge location to aid in hood installation.
NOTE: RH shown, LH similar.
Remove the 4 bolts (2 shown) and the hood.
3. Release the fuel system pressure. For additional information, refer to Section 310-00 .
4. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
5. If equipped, disconnect the block heater electrical connector at the thermostat housing.
z Detach the block heater wiring harness retainer from the LH valve cover stud bolt and position
aside.
6. Remove the cooling module. For additional information, refer Section 303-03 .
7. Remove the LH and RH turbocharger intake tubes. For additional information, refer to 3.5L Gasoline
Turbocharged Direct Injection (GTDI) Charge Air Cooler (CAC) and Tubes Exploded View in Section
303-12 .
8. Remove the 2 Charge Air Cooler (CAC) inlet tubes and the CAC outlet tube. For additional
information, refer to 3.5L Gasoline Turbocharged Direct Injection (GTDI) Charge Air Cooler (CAC)
and Tubes Exploded View in Section 303-12 .
9. Disconnect the Battery Junction Box (BJB) wiring harness and the A/C pressure transducer electrical
connectors.
10. Remove the nut and disconnect the A/C tube.

z Discard the O-ring seal and gasket seal.
11. Remove the nut and the transmission cooler line bracket from the engine front cover stud bolt.
12. Detach the generator wiring harness from the engine front cover.
13. Disconnect the A/C compressor electrical connector.

z Detach the A/C compressor wiring harness from the A/C compressor.
14. Remove the generator. For additional information, refer to Section 414-00 .
15. Remove the A/C compressor belt. For additional information, refer to Section 303-05 .
16. Disconnect the PCM electrical connector and the engine wire harness electrical connector.
z Detach the wiring harness retainers from the fender splash shield.
17. Remove the fuel injection pump. For additional information, refer to Section 303-04A .
18. Remove the intake manifold. For additional information, refer to Intake Manifold in this section.
19. Disconnect the 2 heater hose couplings at the RH rear of the engine.
20. Disconnect the 2 coolant hoses from the degas bottle.
21. Detach the wiring harness retainers from the rear of the RH valve cover stud bolt and the rear of the
vacuum pump.
22. Disconnect the vacuum pump tube and position aside.
23. Remove the bolt and the ground strap from the cowl.
24. Remove the cowl panel grille. For additional information, refer to Section 501-02 .
25. Remove the 6 screws and release the 2 cowl panel clips and remove the cowl panel.
26. Disconnect the Heated Oxygen Sensor (HO2S) electrical connector from the engine wiring harness at
the rear of the LH cylinder head.
z Disconnect the HO2S electrical connector from the wiring harness retainer.
27. Release the 4 fasteners and the splash shield.
28. NOTE: Only one wire harness retainer and one electrical connector shown, others similar.
Disconnect the 2 HO2S electrical connectors.

z Disconnect the 2 HO2S electrical connector retainers.
z If equipped, disconnect the 5 transmission wire harness retainers from the transfer case wire
harness.
29. Disconnect the HO2S electrical connector at the LH rear of the transmission.
z Disconnect the electrical connector retainer from the bracket at the rear of the transmission.
30. NOTICE: Do not pull on the wire harness to disconnect the connector or damage to the
connector will occur.
Disconnect the transmission vehicle harness connector by twisting the outer shell and pulling back on
the connector.
31. Remove the 4 bolts and the skid plate.
32. If equipped, remove the front driveshaft. For additional information, refer to Section 205-01 .
33. Remove the starter motor. For additional information, refer to Section 303-06 .
34. Detach the starter motor wiring harness retainer from the oil pan.
35. Remove the 2 pin-type retainers and the access cover.
36. NOTE: Index-mark the end of one torque converter stud and the flexplate for installation.
Remove the 4 torque converter nuts.
37. Remove the 2 exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolts and
separate.
z Discard the bolts.
38. NOTE: LH shown, RH similar.
Remove and discard the 2 LH and RH catalytic converter-to-exhaust manifold nuts.
39. Remove the drain plug and drain the engine oil.
z Install the drain plug and tighten to 27 Nm (20 lb-ft).
40. Remove and discard the engine oil filter.
41. NOTICE: Only use hand tools when removing the engine support insulator nuts and studs or
damage to the engine support insulator can occur.
Remove and discard the 2 RH engine support insulator nuts and the 2 studs.
42. Remove the engine-to-bellhousing bolt.
43. Remove the oil pan-to-bellhousing bolt.
44. Remove the 2 LH bellhousing-to-engine bolts.
45. Remove the 4 upper bellhousing-to-engine bolts.
46. NOTICE: Only use hand tools when loosening or tightening the engine support insulator
through bolts or damage to the engine support insulator-to-cylinder block bracket can occur.
Remove and discard the LH engine mount through bolt.
47. NOTICE: Do not support the transmission by the fluid pan, failure to follow this instruction
may result in serious damage to the transmission.
Support the bellhousing of the transmission with a suitable floor jack and a block of wood.
48. Remove the 2 LH bellhousing-to-oil pan bolts.
49. Remove the 2 nuts and the CAC tube bracket.

z Disconnect the coolant hose from the valve cover stud.
50. Install the Right Front Lift Eye.
51. Using part of the Engine Lifting Bracket and a chain, assemble the Engine Spreader Bar as shown.
52. NOTICE: Only use hand tools when removing or installing the engine support insulator-to-
frame bolts or damage to the engine support insulator-to-frame nut plate can occur.
NOTE: After removing the bolts leave the LH engine support insulator in place.
Remove and discard the 3 bolts for the LH engine support insulator.
53. NOTE: The use of a ratchet strap may be needed to level the engine.
Using the Floor Crane and Engine Spreader Bar assembly, lift the engine.
54. Remove the LH engine support insulator.
55. NOTE: The transmission wiring harness is part of the engine wiring harness.
Detach the generator wiring harness retainer from the lower LH side of the engine block.
z Position the transmission wiring harness on top of the engine for removal.
56. Using the Floor Crane and Engine Spreader Bar assembly, remove the engine.
57. Install the Torque Converter Retainer.

DISASSEMBLY Procedure revision date: 10/25/2013
Engine
Special Tool(s)
303-1454
3 Jaw Puller
303-D121
Brush, Fuel Injector

310-205
Handle
205-153 (T80T-4000-W)

Hold Down, Secondary Chain

303-1530
Installer, Differential Bearing Cone
205-142 (T80T-4000-J)
Installer, Spindle Bearing

205-150 (T80T-4000-S)

303-1566
Remover, Fuel Injector

310-206
Remover, Oil Seal

303-409 (T92C-6700CH)
Remover, VCT Spark Plug Tube

Seal
303-1247/1
Slide Hammer
307-005 (T59L-100-B)
Strap Wrench
303-D055 (D85L-6000-A)
Tool, Camshaft Holding

303-1248
Material
Item Specification
ZC-31-A
Motorcraft® Silicone Gasket —
Remover
ZC-30
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material,
including any material created while cleaning gasket surfaces that enters the oil passages, coolant
passages or the oil pan, may cause engine failure.
NOTE: For additional information, refer to the exploded view under the Assembly procedure in this section.
All engines
1. Remove the 8 bolts and the flexplate.
2. Remove the spacer plate.
3. Remove the crankshaft sensor ring.
4. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil
pan.
Using the Floor Crane and Engine Spreader Bar, mount the engine on a suitable engine stand.
5. Remove the 2 bolts and the Right Front Lift Eye.
6. Remove the A/C compressor and the 3 bolts.
7. Remove the LH crankcase vent tube. For additional information, refer to Section 310-00 .
8. Remove the RH PCV tube. Refer to Section 310-00 .
Disconnect the 2 wastegate hoses at the turbochargers.
Remove the 2 tie straps for the wastegate hose assembly.
11. Disconnect the turbocharger pressure regulator electrical connector. Remove the 2 tie straps and the
wastegate hose assembly.
12. Using a commercially available quick disconnect tool, remove the LH turbocharger coolant supply
tube.
13. Remove the 2 bolts at the LH turbocharger oil return tube.

z Remove and discard the turbocharger return tube gasket.
14. Remove the bolt for the LH turbocharger coolant and oil tubes.
15. Remove the 3 bolts and the LH turbocharger.

z Discard the turbocharger exhaust manifold gasket.
16. Remove the bolt and the LH oil turbocharger oil return tube.
z Remove and discard the O-ring seal.
17. Using a commercially available quick disconnect tool, remove the RH turbocharger coolant supply
tube.
18. Remove the 2 bolts at the RH turbocharger oil return tube.

z Remove and discard the turbocharger oil return tube gasket.
19. Remove the bolt for the RH turbocharger coolant and oil tubes.
20. Remove the 3 bolts and the RH turbocharger.

21. Remove the bolt and the RH turbocharger oil return tube.
22. Remove the 4 bolts and the RH engine support insulator.

23. Remove the 4 bolts and the LH engine support insulator-to-cylinder block bracket.
24. NOTICE: Do not use excessive force when removing the vacuum pump or the vacuum pump
oil tube may be dislodged from the vacuum pump causing internal oil seal damage to the
pump. If the oil tube becomes dislodged from the pump, a new vacuum pump must be
installed.
Remove the 3 bolts and the vacuum pump.
25. Remove the engine oil level indicator.
26. Disconnect the 2 LH Variable Camshaft Timing (VCT) solenoid electrical connectors. Remove the tie
strap.
27. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
z Detach the EOP switch wiring harness retainer from the cylinder head.
28. Disconnect the 3 LH ignition coil-on-plug electrical connectors.
29. Remove the nut, the bolt and the CKP heat shield.
30. Remove the wiring harness retainer stud bolt.
31. Remove the wiring harness grommet.
32. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
33. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
34. Disconnect the 2 LH Camshaft Position (CMP) sensor electrical connectors. Disconnect the CKP wire
retainer. Remove the ground stud bolt.
35. Disconnect the Knock Sensor (KS) sensor electrical connector. Disconnect the 2 fuel charge harness
and the Fuel Rail Pressure (FRP) electrical connectors.
36. Disconnect the wire retainer. Remove the bolt, nut and the CMP heat shield.
37. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. Remove the ground
stud bolt and the tie strap.
38. Disconnect the 2 RH VCT solenoid electrical connectors. Remove the tie strap.
39. Disconnect the 3 RH ignition coil-on-plug electrical connectors.
40. Disconnect the 2 RH CMP electrical connectors.
41. Disconnect the wire harness retainer and remove the tie strap.
42. Detach all of the wiring harness retainers from the RH valve cover and stud bolts. Remove the engine
wire harness.
43. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
z Inspect the crankshaft pulley sealing surface for nicks or scratches that may effect the
crankshaft front seal lip, replace the crankshaft pulley if necessary.
z Discard the bolt.
44. Using the 3 Jaw Puller, remove the crankshaft pulley.
45. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
46. Remove the 2 bolts and the accessory drive belt tensioner.
47. Remove the LH cylinder block drain plug.

z Allow coolant to drain from the cylinder block.
48. Remove the RH cylinder block drain plug.

49. Remove the 4 bolts and the thermostat housing.

z Discard the thermostat housing and coolant inlet tube O-ring seals.
50. Remove the 4 bolts and the coolant pump pulley.
51. Remove the 7 bolts and the coolant pump.

z Discard the coolant pump gasket and coolant pump O-ring seal.
52. Remove the coolant inlet pipe.

z Remove and discard the coolant inlet pipe O-ring seals.
53. Remove the 3 bolts and the coolant crossover manifold assembly.
z Remove and discard the 2 gaskets.
54. Remove the bolt for the high-pressure fuel tube.
55. Loosen the 2 flare nuts, remove and discard the high-pressure fuel tube assembly.
56. NOTICE: Pull out the fuel rails in the direction of the fuel injector axis or damage may occur to
the fuel injectors
NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally
remain lodged in the cylinder heads and require the use of a Fuel Injector Remover to extract.
Remove the 6 bolts and the LH fuel rail.

the fuel injectors
NOTE: When removing the fuel rails, the fuel injectors may remain in the fuel rails but normally
remain lodged in the cylinder heads and require the use of a Fuel Injector Remover to extract.
Remove the 6 bolts and the RH fuel rail.

58. NOTE: RH shown, LH similar.
Disconnect the 6 fuel injector electrical connectors and remove the 2 fuel injector wire harness.
59. Using the Slide Hammer and the Fuel Injector Remover, remove any fuel injectors remaining in the
cylinder head.
60. Remove and discard the 6 upper fuel injector O-rings.
61. Remove and discard the 6 fuel injector clips.
62. NOTE: Make sure to thoroughly clean any residual fuel or foreign material from the cylinder head,
block and general surrounding area of the fuel rails and fuel injectors.
NOTE: Do not use compressed air to clean the tip of the fuel injector.
NOTE: Do not use the brush to clean the tip of the fuel injector.
Using the Fuel Injector Brush, clean the 6 fuel injector bores in the cylinder heads.
63. Remove the bolt and the fuel injection pump mounting plate.
z Remove and discard the gaskets.
64. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease
removal.
Remove the 3 bolts and the 3 LH ignition coil-on-plugs.
65. NOTICE: Only use hand tools when removing the spark plugs, or damage may occur to the
cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the
spark plugs.
Remove the 3 LH spark plugs.
66. NOTICE: While removing the valve cover do not apply excessive force to the Variable
Camshaft Timing (VCT) oil control solenoid or damage may occur.
NOTICE: If the Variable Camshaft Timing (VCT) oil control solenoid sticks to the VCT seal,
carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT
oil control solenoid may occur.
NOTE: The plastic electrical connector on the VCT oil control solenoid will rotate approximately 12
degrees inside the steel housing, which is normal.
Loosen the 11 stud bolts and remove the LH valve cover.

z Discard the gasket.
67. Inspect the 2 VCT solenoid seals. Remove any damaged seals.
z Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
68. Inspect the spark plug tube seals. Remove any damaged seals.
z Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
69. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.
70. Remove the 8 nuts and the LH exhaust manifold.

z Discard the nuts and exhaust manifold gasket.
71. Clean and inspect the LH exhaust manifold. For additional information, refer to Section 303-00 .
72. Remove and discard the 8 LH exhaust manifold studs.
removal.
Remove the 3 bolts and the 3 RH ignition coil-on-plugs.
spark plugs.
Remove the 3 RH spark plugs.
75. Remove the 2 bolts and the CMP sensors.
Loosen the 12 stud bolts and remove the RH valve cover.

80. Remove the 8 nuts and the RH exhaust manifold.

z Discard the nuts and exhaust manifold gasket.
81. Clean and inspect the RH exhaust manifold. For additional information, refer to Section 303-00 .
82. Remove and discard the 8 RH exhaust manifold studs.
83. Remove the 2 bolts and the LH CMP sensors.
84. Remove and discard the CHT sensor
85. Remove the bolt and the CKP sensor.
86. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.
Remove the threaded shaft and the oil cooler.

z Discard the oil cooler.
87. Remove the 5 bolts and the oil filter adapter.

88. Remove the 22 engine front cover bolts.
89. Using a suitable pry tool, locate the 7 pry pads shown and pry the engine front cover loose and
remove.
90. NOTE: Inspect and replace the front cover radial seal as necessary.
NOTE: Use Spindle Bearing Installer 205-150 to remove the seal.
Using the Spindle Bearing Installer and Handle, remove the front cover radial seal from the rear side
of the front cover.
91. Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown.
92. Remove the 3 bolts and the LH valve train oil tube.
93. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.
Install the Camshaft Holding Tool onto the flats of the LH camshafts.
94. Remove the 3 bolts and the RH valve train oil tube.
95. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install the Camshaft Holding Tool onto the flats of the RH camshafts.
NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
96. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown.
97. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown.
98. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown.
99. Remove the 2 bolts and the primary timing chain tensioner.
100. Remove the primary timing chain tensioner arm.
101. Remove the 2 bolts and the lower LH primary timing chain guide.
102. NOTE: Removal of the VCT oil control solenoid will aid in the removal of the primary timing chain.
NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
Remove the bolt and the LH intake VCT oil control solenoid.
Remove the bolt and the RH intake VCT oil control solenoid.
104. Remove the primary timing chain.
105. Remove the crankshaft timing chain sprocket.
106. NOTICE: Do not use power tools to remove the bolt or damage to the LH primary timing chain
guide may occur.
Remove the bolt and the upper LH primary timing chain guide.
107. NOTE: The 2 VCT oil control solenoids are removed for clarity.
NOTE: The Secondary Chain Hold Down is inserted through a hole in the top of the mega cap.
Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down in the
hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to
retain the tensioner in the collapsed position.
108. Remove and discard the 2 LH VCT assembly bolts.
109. Remove the 2 LH VCT assemblies and secondary timing chain.
Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down in
the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega
cap to retain the tensioner in the collapsed position.
111. Remove and discard the 2 RH VCT assembly bolts.
112. Remove the 2 RH VCT assemblies and secondary timing chain.
113. NOTICE: Do not use power tools to remove the bolt or damage to the RH primary timing chain
guide may occur.
Remove the 2 bolts and the RH primary timing chain guide.
114. Remove the 9 bolts and the timing chain gear.

Engines with secondary timing chain tensioner removed
NOTICE: The following steps are only for the replacement of the secondary timing chain tensioners.
Do not reuse the secondary timing chain tensioners if removed, or damage to the engine may occur.
115. NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
Remove the LH exhaust VCT oil control solenoid.
116. Remove the LH secondary timing chain tensioner shoe.
117. Remove the LH secondary timing chain tensioner by pushing up from the bottom and remove.
Remove the RH exhaust VCT oil control solenoid.
119. Remove the RH secondary timing chain tensioner shoe.
120. Remove the RH secondary timing chain tensioner by pushing up from the bottom and remove.
All engines
121. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the LH
camshafts approximately 3 degrees to a neutral position.
Remove the Camshaft Holding Tool from the LH camshafts.
122. NOTICE: The camshafts must remain in the neutral position during removal or engine damage
may occur.
Verify the LH camshafts are in the neutral position.
123. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their
original positions.
NOTE: Mark the exhaust and intake camshafts for installation into their original locations.
Remove the 12 bolts, 6 camshaft caps, mega cap and the LH camshafts.
124. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the RH
Remove the Camshaft Holding Tool from the RH camshafts.
may occur.
Rotate the RH camshafts counterclockwise to the neutral position.
126. Remove the 2 bolts and the camshaft bearing cap assembly.
original positions.
Remove the 12 bolts, 6 camshaft caps, mega cap and the RH camshafts.
128. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the
components for installation into their original locations.
NOTE: LH shown, RH similar.
Remove the valve tappets from the cylinder heads.
129. Inspect the valve tappets. For additional information, refer to Section 303-00 .
Remove and discard the M6 bolt from each cylinder head.
131. NOTICE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the
towels so foreign material is not dropped into the engine. Any foreign material (including any
material created while cleaning gasket surfaces) that enters the oil passages or the oil pan,
may cause engine failure.
NOTICE: Aluminum surfaces are soft and may be scratched easily. Never place the cylinder
head gasket surface, unprotected, on a bench surface.
NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a
tighten-to-yield design and cannot be reused.
Remove and discard the 8 bolts from each cylinder head.

z Remove the cylinder heads.
z Discard the cylinder head gaskets.
132. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
means to clean the sealing surfaces. These tools cause scratches and gouges that make leak
paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: Observe all warnings or cautions and follow all application directions contained on the
packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and
prepare the surfaces.
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder heads and the cylinder
block in the following sequence.
1. Remove any large deposits of silicone or gasket material with a plastic scraper.
2. Apply silicone gasket remover, following package directions, and allow to set for several
minutes.
3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone
gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep, following package directions, to remove any remaining traces of oil
or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make
the metal shiny. Some staining of the metal surfaces is normal.
133. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion. For additional information, refer to Section 303-00 .
134. Remove the 2 bolts and the KS .
135. Remove the 16 oil pan bolts.
Using a suitable pry tool, locate the 2 pry pads at the LH and RH side of the oil pan and pry the oil
pan loose and remove.
137. Remove the 3 bolts and the oil pump screen and the pickup tube.
z Discard the O-ring seal.
138. Remove the 3 bolts and the oil pump.
139. Remove the 8 bolts and the crankshaft rear seal retainer plate.
z Discard the plate and seal assembly.
140. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or
carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's
instructions.
141. NOTE: The main bearing cap support brace bolts must be discarded and new bolts must be installed.
They are a tighten-to-yield design and cannot be reused.
Remove the bolts in the sequence shown.

z Remove the main bearing cap support brace.
142. NOTE: The connecting rod cap bolts are a tighten-to-yield design. The original connecting rod cap
bolts will be used when measuring the connecting rod large end bore during assembly. The
connecting rod cap bolts will be discarded after measurement.
NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and
connecting rod bearings for reassembly.
Remove the connecting rod cap bolts and cap.
143. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Remove the piston/rod assembly from the engine block.
144. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
145. NOTE: The 8 main bearing cap side bolts must be discarded and new bolts must be installed. They
are a tighten-to-yield design and cannot be reused.
NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
Remove the 8 main bearing cap side bolts in the sequence shown.
146. NOTE: The 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a
Remove the 8 main bearing cap bolts in the sequence shown.

147. NOTE: If the main bearings are being reused, mark them for correct position and orientation for
reassembly.
NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.
Remove the 4 main bearing caps.
148. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing
bulkhead.
Remove the crankshaft.
149. NOTE: Inside shown, outside similar.
Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
reassembly.
Remove the 4 crankshaft main bearings from the cylinder block.
151. Using a hexagonal screwdriver, remove the 6 piston oil cool valves.
reassembly.
Remove the 4 crankshaft main bearings from the main bearing caps.
153. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional
154. NOTICE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in
white, part number 07528) to clean the sealing surfaces. These tools cause scratches and
gouges that make leak paths. They also cause contamination that causes premature engine
failure. Remove all traces of the gasket.
Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following
sequence.
1. Remove any large deposits of silicone or gasket material.
2. Apply silicone gasket remover and allow to set for several minutes.
3. Remove the silicone gasket remover. A second application of silicone gasket remover may be
required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep to remove any remaining traces of oil and to prepare the surfaces to
bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
155. NOTICE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the
engine front cover and oil pan. Do not use metal scrapers, wire brushes or any other power
abrasive disk to clean the engine front cover and oil pan. These tools cause scratches and
gouges that make leak paths.
Clean the engine front cover and oil pan using a 3M™ Roloc® Bristle Disk (2-in white, part number
07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
z Thoroughly wash the engine front cover and oil pan to remove any foreign material, including
any abrasive particles created during the cleaning process.

ASSEMBLY Procedure revision date: 04/11/2013
Engine
Special Tool(s)
Compressor, Piston Ring
303-D032 (D81L-6002-C)

Fixture
100-002 (TOOL-4201-C)

303-1454
Feeler Gauge Set

303-D027 (D81L-4201-A) or
equivalent
Handle
205-153 (T80T-4000-W)

303-1530
205-142 (T80T-4000-J)

205-149 (T80T-4000-R)

Installer, Crankshaft Vibration

Damper
303-102 (T74P-6316-B)
Installer, Front Cover Oil Seal

303-335
Installer, Front Crankshaft Seal

303-1251
Installer, VCT Spark Plug Tube

Seal
303-1247/2

303-1566
Seal Installer, Fuel Injector

310-207
Sizer, Teflon® Seal

303-1567
Strap Wrench
303-D055 (D85L-6000-A)

303-1248
Material
Item Specification
Motorcraft® Gasket Maker WSK-
TA-16 M2G348-A5
Motorcraft® High Performance WSE-
TA-357
LSP12 (Canada)
Motorcraft® Orange WSS-
VC-3-B (US); CVC-3-B2 (Canada)
Motorcraft® Thread Sealant with WSK-
PTFE M2G350-A2
TA-24
Engine Upper

1 12A581 Engine control harness
2 9424 Intake manifold
3 9439 Intake manifold gasket
4 8C368 Coolant crossover
5 — Coolant crossover gasket (2 required)
6 8A505 Thermostat housing inlet tube
7 8592 Thermostat housing
8 9D280 RH Fuel rail
9 9D280 LH Fuel rail
10 12A699 Knock Sensor (KS)
Engine Upper — LH Cylinder Head
Part
1 12029 Ignition coil-on-plug (3 required)
2 6582 LH valve cover
3 6K602 Valve train oil feed tube
4 6K254 LH secondary timing chain tensioner

5 6A258 LH camshaft cap
6 6M280 Intake camshaft Variable Camshaft Timing (VCT) oil
control solenoid
7 6M280 Exhaust camshaft VCT oil control solenoid
8 6B280 Camshaft mega cap
9 6A258 LH camshaft cap (4 required)
10 6K297 LH secondary tensioner shoe
11 6250 LH intake camshaft
12 6250 LH exhaust camshaft
13 6256 Intake camshaft VCT assembly
14 6C525 Exhaust camshaft VCT assembly
15 6268 LH secondary timing chain
16 12405 Spark plug (3 required)
17 6500 Valve tappet (16 required)
18 6B288 LH cylinder head Camshaft Position (CMP) sensor (2
required)
19 6049 LH cylinder head
20 6051 LH cylinder head gasket
21 W712244 LH exhaust manifold stud (8 required)
22 9448 LH exhaust manifold gasket
23 9431 LH exhaust manifold
Engine Upper — RH Cylinder Head
Part
1 6B288 RH cylinder head Camshaft Position (CMP) sensor (2
required)
3 6582 RH valve cover
5 6K254 RH secondary timing chain tensioner
7 6M280 Exhaust camshaft Variable Camshaft Timing (VCT) oil
control solenoid
8 6M280 Intake camshaft VCT oil control solenoid

9 6K297 RH secondary tensioner shoe
10 6A258 RH camshaft cap (6 required)
11 6B284 RH rear camshaft bearing cap assembly
12 2A251 Vacuum pump
13 6250 RH exhaust camshaft
15 6250 RH intake camshaft
16 6268 RH secondary timing chain
19 6049 RH cylinder head
20 6051 RH cylinder head gasket
22 W712244 RH exhaust manifold stud (8 required)
23 6G004 Cylinder Head Temperature (CHT) sensor
24 9448 RH exhaust manifold gasket
25 9430 RH exhaust manifold
Engine Front

1 6A340 Crankshaft pulley bolt
2 6378 Crankshaft pulley washer
3 6312 Crankshaft pulley
4 6700 Crankshaft front seal
5 8501 Coolant pump
6 6019 Engine front cover
7 6268 Timing chain
8 6306 Crankshaft timing sprocket
9 6K254 Primary timing chain tensioner
10 6K255 Primary timing chain tensioner arm
11 6B274 LH lower primary timing chain guide
12 8501 Timing chain gear
13 6M256 RH primary timing chain guide
14 6K297 LH upper primary timing chain guide
15 6010 Cylinder block
Lower Engine Block (View 1)

1 6600 Oil pump
2 6625 Oil pump screen and pickup tube O-ring seal
4 6K301 Crankshaft rear seal retainer plate
5 6C315 Crankshaft Position (CKP) sensor
6 12A227 Crankshaft sensor ring
7 6375 Flexplate
8 6622 Oil pump screen and pickup tube
9 6881 Oil filter adapter
10 9278 Engine Oil Pressure (EOP) switch
11 6675 Oil pan
12 6731 Engine oil filter
13 6L626 Oil cooler insert bolt
14 6A642 Oil cooler
Part
1 — Piston compression upper ring (part of 6148) (6
required)
2 — Piston compression lower ring (part of 6148) (6
required)
3 — Piston oil control upper segment ring (part of 6148) (6
required)
4 — Piston oil control spacer (part of 6148) (6 required)
5 — Piston oil control lower segment ring (part of 6148) (6
required)
6 6140 Piston pin (6 required)
7 6110 Piston (6 required)

8 6135 Piston pin retainer (12 required)
9 6200 Connecting rod (6 required)
10 6211 Connecting rod upper bearing (6 required)
12 6K868 Piston oil cool valve (6 required)
13 6211 Connecting rod lower bearing (6 required)
14 6A341 Crankshaft upper thrust washer (2 required)
15 6D309 Cylinder block crankshaft main bearing (4 required)
16 6303 Crankshaft
17 6K302 Crankshaft lower thrust washer
18 6D309 Lower crankshaft main bearing (4 required)
19 6325 Lower crankshaft main bearing cap (4 required)
20 6C364 Main bearing cap support brace
NOTE: Assembly of the engine requires various inspections/measurements of the engine components
(engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will
aid in determining if the engine components will require replacement. For additional information, refer to
Section 303-00 .
All engines
1. NOTE: This procedure is for selecting bearings using a new crankshaft.
Select the crankshaft main bearings for each crankshaft journal.

z Read the code on the crankshaft flange.
z Read the code on the cylinder block face.
The first letter after the first asterisk makes up the code for main No. 1 and the next
letter for main No. 2. The first letter after the second asterisk makes up the code for
main No. 3 and the last letter for main No. 4.
2. Using a hexagonal screwdriver, install the 6 piston oil cool valves.

3. NOTE: This chart is for selecting main bearings 1 and 4 only, the remaining bearings will be selected
using a different chart in the next step.
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the
required bearing grade for main bearings 1 and 4.
z Read the first letter of the engine block main bearing code and the first letter of the crankshaft
main bearing code.
z Read down the column below the engine block main bearing code letter and across the row
next to the crankshaft main bearing code letter, until the 2 intersect. This is the required
bearing grade(s) for the No. 1 crankshaft main bearing.
z As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the
correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower
bearing.
z Repeat the above steps using the fourth letter of the block and crankshaft codes to select the
No. 4 bearing.
4. NOTE: This chart is for selecting main bearings 2 and 3 only.
z Read the second letter of the engine block main bearing code and the second letter of the
crankshaft main bearing code.
bearing grade for the No. 2 crankshaft main bearing.
correct bearing grade for this main bearing is "1".
z Repeat the above steps using the third letter of the block and crankshaft codes to select the
No. 3.
5. NOTICE: The rod cap installation must keep the same orientation as marked during
disassembly or engine damage may occur.
Using the original connecting rod cap bolts, install the connecting rod caps and bolts.
z Tighten the bolts in 3 stages.
6. Measure the connecting rod large end bore in 2 directions. For additional information, refer to
z Remove the bolts and the rod cap.
Discard the connecting rod cap bolts.
7. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions. For
8. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod
journal.
9. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and
foreign material. Also, make sure the coolant and oil passages are clear.
Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main
bearings in the cylinder block.
10. NOTE: Do not install the upper thrust bearings until the crankshaft is installed.
NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.
Install the crankshaft onto the upper main bearings.
11. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust
surface.
Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the
No. 4 rear bulkhead.
surface.
Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No.
4 rear bulkhead.
13. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main
bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating
in caps.
14. Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as
square as possible, alternately draw the caps down evenly using the new bolts until the main bearing
caps are seated.
surface.
NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the
tab aligned with the cutout in the main bearing cap.
16. Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible,
alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.
17. Loosen the No. 4 main bearing cap bolts.
18. NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4
main bearing cap rearward to seat the crankshaft thrust washers.
Tighten the main bearing bolts in 2 stages in the sequence shown.

z Stage 1: Tighten fasteners 1 through 8 to 33 Nm (24 lb-ft).
z Stage 2: Tighten fasteners 1 through 8 an additional 90 degrees.
19. Install the new 8 main bearing cap side bolts. Tighten in 2 stages in the sequence shown.
20. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
z Position the crankshaft to the rear of the cylinder block.
z Zero the Dial Indicator Gauge.
z Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
Prepare the connecting rod and cap.

z Insert the new bolts in the rod cap.
z Insert the upper and lower rod bearings into the rod and cap.
22. Before installing the pistons into the cylinder block, verify proper ring gap location.
1. Center line of the piston parallel to the wrist pin bore
2. Upper compression ring gap location
3. Upper oil control segment ring gap location
4. Lower oil control segment ring gap location
5. Expander ring and lower compression ring gap location
23. NOTICE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting
rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE: The next 3 steps are for all 6 connecting rods, rod caps and pistons. Only 1 connecting rod,
rod cap and piston is shown.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with
clean engine oil.
NOTE: Make sure the piston rings are positioned to specifications for installation. For additional
information, refer to Disassembly and Assembly of Subassemblies - Piston in this section.
NOTE: If the piston and/or connecting rod are being installed new, the piston rod orientation marks
and the arrow on the top of the dome of the piston should be facing toward the front of the engine
block.
NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same
orientation as disassembled.
Using the Piston Ring Compressor, install the piston and connecting rod assemblies.
24. Seat the connecting rod on the crankshaft journal.
NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to
verify smooth operation.
Install the connecting rod cap and bolts. Tighten the bolts in 3 stages.
26. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are
installed.
27. Install the main bearing cap support brace and the new bolts. Tighten in 2 stages in the sequence
shown.
z Stage 1: Tighten fasteners to 24 Nm (18 lb-ft).
z Stage 2: Tighten fasteners an additional 180 degrees.
28. NOTICE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the
engine oil to foam excessively and result in serious engine damage.
NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 10 minutes
of sealant application.
NOTE: The stamped steel crankshaft rear seal retainer plate comes with the crankshaft rear seal.
Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing
surface of the crankshaft rear seal retainer.
29. NOTE: Lubricate the crankshaft rear seal and the crankshaft with clean engine oil prior to installation.
NOTE: Use the handles during installation to avoid touching the sealant.
Install the 8 crankshaft rear seal retainer plate bolts. Tighten in the sequence shown.
30. Install the oil pump and the 3 bolts.

31. Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts.
NOTE: The oil pan and the 4 specified bolts must be installed and the oil pan aligned to the cylinder
block within 4 minutes of sealant application. Final tightening of the oil pan bolts must be carried out
within 60 minutes of sealant application.
Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone on the inside
edge of the oil pan to the sealing surface of the oil pan-to-engine block mating surface.
33. Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2
crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
34. NOTE: The oil pan and the 4 specified bolts must be installed within 4 minutes of the start of sealant
application.
Install the oil pan and bolts 10, 11, 13 and 14 finger tight.
35. Laterally align the oil pan to the block. Make sure the oil pan is flush with the block at these 2 points.
36. Tighten bolts 10, 11, 13 and 14 in the sequence shown.

37. Install the remaining oil pan bolts and tighten in the sequence shown.
z Tighten bolts 1-9 and 11-14 to 20 Nm (177 lb-in), then rotate an additional 45 degrees.
z Tighten bolts 15 and 16 to 10 Nm (89 lb-in), then rotate an additional 45 degrees.
z Tighten bolt 10 to 20 Nm (177 lb-in), then rotate an additional 90 degrees.
38. Install the Knock Sensor (KS) and the 2 bolts.

39. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in 5 stages in the sequence
shown.
z Stage 1: Tighten to 20 Nm (177 lb-in).
z Stage 3: Tighten 90 degrees.
40. Install the new M6 bolt.

41. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in 5 stages in the sequence
shown.

43. NOTE: The valve tappets must be installed in their original positions.
NOTE: Coat the valve tappets with clean engine oil prior to installation.
Install the valve tappets.
44. NOTICE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9
o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do
not turn the crankshaft until instructed to do so. Failure to follow this process will result in
severe engine damage.
Position the crankshaft dowel pin in the 9 o'clock position.
45. NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the RH cylinder head in the neutral position as shown.
46. NOTICE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine
may occur.
Position the 4 camshaft seals gaps as shown.
original positions.
Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown.
z Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
48. Loosen the 4 camshaft caps bolts.
49. Tighten the 4 camshaft caps bolts in the sequence shown.

z Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
50. NOTICE: If any components are installed new, the engine valve clearance must be
checked/adjusted or engine damage may occur.
NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet
clearances are not within specification, the clearance must be adjusted by installing new valve tappet
(s) of the correct size. For additional information, refer to Valve Clearance Check in this section.
51. NOTE: The camshaft bearing cap assembly must be secured within 10 minutes of the Gasket Maker
application. If the camshaft bearing cap assembly is not secured within 10 minutes, the sealant must
be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep.
Apply a 3 mm (0.118 in) bead of sealant to the camshaft bearing cap assembly.
52. Install the camshaft bearing cap assembly and the 2 bolts.
z Remove the excess gasket maker.
54. Rotate the RH camshafts to the Top Dead Center (TDC) position as shown.
Position the camshafts onto the LH cylinder head in the neutral position as shown.
may occur.
original positions.

63. Rotate the LH camshafts to the TDC position as shown.
65. Using a new gasket, install the timing chain gear and the 9 bolts. Tighten in 2 stages in the sequence
shown.
66. Install the RH primary timing chain guide and the 2 bolts.
Do not reuse the secondary timing chain tensioners if removed or damage to the engine may occur.
67. NOTE: Apply clean engine oil to the secondary timing chain tensioner O-ring seals and mega cap
bore.
NOTE: Do not remove the secondary timing chain tensioner shipping clip, until instructed to do so.
Install the RH secondary timing chain tensioner by pushing it down all the way until a snap is heard
and the tensioner is seated all the way down the mega cap bore.
68. Install the RH secondary timing chain tensioner shoe.
69. Remove and discard the RH secondary timing chain tensioner shipping clip.
70. Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and
the RH secondary timing chain.
z Align the colored links with the timing marks.
71. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing
assembly.
Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the
holes in the VCT assemblies with the dowel pins in the camshafts.
72. Install the 2 new RH VCT bolts and tighten in 4 stages.

z Stage 2: Loosen one full turn.
73. Activate the RH secondary timing chain tensioner by pressing down on the secondary tensioner shoe
until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
74. NOTICE: Do not use excessive force when installing the Variable Camshaft Timing (VCT) oil
control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If
difficult to install the VCT oil control solenoid, inspect the bore and VCT oil control solenoid to
ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only
clean the external surfaces as necessary.
NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
Install the RH exhaust VCT oil control solenoid.

bore.
Install the LH secondary timing chain tensioner by pushing it down all the way until a snap is heard
76. Install the LH secondary timing chain tensioner shoe.
77. Remove and discard the LH secondary timing chain tensioner shipping clip.
78. Assemble the 2 LH VCT assemblies and the LH secondary timing chain.
79. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing
assembly.
Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the
80. Install the 2 new LH VCT bolts and tighten in 4 stages.

81. Activate the LH secondary timing chain tensioner by pressing down on the secondary tensioner shoe
Install the LH exhaust VCT oil control solenoid.

Engines with secondary timing chain tensioner not removed
83. Compress the RH secondary chain tensioner and install the Secondary Chain Hold Down to retain
the tensioner in the collapsed position.
assembly.

87. Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down.
z Make sure the secondary timing chain is centered on the timing chain tensioner guides.
88. Compress the LH secondary chain tensioner and install the Secondary Chain Hold Down to retain the
tensioner in the collapsed position.
assembly.

92. Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down.
All engines
93. Install the upper LH primary timing chain guide and the bolt.
94. Rotate the crankshaft 60 degrees to the Top Dead Center (TDC) position (crankshaft dowel at 11
o'clock).
95. Install the crankshaft timing chain sprocket with timing dot mark out.
96. NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.
Install the primary timing chain with the colored links aligned with the timing marks on the VCT
assemblies and the crankshaft sprocket.
97. Install the lower LH primary timing chain guide and the 2 bolts.
98. Install the primary timing chain tensioner arm.
99. Reset the primary timing chain tensioner.

1. Release the ratchet detent.
2. Using a soft-jawed vise, compress the ratchet plunger.
3. Align the hole in the ratchet plunger with the hole in the tensioner housing and install a suitable
lockpin.
100. NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to
install the tensioner.
Install the primary timing chain tensioner and the 2 bolts.

z Remove the lockpin.
101. As a post-check, verify correct alignment of all timing marks.

z There are 48 links in between the RH intake VCT assembly colored link (1) and the LH intake
VCT assembly colored link (2).
z There are 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft
sprocket links (3).
Install the LH intake VCT oil control solenoid and the bolt.
Install the RH intake VCT oil control solenoid and the bolt.
104. Remove the RH Camshaft Holding Tool.
105. Install the RH valve train oil tube and the 3 bolts and tighten in 2 stages.
106. Remove the LH Camshaft Holding Tool.
107. Install the LH valve train oil tube and the 3 bolts and tighten in 2 stages.
108. NOTE: Use Spindle Bearing Installer 205-149 to install the seal.
Using the Spindle Bearing Installer, install the front cover radial seal from the rear side of the front
cover.
NOTICE: Do not expose the Motorcraft® High Performance Engine RTV Silicone to engine oil
for at least 90 minutes after installing the engine front cover. Failure to follow this procedure
can cause engine oil leakage.
NOTE: The engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 must be installed within
10 minutes of the initial sealant application. The remainder of the engine front cover bolts and the
engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant
application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned
and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface
prep. Failure to follow this procedure can cause future oil leakage.
Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone on the inside
edge of the engine front cover to the engine front cover sealing surfaces including the 2 engine front
cover bolt bosses.
z Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil
pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front
cover in 5 places as indicated.
110. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 and tighten in the
sequence shown in 3 stages:
z Stage 1: Tighten bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 in sequence to 10 Nm (89 lb-in).
z Stage 2: Tighten bolts 1, 2, 7, 8, 15, 17, 18, 19 and 20 in sequence to 20 Nm (177 lb-in) then
an additional 45 degrees.
z Stage 3: Tighten bolt 21 to 20 Nm (177 lb-in) then an additional 90 degrees.
111. Install the remaining 12 engine front cover bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 16, 22 and tighten in
the sequence shown in 3 stages:
z Stage 1: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, and 16 to 10 Nm (89 lb-in).
z Stage 2: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, and 16 to 20 Nm (177 lb-in) then an
additional 45 degrees.
112. Using a new gasket, install the oil filter adapter and the 5 bolts and tighten in sequence shown.
Install the new oil cooler and the oil cooler insert bolt.
114. Install the Crankshaft Position (CKP) sensor and install the bolt.
115. Install the new the Cylinder Head Temperature (CHT) sensor.
116. NOTE: Lubricate the 2 CMP sensor O-ring seals with clean engine oil.
Install the 2 LH CMP sensors and the bolts.

117. Install the 8 new RH exhaust manifold studs.

118. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause
the exhaust manifold to develop an exhaust leak.
Using a new gasket, install the RH exhaust manifold and the 8 new nuts. Tighten in 2 stages in the
sequence shown.
119. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).
121. NOTICE: Failure to use the correct Motorcraft® High Performance Engine RTV Silicone may
cause the engine oil to foam excessively and result in serious engine damage.
NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant
must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket
remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine
front cover-to-RH cylinder head joints.
122. Using a new gasket, install the RH valve cover and tighten the 12 stud bolts in the sequence shown.
123. Ensure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical
connector or the VCT seal may leak oil.
Install the 2 RH CMP sensors and the bolts.

125. NOTICE: Only use hand tools when installing the spark plugs, or damage may occur to the
Install the 3 RH spark plugs.

126. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
z To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
127. Install the 3 RH ignition coil-on-plug assemblies and the 3 bolts.

128. Install the 8 new LH exhaust manifold studs.

Using a new gasket, install the LH exhaust manifold and 8 new nuts. Tighten in 2 stages in the
sequence shown.
front cover-to-LH cylinder head joints.
133. Using a new gasket, install the LH valve cover and tighten the 11 stud bolts in the sequence shown.
Install the 3 LH spark plugs.

137. Install the 3 LH ignition coil-on-plug assemblies and the 3 bolts.

138. Using new gaskets, install the fuel injection pump mounting plate and bolt.
z Tighten finger-tight.
139. NOTICE: Do not attempt to cut the lower Teflon® seal without pulling it away from the fuel
injector or damage to the fuel injector may occur.
NOTE: Be very careful when removing the lower Teflon® seals, not to scratch, nick or gouge the fuel
injectors.
Pull the Teflon® seal away from the fuel injector with narrow tip pliers.
140. Carefully cut and discard the lower fuel injector Teflon® seals.
141. Place the Teflon® Seal Sizer, knurled side out, over the fuel injector tip until the fuel injector seal
recess is exposed.
142. NOTE: Do not lubricate the new lower Teflon® fuel injector seals.
Install the new lower Teflon® seals on the narrow end of the Arbor (part of the Fuel Injector Seal
Installer), then install the Arbor on the fuel injector tip.
143. NOTICE: Once the Teflon® seal is installed on the Arbor, it should immediately be installed
onto the fuel injector to avoid excessive expansion of the seal.
Using the Pusher Tool (part of the Fuel Injector Seal Installer), slide the Teflon® seals off of the Arbor
and into the groove on the fuel injector.
144. NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before sizing the
seal.
Slide the Teflon® Seal Sizer off the end of the fuel injector to size the seal.
145. NOTICE: Use fuel injector O-ring seals that are made of special fuel-resistant material. The use
of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-rings.
NOTE: Apply clean engine oil to the 6 new upper fuel injector O-ring seals.
NOTE: Inspect the fuel injector support disk and replace if necessary.
Install the 6 new upper fuel injector O-ring seals.
146. Install the 6 new fuel injector clips.
NOTE: The anti rotation device on the fuel injector has to slip into the groove of the fuel rail cup.
Install the 6 fuel injectors into the fuel rails and connect the fuel injector electrical connector.
148. NOTICE: It is very important to visually inspect the routing of the fuel charge wire harness to
make sure that they will not be pinched or damaged between the fuel rail and the cylinder
head during installation.
NOTE: Tighten the bolts using a method that draws the fuel rail evenly to the cylinder head,
preventing a rocking motion.
Install the RH fuel rail assembly and the 6 new bolts. Tighten in 3 stages in the sequence shown.
z Stage 1: Push down on the fuel rail face above the fuel injectors.
NOTE: Tighten the bolts using a method that draws the fuel rail evenly to the cylinder head,
preventing a rocking motion.
Install the LH fuel rail assembly and the 6 new bolts. Tighten in 3 stages in the sequence shown.
z Stage 1: Push down on the fuel rail face above the fuel injectors.
150. NOTE: Apply clean engine oil to the threads of the 2 high-pressure fuel tube flare nuts.
Position the new high-pressure fuel tube and hand start the flare nuts in 2 stages.
z Stage 1: Hand tighten the high-pressure fuel tube-to-RH fuel rail flare nut.
z Stage 2: Hand tighten the high-pressure fuel tube-to-LH fuel rail flare nut.
151. Loosely install the bolt for the high-pressure fuel tube.
152. Connect the high-pressure fuel tube to the fuel rails. Tighten in 6 stages.
z Stage 1: Tighten the high-pressure fuel tube-to-RH fuel rail flare nut to 15 Nm (133 lb-in).
z Stage 4: Tighten the high-pressure fuel tube-to-LH fuel rail flare nut to 15 Nm (133 lb-in).
153. Tighten the bolt for the high-pressure fuel tube.

z Tighten the bolt to 10 Nm (89 lb-in) then an additional 45 degrees.
154. Using new gaskets, install the coolant crossover manifold assembly and the 3 bolts.
155. NOTE: Lubricate the O-ring seal with clean engine coolant.
Using new O-ring seals, install the coolant inlet pipe.
Using new coolant pump gasket and coolant pump O-ring seal, install the coolant pump and the 7
bolts and tighten in 2 stages in the sequence shown.
157. Install the coolant pump pulley and the 4 bolts.

158. NOTE: Lubricate the coolant inlet tube O-ring seal with clean engine coolant.
Install the thermostat housing and the 4 bolts and tighten in 2 stages in the sequence shown.
159. NOTE: Apply thread sealant with PTFE to the threads prior to installing the cylinder block drain plug.
Install the RH cylinder block drain plug.

160. NOTE: Apply thread sealant with PTFE to the threads prior to installing the cylinder block drain plug.
Install the LH cylinder block drain plug.

z Tighten the cylinder block drain plug to 10 Nm (89 lb-in) then an additional 720 degrees.
161. Install the accessory drive belt tensioner and the 2 bolts.
162. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new
crankshaft front seal.
163. Lubricate the crankshaft front seal inner lip with clean engine oil.
164. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Replacer, install the
crankshaft pulley.
165. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
166. Position the engine wire harness on the engine. Attach all of the wiring harness retainers to the RH
valve cover and stud bolts.
167. Connect the wire harness retainer and install the tie strap.
168. Connect the 2 RH CMP electrical connectors.
169. Connect the 3 RH ignition coil-on-plug electrical connectors.
170. Connect the 2 RH VCT solenoid electrical connectors. Install the tie strap.
171. Connect the CHT sensor electrical connector. Install the ground stud bolt and the tie strap.
172. Install the CMP heat shield, bolt and the nut. Connect the wire retainer.
z Tighten the bolt to 10 Nm (89 lb-in).
z Tighten the nut to 10 Nm (89 lb-in).
173. Connect the 2 fuel charge harness and the Fuel Rail Pressure (FRP) electrical connectors. Connect
the KS sensor electrical connector.
174. Connect the 2 LH CMP sensor electrical connectors. Install the ground stud bolt. Install the CKP wire
retainer.
175. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
176. Connect the CKP sensor electrical connector.
177. Install the wiring harness grommet.
178. Install the wiring harness retainer stud bolt.

179. Install the CKP heat shield, the nut and the bolt.
180. Connect the 3 LH ignition coil-on-plug electrical connectors.
181. Connect the Engine Oil Pressure (EOP) switch electrical connector.
z Attach the EOP switch wiring harness retainer to the cylinder head.
182. Connect the 2 LH VCT solenoid electrical connectors. Install the tie strap.
183. Install the engine oil level indicator.
184. NOTICE: Make sure the oil tube filter screen is free of contaminants prior to the installation of
the vacuum pump or damage to components may occur.
Visual check. Install a new gasket if necessary.
185. NOTICE: If the brake vacuum pump is not secured within 10 minutes of sealant application,
the sealant must be removed and the sealing area cleaned with metal surface prep. Failure to
NOTE: Make sure the mating surfaces are clean and free of foreign material.
Apply a bead of the specified diameter from the specified tube.
186. NOTE: Manually align the brake vacuum pump drive key with the camshaft slot before installation.
Visual check.
z Tighten in the sequence shown to 10 Nm (89 lb-in) then an additional 45 degrees.
187. Install the LH engine support insulator-to-cylinder block bracket and the 4 new bolts.
188. Install the RH engine support insulator and the 4 new bolts.
z For standard payload package, tighten to 63 Nm (46 lb-ft).
z For heavy duty payload package, tighten to 77 Nm (57 lb-ft).
189. NOTE: Lubricate the cylinder block bore with clean engine oil.
NOTE: Apply clean engine oil to the O-ring seal.
NOTE: Make sure the turbocharger oil supply tube in positioned in the cylinder block during the
installation of the turbocharger oil return tube.
Using a new O-ring seal, install the RH turbocharger oil return tube.
190. NOTE: Install the RH turbocharger coolant return tube in the turbocharger prior to installation.
Using a new turbocharger exhaust manifold gasket, install the RH turbocharger and the 3 bolts.
191. Tighten the RH turbocharger mounting bolts.

192. Using a new turbocharger oil return tube gasket, install the 2 bolts at the turbocharger. Tighten in the
following stages.
z Stage 1: Install the bolt for the oil pressure tube side halfway.
z Stage 2: Install the bolt for the oil drain tube side and tighten to 10 Nm (89 lb-in).
z Stage 3: Tighten the bolt for the oil drain tube side an additional 30 degrees.
z Stage 4: Tighten the bolt for the oil pressure tube side to 10 Nm (89 lb-in).
z Stage 5: Tighten the bolt for the oil pressure tube side an additional 30 degrees.
193. Install the RH turbocharger oil return tube bolt at the cylinder block. Tighten in the following stages.
194. Install the bolt for the RH turbocharger coolant and oil tubes. Tighten in the following stages.
195. Install the RH turbocharger coolant supply tube.
NOTE: Apply clean engine oil to the O-ring seal.
NOTE: Make sure the turbocharger oil supply tube in positioned in the cylinder block during the
installation of the turbocharger oil return tube.
Using a new O-ring seal, install the LH turbocharger oil return tube.
197. NOTE: Install the LH turbocharger coolant return tube in the turbocharger prior to installation.
Using a new turbocharger exhaust manifold gasket, install the LH turbocharger and the 3 bolts.
198. Tighten the LH turbocharger mounting bolts.

199. Using a new turbocharger oil return tube gasket, install the 2 bolts at the turbocharger. Tighten in the
following stages.
200. Install the LH turbocharger oil return tube bolt at the cylinder block. Tighten in the following stages.
201. Remove the bolt for the LH turbocharger coolant and oil tubes. Tighten in the following stages.
202. Install the LH turbocharger coolant supply tube.
203. Install the wastegate hose assembly and 2 tie straps. Connect the turbocharger pressure regulator
electrical connector.
Position the wastegate hoses and install the 2 tie straps.
Connect the 2 wastegate hoses at the turbochargers.
206. Install the RH PCV tube. For additional information, refer to Section 310-00 .
207. Install the LH crankcase vent tube. For additional information, refer to Section 310-00 .
208. Install the A/C compressor and the 3 bolts.

209. Install the Right Front Lifting Eye and the 2 bolts.
210. Using the Floor Crane and Engine Spreader Bar, remove the engine from the stand.
211. Install the crankshaft sensor ring.
212. Install the spacer plate.
213. Install the flexplate and the 8 bolts and tighten is sequence shown.

INSTALLATION Procedure revision date: 10/25/2013
Engine
Special Tool(s)
303-1454

303-F047 (014-00073) or
equivalent

303-1566
2,200# Floor Crane, Floor Crane


Material
Item Specification
LSP12 (Canada)
Motorcraft® Multi-Purpose Grease ESB-M1C93-
XL-5 B
1. NOTICE: Prior to installation of the engine, the torque converter pilot hub must be lubricated
with multi-purpose grease or damage to the torque converter or the engine crankshaft can
occur
Lubricate the torque converter pilot hub with multi-purpose grease.
2. Align the torque converter stud and flexplate hole near the paint marks at the 12 o'clock position.
3. Using the Floor Crane and Engine Spreader Bar, position the engine in the engine compartment.
4. NOTE: The transmission wiring harness is part of the engine wiring harness.
Attach the generator wiring harness retainer to the lower LH side of the engine block.
z Position the transmission wiring harness along the side of the transmission for installation.
5. Using the Floor Crane and Engine Spreader Bar, position the engine to the transmission.
6. Align the engine to the transmission and install the 2 LH bellhousing-to-oil pan bolts.
7. Using the Floor Crane and Engine Spreader Bar, raise the engine for clearance for the LH engine
support insulator.
8. NOTICE: Only use hand tools when loosening or tightening the LH engine support insulator
through bolt or damage to the engine support insulator-to-cylinder block bracket can occur.
NOTE: Clean the LH and RH engine support insulator-to-frame mating surfaces of any dirt or foreign
material prior to installation.
Install the LH engine support insulator and the new through bolt.
z Do not torque at this time.
9. Lower the engine.
10. NOTICE: Use only hand tools when removing or installing the engine support insulator-to-
frame bolts or the damge to the engine support insulator-to-frame nut plate can occur.
Install the 3 new LH engine support insulator bolts.

11. Position back the coolant hose to the valve cover stud. Install the Charge Air Cooler (CAC) bracket
and 2 nuts.
12. NOTICE: Use only hand tools when installing the engine support insulator stud bolts or
Install the 2 new RH engine support insulator studs.

13. NOTICE: Use only hand tools when installing the RH engine support insulator nuts or damage
to the engine support insulator can occur.
Install the 2 new RH engine support insulator nuts.

14. NOTICE: Only use hand tools when loosening or tightening the LH engine support insulator
Tighten the LH engine mount through bolt.

15. NOTE: Do not lubricate the engine oil filter gasket.
Install a new engine oil filter.

z Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
16. Install the LH bellhousing-to-engine bolt.

z Tighten the bolt, it will be torqued at a later step.
17. Install the engine-to-bellhousing bolt.

18. Install the oil pan-to-bellhousing bolt.

19. Tighten the engine-to-bellhousing bolt.


21. Tighten the LH bellhousing-to-engine bolt.

22. Install the 4 upper bellhousing-to-engine bolts.

Install the new 2 LH and RH catalytic converter-to-exhaust manifold nuts.

24. Position the exhaust Y-pipe dual catalytic converter-to-intermediate pipe and install the 2 bolts.
z Tighten the inner exhaust Y-pipe catalytic converter-to-exhaust intermediate pipe bolt to 63 Nm
(46 lb-ft).
z Tighten the outer exhaust Y-pipe catalytic converter-to-exhaust intermediate pipe bolt to 63
Nm (46 lb-ft).
25. Install the 4 torque converter nuts.

26. Install the access cover and the 2 pin-type retainers.
27. Attach the starter motor wiring harness retainer to the oil pan.
28. Install the starter motor. For additional information, refer to Section 303-06 .
29. If equipped, install the front driveshaft. For additional information, refer to Section 205-01 .
30. Install the skid plate and the 4 bolts.

31. Connect the transmission vehicle harness connector by pushing the connector into the transmission
and twisting the outer shell.
32. Connect the electrical connector retainer to the bracket at the rear of the transmission.
z Connect the Heated Oxygen Sensor (HO2S) electrical connector.
33. NOTE: Only one wire harness retainer and one electrical connector shown, others similar.
If equipped, connect the 5 transmission wire harness retainers to the transfer case wire harness.
z Connect the 2 HO2S electrical connector retainers.
z Connect the 2 HO2S electrical connectors.
34. Install the splash shield and the 4 retainers.
35. Connect the HO2S electrical connector to the wiring harness retainer.
z Connect the HO2S electrical connector to the engine wiring harness at the rear of the LH
cylinder head.
36. Install the cowl panel and attach the 2 clips and install the 6 screws.
37. Install the cowl panel grille. For additional information, refer to Section 501-02 .
38. Install the ground strap and bolt to the cowl.

39. Connect the vacuum pump tube.
40. Attach the wiring harness retainers to the rear of the RH valve cover stud bolt and the rear of the
vacuum pump.
41. Connect the 2 coolant hoses to the degas bottle.
42. Connect the 2 heater hose couplings at the RH rear of the engine.
43. Install the intake manifold. For additional information, refer to Intake Manifold in this section.
44. Install the fuel injection pump. For additional information, refer to Section 303-04A .
45. Connect the PCM electrical connector and the engine harness electrical connector.
z Attach the wiring harness retainers to the fender splash shield.
46. Install the A/C compressor belt. For additional information, refer to Section 303-05 .
47. Install the generator. For additional information, refer to Section 414-00 .
48. Connect the A/C compressor electrical connector.

z Attach the A/C compressor wiring harness to the A/C compressor.
49. Attach the generator wiring harness to the engine front cover.
50. Install the transmission cooler line bracket and nut to the engine front cover stud bolt.
51. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
52. Connect the Battery Junction Box (BJB) wiring harness and the A/C pressure transducer electrical
connectors.
53. Fill the engine with clean engine oil.
54. Install the 2 Charge Air Cooler (CAC) inlet tubes and the CAC outlet tube. For additional information,
refer to 3.5L Gasoline Turbocharged Direct Injection (GTDI) Charge Air Cooler (CAC) and Tubes
Exploded View in Section 303-12 .
55. Install the LH and RH turbocharger intake tubes. For additional information, refer to 3.5L Gasoline
Turbocharged Direct Injection (GTDI) Charge Air Cooler (CAC) and Tubes Exploded View in Section
303-12 .
56. Install the cooling module. For additional information, refer Section 303-03 .
57. If equipped, connect the block heater electrical connector at the thermostat housing.
z Attach the block heater wiring harness retainer to the LH valve cover stud bolt.
58. Connect the battery ground cable. For additional information, refer to Section 414-01 .
59. NOTE: Align the index marks made during hood removal.
Position the hood and install the 4 bolts.

60. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile
Correction procedure following the on-screen instructions.

Camshaft — LH
Special Tool(s)
303-1530

303-1248
Material
Item Specification
LSP12 (Canada)
Removal
1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section.
20. Remove the 12 camshaft cap bolts, the 6 camshaft caps, and the mega cap.
z Remove the LH camshafts.
Installation
2. NOTICE: The crankshaft must remain in the free wheeling position (crankshaft dowel pin at 9
o'clock) until the camshafts are installed and the valve clearance is checked/ adjusted. Do not
turn the crankshaft until instructed to do so. Failure to follow this process will result in severe
engine damage.
Rotate the crankshaft couterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
may occur.
original positions.
z Tighten to 8 Nm (71 lb-in) then additional 45 degrees.

z Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
11. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to
assembly.

Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down.
16. Rotate the crankshaft clockwise 60 degrees to TDC position (crankshaft dowel pin at the 11 o'clock
position).

3. Align the hole in the ratchet plunger with the hole in the tensioner housing and Install a suitable
lockpin.


sprocket links (3).
29. Install the engine front cover. For additional information, refer to Engine Front Cover in this section.

Camshaft — RH
Special Tool(s)
303-1530

303-1248
Material
Item Specification
Motorcraft® Gasket Maker WSK-
TA-16 M2G348-A5
LSP12 (Canada)
Removal
2. Remove the vacuum pump. Refer to Section 206-07 .
21. Remove the 2 bolts and the camshaft bearing cap assembly.
22. Remove the 12 camshaft cap bolts, the 6 camshaft caps, and the mega cap.
z Remove the RH camshafts.
Installation
2. NOTICE: The crankshaft must remain in the free wheeling position (crankshaft dowel pin at 9
o'clock) until the camshafts are installed and the valve clearance is checked/ adjusted. Do not
turn the crankshaft until instructed to do so. Failure to follow this process will result in severe
engine damage.
Rotate the crankshaft couterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
may occur.
original positions.

8. NOTE: The camshaft bearing cap assembly must be secured within 10 minutes of the Gasket Maker
application. If the camshaft bearing cap assembly is not secured within 10 minutes, the sealant must
be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep.
Apply a 3 mm (0.118 in) bead of sealant to the camshaft bearing cap assembly.
9. Install the camshaft bearing cap assembly and the 2 bolts.

z Remove the excess gasket maker.
11. Rotate the RH camshafts to the TDC position as shown.
13. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to
14. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing
chain.
assembly.

Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down.
18. Rotate the crankshaft clockwise 60 degrees to TDC position (crankshaft dowel pin at the 11 o'clock
position).

lockpin.


sprocket links (3).
31. Install the vacuum pump. Refer to Section 206-07 .

Crankshaft Front Seal
Special Tool(s)
Damper
303-102 (T74P-6316-B)

303-1251
Remover, Oil Seal

303-409 (T92C-6700CH)
Material
Item Specification
ZC-31-A
LSP12 (Canada)
Removal
02 .
2. Remove the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.
z Clean all sealing surfaces with metal surface prep.
Installation
2. Install the crankshaft pulley. For additional information, refer to Crankshaft Pulley in this section.

Crankshaft Pulley and Crankshaft Front Seal — Exploded View

1 W701512 Crankshaft pulley bolt
2 N806165 Washer
1. Refer to the procedures and/or exploded views in this section for any Warnings, Notices, Notes,
Materials, Specifications, and Special Tools. Items in the exploded views may not be listed in order of
removal.

Crankshaft Pulley
Special Tool(s)
3 Jaw Puller
303-D121 or equivalent

303-335
Replacer, Crankshaft Vibration

Damper
303-102 (T74P-6316-B)
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent

Material
Item Specification
LSP12 (Canada)
Removal
02 .
2. Remove the Air Cleaner (ACL) outlet pipe and the RH & LH ACL pipe-to-turbocharger pipes. Remove
the LH turbocharger-to-Charge Air Cooler (CAC) tube and the CAC -to-Throttle Body (TB) pipe. For
additional information, refer to Intake Air System Components — Exploded View, 3.5L Gasoline
Turbocharged Direct Injection (GTDI) in Section 303-12 .
3. Remove the accessory drive belt and the A/C belt. For additional information, refer to Section 303-
05 .
z Discard the bolt.
Installation
crankshaft pulley.
4. Install the accessory drive belt and the A/C belt. For additional information, refer to Section 303-05 .
5. Install the CAC -to- TB pipe and the LH turbocharger-to- CAC tube. Install the RH & LH ACL pipe-to-
turbocharger pipes and the ACL outlet pipe. For additional information, refer to Intake Air System
Components — Exploded View, 3.5L GTDI in Section 303-12 .

Crankshaft Rear Seal with Retainer Plate
Material
Item Specification
TA-357
ZC-31-A
LSP12 (Canada)
Remover
ZC-30
Removal
passages or the oil pan, can cause engine failure.
NOTICE: The engine is equipped with a cast aluminum (early build) or stamped steel (late build)
crankshaft rear seal retainer plate. If the engine is equipped with a stamped steel retainer plate, the
seal and plate must be removed as an assembly and discarded.
2. Remove the flexplate. Refer to Flexplate in this section.
3. NOTE: The engine can be equipped with a cast aluminum (early build) or stamped steel (late build)
crankshaft rear seal retainer plate.
NOTE: Cast aluminum crankshaft rear seal retainer plate shown, stamped steel crankshaft rear seal
retainer plate similar.
Remove the crankshaft sensor ring.
4. Remove the engine-to-transmission spacer plate.
5. If equipped, remove the 2 bolts and the exhaust system heat shield.
6. NOTE: The Crankshaft Position (CKP) heat shield is only positioned aside.
Remove the nut and the bolt. Position the Crankshaft Position (CKP) heat shield aside.
8. Disconnect the CKP sensor electrical connector.
10. If equipped, remove the 4 bolts and the skid plate.
11. Remove the 2 oil pan-to-crankshaft rear seal retainer plate bolts.
z Discard the crankshaft rear seal retainer plate.
13. NOTICE: Place clean, lint free shop towels over exposed engine cavities. Carefully remove the
material created while cleaning gaskets surfaces) that enters the oil passages or the oil pan,
NOTICE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in
Clean the sealing surfaces of the cylinder block and oil pan flange in the following sequence.
Installation
Apply a 5 mm (0.196 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 cylinder
block/oil pan joints.
3. NOTE: Use the 2 handles during installation to avoid touching the sealant.
NOTE: Lubricate the crankshaft rear seal with clean engine oil.
Install the crankshaft rear seal retainer at an angle above the oil pan flange to avoid scraping off the
sealer. Tilt the seal retainer up and onto the rear of the cylinder block.
4. Install the 8 crankshaft rear seal retainer plate bolts. Tighten in the sequence shown.
5. Install the 2 oil pan-to-crankshaft rear seal retainer plate bolts.

z Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.
6. If equipped, install the skid plate and the 4 bolts.

7. Install the CKP sensor and the bolt.

10. Position back the CKP heat shield. Install the nut and bolt.
11. If equipped, install the exhaust system heat shield and the 2 bolts.
12. Install the engine-to-transmission spacer plate.
14. Install the flexplate. Refer to Flexplate in this section.
15. After completing the repairs, use the scan tool to preform the Misfire Monitor Neutral Profile

Cylinder Head — LH
Material
Item Specification
ZC-31-A
LSP12 (Canada)
Remover
ZC-30

1 W709818 LH upper primary timing chain guide bolt
3 W710702 Cylinder head M6 bolt
4 6065 Cylinder head bolt (8 required)
5 6049 Cylinder head

6 6051 Cylinder head gasket
Removal
equipment of any type when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these instructions may result in
evaporative emission (EVAP) system or fuel-related component. Highly flammable mixtures are
always present and may be ignited. Failure to follow these instructions may result in serious
personal injury.
may ignite when the engine is returned to operation. Failure to follow this instruction may result in
NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.
1. Release the fuel pressure. For additional information, refer to Section 310-00 .
2. Remove the LH turbocharger. For additional information, refer to Section 303-04E .
3. Remove the LH camshafts. For additional information, refer to Camshaft — LH in this section.
4. Remove the fuel rail. For additional information, refer to Section 303-04A .
guide may occur.
Remove the bolt and the LH upper primary timing chain guide.
6. Disconnect the 2 LH Camshaft Position (CMP) sensor electrical connectors. Position back the
Crankshaft Position (CKP) wire retainer. Remove the ground stud bolt.
7. Remove the 2 bolts and the 2 LH CMP sensors.
components for installation into their original positions.
Remove the valve tappets form the cylinder head.
10. Remove and discard the M6 bolt.
may cause engine failure
Remove and discard the 8 bolts from the cylinder head.

z Remove the cylinder head.
z Discard the cylinder head gasket.
minutes.
the metal shiny. Some staining of the metal surfaces is normal
Installation
1. NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be
installed.
Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5
stages:
z Stage 4: Tighten 90 degrees

Install the 2 LH CMP sensors and the 2 bolts.

5. Install the ground stud bolt. Position back the CKP wire retainer. Connect the 2 LH CMP sensor
electrical connectors.
6. Install the LH upper primary timing chain guide and the bolt.
7. Install the fuel rail. For additional information, refer to Section 303-04A .
8. Install the LH camshafts. For additional information, refer to Camshaft — LH in this section.
9. Install the LH turbocharger. For additional information, refer to Section 303-04E .

Cylinder Head — RH
Material
Item Specification
ZC-31-A
LSP12 (Canada)
Remover
ZC-30

1 W715145 RH primary timing chain guide bolt
2 W715118 RH primary timing chain guide bolt
3 6K297 RH primary timing chain guide

Removal
personal injury.
2. Remove the RH turbocharger. For additional information, refer to Section 303-04E .
3. Remove the RH camshafts. For additional information, refer to Camshaft — RH in this section.
4. Remove the fuel rail. For additional information, refer to Section 303-04A .
5. NOTICE: Do not use power tools to remove the bolts or damage to the RH primary timing
chain guide may occur.
Remove the 2 bolts and the RH upper primary timing chain guide.
6. Disconnect the wire retainer. Remove the nut, bolt and the CMP heat shield.
7. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. Remove the ground
stud bolt and the tie strap.
8. Remove and discard CHT sensor.
9. Remove the bolt and position aside the ground strap.
components for installation into their original positions.
Remove the valve tappets form the cylinder head.

minutes.
the metal shiny. Some staining of the metal surfaces is normal
Installation
installed.
Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5
stages:

4. Position back the ground strap and install the bolt.

5. Install a new CHT sensor.

6. Install the ground stud bolt and the tie strap. Connect the CHT sensor electrical connector.
7. Install the CMP heat shield, nut and the bolt. Connect the wire retainer.
z Tighten the nut to 10 Nm (89 lb-in).
8. Install the RH upper primary timing chain guide and the 2 bolts.
9. Install the fuel rail. For additional information, refer to Section 303-04A .
10. Install the RH camshafts. For additional information, refer to Camshaft — RH in this section.
11. Install the RH turbocharger. For additional information, refer to Section 303-04E .

Engine Front Cover
Special Tool(s)
Handle
205-153 (T80T-4000-W)

205-149 (T80T-4000-R)

205-150 (T80T-4000-S)
Material
Item Specification
TA-357
ZC-31-A
LSP12 (Canada)
Remover
ZC-30
NOTE: Engine Front Cover (View 1 of 2)

1 6730 Oil pan drain plug.
2 W520414 Generator nut
3 W714577 Generator bolt
4 10346 Generator
5 W714329 Generator stud
6 W713261 Accessory drive belt tensioner bolt (2 required)
7 6B209 Accessory drive belt tensioner

1 6020 Front cover radial seal
2 W503285 Engine front cover bolt
4 W503301 Engine front cover bolt (4 required)
Removal
1. Release the fuel pressure. Refer to Section 310-00 .
2. Remove the Charge Air Cooler (CAC)-to-Throttle Body (TB) pipe. For additional information, refer to
Intake Air System Components — Exploded View, 3.5L in Section 303-12 .
4. Remove the LH and RH valve covers. For additional information, refer to Valve Cover — LH and
Valve Cover — RH in this section.

6. Remove the coolant pump. For additional information, refer to Section 303-03 .
7. Remove the bolt and position the generator aside.
8. Remove the generator stud.
10. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal in this
section.
11. Remove the pushpin retainer from the oil pan.
12. Remove the nut and the transmission cooler tube bracket from the engine front cover stud bolt.
13. Disconnect the generator wiring harness from the engine front cover and the stud bolt.
remove.
16. NOTE: Inspect and replace the front cover radial seal as necessary.
Using the Spindle Bearing Installer and Handle, remove the front cover radial seal from the rear side
of the front cover.
Installation
engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk
to clean. These tools cause scratches and gouges that make leak paths.
Clean the engine front cover using 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a
suitable tool turning at the recommended speed of 15,000 rpm.
z Thoroughly wash the engine front cover to remove any foreign material, including any abrasive
particles created during the cleaning process.
material created while cleaning gasket surfaces) that enters the oil passages or the oil pan
gouges that make leak paths. These tools cause contamination that can cause premature
engine failure. Remove all traces of sealant, including any sealant from the inner surface of
the cylinder block and cylinder head.
sequence.
2. Apply silicone gasket remover and allow to sit for several minutes.
5. Make sure the 2 locating pins are seated correctly in the cylinder block.
3. Using the Spindle Bearing Installer, install a new front cover radial seal from the rear side of the front
cover.
for at least 90 minutes after installing the engine front cover. Failure to follow this procedure
can cause engine oil leakage.
cover bolt bosses.
Install the engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 and tighten in the
sequence shown in 3 stages:
6. Install the remaining 12 engine front cover bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 16, 22 and tighten in
the sequence shown in 3 stages:
z Stage 1: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, and 16 to 10 Nm (89 lb-in).
z Stage 2: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, and 16 to 20 Nm (177 lb-in) then an
7. Position the generator wiring harness on the stud bolt and clip the engine harness on the engine front
cover.
8. Install the transmission cooler tube bracket and the nut on the engine front cover stud bolt.
9. Install the pushpin retainer into the oil pan.
10. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal in this
section.
11. Install the accessory drive belt tensioner and 2 bolts.

12. Install the generator stud.

13. Position back the generator and install the bolt.

14. Install the coolant pump. For additional information, refer to Section 303-03 .
15. Install the LH and RH valve covers. For additional information, refer to Valve Cover — LH and Valve
Cover — RH in this section.
17. Install the CAC -to- TB pipe. For additional information, refer to Intake Air System Components —
Exploded View, 3.5L in Section 303-12 .

Engine Lubrication Components — Exploded View
Skid Plate
NOTE: For vehicles equipped with skid plate.

1 W706894 Skid plate bolt (4 required)
2 5D032 Skid plate
Engine Lubrication Components
Part
1 — Engine Oil Pressure (EOP) switch electrical connector
(part of 14A411)
2 9278 EOP switch
4 6L626 Oil cooler insert bolt
5 6A642 Oil cooler
6 W503278 Oil filter adapter bolt (5 required)
8 6840 Oil filter adapter gasket
9 6730 Oil pan drain plug

10 W712943 Oil pan bolt (13 required)
12 W708221 Oil pan bolt
13 6675 Oil pan
14 W503278 Oil pump screen and pickup tube bolt (3 required)
17 W500300 Primary timing chain tensioner bolt (2 required)
18 6L266 Primary timing chain tensioner
19 6K255 RH primary timing chain tensioner arm
20 W503284 LH primary timing chain guide bolt
22 6B274 LH primary timing chain guide
23 6268 Primary timing chain
25 W503282 Oil pump bolt (3 required)
26 6600 Oil pump
removal.

Engine Oil Pressure (EOP) Switch
Material
Item Specification
Motorcraft® Thread Sealant with WSK-M2G350-
PTFE A2
TA-24
2. Remove the EOP switch.

z To install, tighten to 14 Nm (124 lb-in) then an additional 180 degrees.

z Apply thread sealant with PTFE to the EOP switch threads prior to installation.

Engine Support Insulators
Special Tool(s)
303-1454

303-1566
Support Bar, Engine

303-F070
Engine Support Insulator — LH

1 W713244 LH engine support insulator bolt (3 required)
2 W715211 LH engine support insulator through bolt
3 6038 LH engine support insulator
4 W714735 LH engine support insulator bracket bolt (3 required)
5 6038 LH engine support insulator bracket
Engine Support Insulator — RH
Part
1 W707251 RH engine support insulator nut (2 required)
2 — RH engine support insulator stud (part of 6038) (2
required)
3 — RH engine support insulator through bolt (part of
6038)
4 6038 RH engine support insulator
5 W714735 RH engine support insulator bracket bolt (4 required)
6 — RH engine support insulator bracket (part of 6038)
Removal
NOTICE: Use care when positioning the front axle housing or the vacuum lines to the axle solenoid
may become disconnected or damaged.
NOTE: Discard all engine support insulator fasteners and install new fasteners.
All vehicles
02 .
3. Remove the Air Cleaner (ACL) outlet pipe, ACL pipe-to-turbocharger pipes, turbocharger bypass
hoses and the turbocharger-to- Charge Air Cooler (CAC) pipes. For additional information, refer to
5. Remove the high-pressure fuel pump. For addition information, refer to Section 303-04A .
8. Remove the 2 nuts and the Charge Air Cooler (CAC) tube bracket.
9. Install the Right Front Lift Eye and 2 bolts.
10. Remove the 4 pushpins and the upper radiator air deflector.
11. Install the Engine Support Bar.
12. Release the 4 fasteners and remove the splash shield.
15. NOTICE: Support the exhaust intermediate pipe prior to removing the bolts or damage to the
flex pipe may occur.
Remove the 2 exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolts and
separate.
z Discard the 2 bolts.
Remove and discard the 2 LH and the 2 RH catalytic converter-to-turbocharger nuts.
17. NOTICE: Only use hand tools when removing the transmission mount-to-crossmember nuts or
damage to the transmission mount can occur.
Loosen the 2 transmission mount-to-crossmember nuts.
RH engine support insulator
18. Remove the Air Conditioning (A/C) compressor belt . For additional information, refer to Section 303-
05 .
19. Remove the 3 bolts and position the A/C compressor aside.
20. Remove the starter. For additional information, refer to Section 303-06 .
Remove and discard the RH and LH engine support insulator through bolts.
22. Remove and discard the 2 RH engine support insulator nuts and the 2 studs.
23. Raise the engine approximately 30 mm (1.18 in).
24. Remove the 4 bolts and the RH engine support insulator-to-cylinder block bracket.
25. Remove the RH engine support insulator.
LH engine support insulator
Remove and discard the LH and RH engine support insulator through bolts.
Remove and discard the 3 LH engine support insulator-to-frame bolts.
Four-Wheel Drive (4WD) — LH engine support insulator
29. Position a suitable hydraulic jack under the front axle. Securely strap the axle to the jack.
30. Remove the upper front axle carrier mounting bushing bolt.
31. Remove the axle shaft housing carrier bushing bolt.
32. Remove the lower front axle carrier mounting bushing bolt.
33. Lower the front axle to allow clearance to the LH engine support insulator.
35. Inspect the engine support insulator-to-frame nut plate for thread damage. If the nut plate is
damaged, bend 2 tabs back and remove the nut plate. Replace the nut plate with service part number
56190 and bend the 2 tabs back to the original position.
NOTE: If necessary, the following 3 steps are to remove the LH engine support insulator-to-cylinder block
bracket.
z Detach the generator wiring harness retainer from the oil filter adapter.
37. Detach the generator wiring harness retainer from the lower LH side of the engine block.
Installation
1. Clean the engine support insulator-to-cylinder block and engine support insulator-to-frame mating
surfaces of any dirt or foreign material prior to installation.
NOTE: If removed, the following 3 steps are to install the LH engine support insulator-to-cylinder block
bracket.
2. Install the LH engine support insulator-to-cylinder block bracket and install the 4 new bolts.
3. Attach the generator wiring harness retainer to the lower LH side of the engine block.

z Attach the generator wiring harness retainer to the oil filter adapter.
5. Position the LH engine support insulator and hand start the 3 new engine support insulator-to-frame
bolts.
4WD — LH engine support insulator
6. Raise the front axle carrier into position.
7. Install the lower front axle carrier mounting bushing bolt.

8. Install the axle shaft housing carrier bushing bolt.

9. Install the upper front axle carrier mounting bushing bolt.

Tighten the 3 LH engine support insulator-to-frame bolts to 175 Nm (129 lb-ft).
11. Lower the engine to the installed position.
Install the new RH and LH engine support insulator through bolts.

14. Position the RH engine support insulator into the vehicle
15. Position the RH engine support insulator-to-cylinder block bracket and install the 4 new bolts.
z For standard payload package, tighten to 63 Nm (46 lb-ft).
z For heavy duty payload package, tighten to 77 Nm (57 lb-ft).
16. NOTICE: Only use hand tools when installing the engine support insulator stud bolts or
Install the 2 new RH engine support insulator studs.

17. NOTICE: Only use hand tools when installing the RH engine support insulator nuts or damage


20. Install the starter. For additional information, refer to Section 303-06 .
21. Position the A/C compressor and install the 3 bolts.
All vehicles
23. NOTICE: Only use hand tools when installing the transmission mount-to-crossmember nuts or
Tighten the 2 transmission mount-to-crossmember nuts.

Install the 2 new LH and the 2 new RH catalytic converter-to-turbocharger nuts.

25. Position the exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe and install the 2
new bolts.
z Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to
63 Nm (46 lb-ft).
z Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to
63 Nm (46 lb-ft).

28. Install the splash shield and the 4 retainers.
29. Remove the Engine Support Bar.
30. Install the upper radiator air deflector and the 4 pushpins.
31. Remove the 2 bolts and the Right Front Lift Eye.
32. Position back the coolant hose to the valve cover stud. Install the CAC tube bracket and the 2 nuts.
35. Install the high-pressure fuel pump. For addition information, refer to Section 303-04A .
37. Install the Air Cleaner (ACL) outlet pipe, ACL pipe-to-turbocharger pipes, turbocharger bypass hoses
and the turbocharger-to- Charge Air Cooler (CAC) pipes. For additional information, refer to Intake Air
System Components — Exploded View, 3.5L in Section 303-12 .


Flexplate
Special Tool(s)
Removal
02 .
2. Remove the automatic transmission. For additional information, refer to Section 307-01 .
Installation
1. NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.
Install the flexplate and the 8 bolts and tighten in sequence shown.
2. Install the automatic transmission. For additional information, refer to Section 307-01 .

Front Cover Radial Seal
Special Tool(s)
Remover/Installer, Water Tube
Seal
303-1528

Removal
1. Remove the accessory drive and A/C compressor belt. For additional information, refer to Section
303-05 .
3. Using the Water Tube Seal Remover, remove the front cover radial seal.
z Reset the Water Tube Seal Remover center bolt to its retracted position.
z Screw the Water Tube Seal Remover onto the front cover radial seal until it bottoms out.
z Using a brass hammer, give the Water Tube Seal Remover a slight tap inward to break front
cover radial seal lose.
z Turn the Water Tube Seal Remover center bolt clockwise and remove the front cover radial
seal.
4. Clean the engine front cover radial seal area.
Installation
1. Using the Water Tube Seal Installer, install the front cover radial seal.
z Position the front cover radial seal on the Water Tube Seal Installer.
z Position the Water Tube Seal Installer into the engine front cover.
z Using a brass hammer, tap the Water Tube Seal Installer until the front cover radial seal
bottoms out.
2. Inspect the front cover radial seal for proper installation or damage.
4. Install the accessory drive and A/C compressor belt. For additional information, refer to Section 303-
05 .

Intake Manifold
NOTE: Refer to the on-line Workshop Manual to view this illustration as an interactive exploded view,
requires Adobe® Acrobat® 8.0 or higher.
NOTE: Refer to the on-line Workshop Manual to learn about using an Interactive Illustration.

1 W503277 Engine cover bracket bolts (3 required)
2 — Engine cover bracket (part of 6A949)
3 W714988 Intake manifold bolt (6 required)
4 W715096 Intake manifold bolt (2 required)

Removal
1. Remove the engine appearance cover.
2. Remove the Air Cleaner (ACL) outlet pipe and the RH ACL pipe-to-turbocharger pipe. For additional
information, refer to Intake Air System Components — Exploded View, 3.5L in Section 303-12 .
3. Loosen the clamp and disconnect the Charge Air Cooler (CAC)-to-Throttle Body (TB) pipe.
4. Disconnect the TB electrical connector.

z Detach the TB electrical connector wiring harness retainer from the TB .
5. Remove the PCV tube. Refer to Section 310-00 .
6. Disconnect the Evaporative Emission (EVAP) hose from the intake manifold. Refer to Section 310-
00 .
7. Disconnect the Manifold Absolute Pressure (MAP) sensor and the EVAP canister purge valve
electrical connectors. Remove the bolt for the EVAP canister purge valve and position aside.
8. Remove the 3 bolts and the engine appearance cover bracket.
9. Disconnect the wire retainer from the intake manifold.
10. Remove the push pin and position the turbocharger vacuum regulator aside.
11. Loosen the 8 bolts and remove the intake manifold.

z Clean and inspect all of the sealing surfaces of the cylinder heads and the intake manifold.
Installation
1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically
including valve or piston damage, check the intake manifold for metal debris. If metal debris is
found, install a new intake manifold. Failure to follow these instructions can result in engine
damage.
Using new gaskets, install the intake manifold and tighten the 8 bolts in the sequence shown.
2. Position back turbocharger vacuum regulator and install the push pin.
3. Connect the wire retainer to the intake manifold.
4. Install the engine appearance cover bracket and 3 bolts.

5. Position back the EVAP canister purge valve and install the bolt. Connect the MAP sensor and the
EVAP canister purge valve electrical connectors.
6. Connect the EVAP hose to the intake manifold. Refer to Section 310-00 .
7. Install the PCV tube. Refer to Section 310-00 .
8. Connect the TB electrical connector.

z Attach the TB electrical connector wiring harness pin-type retainer to the TB .
9. Connect the CAC -to- TB pipe and tighten the clamp.

10. Install the RH ACL pipe-to-turbocharger pipe and the ACL outlet pipe. For additional information, refer
to Intake Air System Components — Exploded View, 3.5L in Section 303-12 .
11. Install the engine appearance cover.

Oil Cooler
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information refer to Section 100-
02 .
2. Remove the Air Cleaner (ACL) outlet pipe and the LH ACL -to-turbocharger pipe. For additional
information, refer to Intake Air System Components — Exploded View, 3.5L Gasoline Turbocharged
Direct Injection (GTDI) in Section 303-12 .
3. If equipped, rotate the 4 retainers and position the air deflector down. Rotate the skid plate cover
counterclockwise and remove.
5. Using hose clamp pliers, clamp the 2 oil cooler coolant hoses.
z Disconnect the 2 coolant hoses from the oil cooler.
6. NOTICE: If metal or foreign material is present in the oil cooler, mechanical concerns exist. To
diagnose the mechanical concerns, refer to Section 303-00 .
Remove the oil cooler insert bolt and the oil cooler.
z Inspect the oil cooler gasket, replace if necessary.
Installation
1. Align the oil cooler to the oil filter adapter and install the oil cooler insert bolt.
2. Connect the oil cooler coolant hoses.

z Remove the hose clamp pliers.

4. If equipped, position the air deflector and fasten the 4 retainers. Install the skid plate cover.
5. Install the ACL outlet pipe and the LH ACL -to-turbocharger pipe. For additional information, refer to
Intake Air System Components — Exploded View, 3.5L GTDI in Section 303-12 .
6. Inspect and adjust the coolant level in the degas bottle.
7. Inspect and adjust the engine oil level.

Oil Filter Adapter
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information refer to Section 100-
02 .
3. Remove the Air Cleaner (ACL) outlet pipe and the LH ACL -to-turbocharger pipe. For additional
information, refer to Intake Air System Components — Exploded View, 3.5L Gasoline Turbocharged
Direct Injection (GTDI) in Section 303-12 .
4. If equipped, rotate the 4 retainers and position the air deflector down. Rotate the skid plate cover
counterclockwise and remove.
6. NOTICE: If metal or foreign material is present in the oil cooler, mechanical concerns exist. To
diagnose the mechanical concerns, refer to Section 303-00 .
Remove the oil cooler insert bolt and position the oil cooler aside.
7. Disconnect the generator electrical connector.
8. Position the generator B+ protective boot aside, remove the B+ nut and position the B+ terminal
aside.
z Detach the generator wiring harness retainer from the oil filter adapter and position the
generator wiring harness aside.
9. Disconnect the Engine Oil Pressure (EOP) electrical connector.

z Clean and inspect all sealing surfaces.
Installation
1. Using a new gasket, install the oil filter adapter and the 5 bolts. Tighten in sequence shown.
z Tighten to 10 Nm (89 lb-in) and then an additional 45 degrees.
2. Connect the EOP electrical connector.
3. Position back the generator wiring harness and B+ terminal and install the nut.
z Position back the generator B+ protective boot.
4. Connect the generator electrical connector.
5. Position back the oil cooler and install the oil cooler insert bolt.
Install the engine oil filter.

7. If equipped, position the air deflector and fasten the 4 retainers. Install the skid plate cover.
8. Install the ACL outlet pipe and the LH ACL -to-turbocharger pipe. For additional information, refer to
Intake Air System Components — Exploded View, 3.5L GTDI in Section 303-12 .

Oil Pan
Material
Item Specification
TA-357
ZC-31-A
LSP12 (Canada)
Remover
ZC-30
Removal
including any material created while cleaning gasket surfaces, that enters the oil passages, coolant
All vehicles
1. NOTE: This step does not apply if the front engine cover is removed.
With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-
02 .
Disconnect the battery ground cable. For additional information, refer to Section 414-01 .
Remove the oil level indicator.
4. Release the 4 fasteners and remove the splash shield.
If equipped, turn the 4 quarter-turn retainers, detach the 8 pushpins and remove the lower air
deflector.
6. If equipped, Remove the 4 bolts and the skid plate.
7. Remove the front air dam. For additional information, refer to the Front End Body Panels — Exploded
View in Section 501-02 .
NOTE: Only one wire harness retainer and one electrical connector shown, others similar.
Disconnect the 2 HO2S electrical connectors.

z Disconnect the 2 HO2S electrical connector retainers.
z If equipped, disconnect the 5 transmission wire harness retainers from the transfer case wire
harness.
Disconnect the HO2S electrical connector at the LH rear of the transmission.

z Disconnect the electrical connector retainer from the bracket at the rear of the transmission.
NOTE: This step does not apply if the front engine cover is removed.
the connector.
Loosen the 4 upper bellhousing-to-engine bolts 5 mm (0.19 in).
12. Remove the bolt and disconnect the 2 retainers for the transmission cooler tubes.
Remove the drain plug and drain the engine oil.

Detach the starter motor wiring harness retainer from the oil pan.
Remove the nut and the transmission cooler line bracket from the engine front cover stud bolt.
Detach the generator wiring harness from the engine front cover.
19. Remove the 4 nuts and bolts and the crossmember.
Four Wheel Drive (4X4) vehicles
20. Position a suitable hydraulic jack under the front axle. Securely strap the axle to the jack.
23. NOTE: Front driveshaft removed for clarity only.
Remove the lower front axle carrier mounting bushing bolt.
24. NOTICE: Use care when lowering the front axle housing, or the vacuum lines to the axle
solenoid may become disconnected or damaged.
Lower the axle to allow clearance for the oil pan to be removed.
All vehicles
Loosen the engine-to-bellhousing bolt above the starter motor 5 mm (0.19 in).
26. Remove the oil pan-to-bellhousing bolt from below the starter motor.
Loosen the 2 LH bellhousing-to-engine bolts 5 mm (0.19 in).
Loosen the 2 transmission crossmember nuts.
Slide the transmission rearward 5 mm (0.19 in).
Remove the 4 lower engine front cover bolts.
33. NOTE: LH rear shown, RH front similar.
Using a suitable pry tool, locate the 2 pry pads at the LH and RH sides of the oil pan and pry the oil
34. NOTE: The generator wiring harness retainer is being removed for clearance to install the oil pan.
Detach the generator wiring harness retainer from the engine block.
35. NOTICE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the oil
pan. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean. These
tools cause scratches and gouges that make leak paths.
Clean the engine oil pan using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a
z Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles
created during the cleaning process.
white, part number 07528) to clean the cylinder block and engine front cover sealing surfaces.
These tools cause scratches and gouges that make leak paths. They also cause contamination
that causes premature engine failure. Remove all traces of the gasket.
Clean the sealing surfaces of the cylinder block and engine front cover in the following sequence.
Installation
All vehicles
Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 engine
front cover-to-cylinder block joint areas on the sealing surface of the oil pan.
application.
NOTE: Keep the oil pan as close as possible to the transmission while installing, then slide forward
towards the engine front cover to prevent wiping off of the sealant.
Install the oil pan and bolts 10, 11, 13 and 14.
Install the 2 LH bellhousing-to-engine bolts.

Install the RH engine-to-bellhousing bolt.

7. Install the 2 LH bellhousing-to-oil pan bolts.

8. Install the RH oil pan-to-bellhousing bolt.

10. Tighten bolts 10, 11, 13 and 14 in the sequence shown.

Install the 4 lower engine front cover bolts.

12. Install the remaining oil pan bolts. Tighten in 3 stages in the sequence shown.
z Stage 1: Tighten bolts 1-9 and 11-14 to 20 Nm (177 lb-in), then rotate an additional 45
degrees.
z Stage 2: Tighten bolts 15 and 16 to 10 Nm (89 lb-in), then rotate an additional 45 degrees.
z Stage 3: Tighten bolt 10 to 20 Nm (177 lb-in), then rotate an additional 90 degrees.
Tighten the 4 lower engine front cover bolts.

Tighten the 2 LH bellhousing-to-engine bolts.

Tighten the RH engine-to-bellhousing bolt.

16. Tighten the 2 LH bellhousing-to-oil pan bolts.

17. Tighten the RH oil pan-to-bellhousing bolt.

Tighten the 2 transmission crossmember nuts.

19. Attach the generator wiring harness retainer to the engine block.
20. NOTICE: Use care when positioning the front axle housing, or the vacuum lines to the axle
Raise the front axle carrier into position.

All vehicles
24. Position the crossmember and install the 4 nuts and bolts.
Attach the generator wiring harness to the engine front cover.
Install the transmission cooler line bracket and nut to the engine front cover stud bolt.
Attach the starter motor wiring harness retainer to the oil pan.

30. Position the transmission cooler tubes and connect the 2 retainers. Install the bolt for the transmission
cooler tube bracket.
Tighten the 4 upper bellhousing-to-engine bolts.

Connect the transmission vehicle harness connector by pushing the connector into the transmission
and twisting the outer shell.
Connect the electrical connector retainer to the bracket at the rear of the transmission.
z Connect the Heated Oxygen Sensor (HO2S) electrical connector.
NOTE: Only one wire harness retainer and one electrical connector shown, others similar.
If equipped, connect the 5 transmission wire harness retainers to the transfer case wire harness.
z Connect the 2 HO2S electrical connector retainers.
z Connect the 2 HO2S electrical connectors.
35. Install the front air dam. For additional information, refer to the Front End Body Panels — Exploded
View in Section 501-02 .

If equipped, install the lower air deflector and the 8 pushpins. Turn the 4 quarter-turn retainers.
38. If equipped, install the splash shield and the 4 fasteners.
Install the oil level indicator.
Fill the engine with clean engine oil.
Connect the battery ground cable. For additional information, refer to Section 414-01 .

Oil Pump Screen and Pickup Tube
passages or the oil pan may cause engine failure.
1. Remove the oil pan. For additional information, refer to Oil Pan in this section.
2. Remove the 3 bolts and the oil pump screen and pickup tube.
3. NOTE: Install a new O-ring seal.

Oil Pump
Special Tool(s)
303-1248
Removal
02 .
3. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT)
assemblies as shown.
Installation

4. NOTE: Do not fill with clean engine oil until the engine front cover is installed.
Install the oil pan. For additional information, refer to Oil Pan in this section.

lockpin. .


z There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake
z There is 35 links in between RH intake VCT assembly colored link (2) and the 2 crankshaft
sprocket links (3).

Timing Drive Components
Special Tool(s)
303-1530

303-1248

1 6256 LH intake Variable Camshaft Timing (VCT) assembly
2 6C525 LH exhaust VCT assembly
3 6K297 LH secondary timing chain tensioner shoe
6 6306 Crankshaft timing chain sprocket
9 6K297 RH secondary timing chain tensioner shoe
10 6C525 RH exhaust VCT assembly

11 6256 RH intake VCT assembly
13 8501 Timing chain gear
14 6K297 LH primary timing chain guide
Removal
All engines
2. Rotate the crankshaft clockwise and align the timing marks on the intake Variable Camshaft Timing
(VCT) assemblies as shown.
guide may occur.
guide may occur.
Remove the 2 bolts and the RH primary timing chain guide.
25. Remove the 9 bolts and the timing chain gear.

Installation
All engines
1. Using a new gasket, install the timing chain gear and the 9 bolts. Tighten in the sequence shown in 2
stages:
2. Install the RH primary timing chain guide and the 2 bolts.

bore.
assembly.


bore.
assembly.


chain.
assembly.

assembly.

All engines

lockpin.
Install the primary tensioner and the 2 bolts.


sprocket links (3).

Valve Cover — LH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
205-142 (T80T-4000-J)
Installer, Spark Plug Tube Seal

303-1247/2
Remover, Spark Plug Tube Seal

303-1247/1
Material
Item Specification
TA-357
ZC-31-A
Remover
ZC-30
Valve Cover — LH
Part
1 6C535 Variable Camshaft Timing (VCT) solenoid seal (2
required)
2 6C535 Spark plug tube seal (3 required)
4 00812 Valve cover bolt and sleeve assembly (11 required)
5 6750 Oil level indicator
6 6584 LH valve cover gasket
Removal
2. Remove the Air Cleaner (ACL) outlet pipe and the LH ACL pipe-to-turbocharger pipe. Remove the LH
turbocharger-to-Charge Air Cooler (CAC) tube. For additional information, refer to Intake Air System
Components — Exploded View, 3.5L Gasoline Turbocharged Direct Injection (GTDI) in Section 303-
12 .
3. Remove the fuel injection pump. For additional information, refer to Section 303-04A .
4. Remove the ignition coil-over-plugs. for additional information, refer to Section 303-07A .
6. Remove the tie strap for the turbocharger wastegate hose.
7. Disconnect the turbocharger wastegate hose and position aside.
9. Disconnect the 2 LH Variable Camshaft Timing (VCT) solenoid electrical connectors. Remove the tie
strap.
11. NOTE: When removing the valve cover do not apply excessive force to the VCT oil control solenoid.
If the VCT solenoid seal sticks to the VCT oil control solenoid carefully wiggle the valve cover until the
seal breaks free. After the valve cover is removed, inspect and replace the VCT solenoids if
damaged. The plastic electrical connector on the VCT solenoid will normally rotate approximately 12
degrees inside the steel housing.
Loosen the 11 valve cover bolt and sleeve assemblies and remove the valve cover.
z Discard the valve cover gasket.
Installation
4. Using a new gasket, install the LH valve cover and tighten the 11 bolt and sleeve assemblies in the
sequence shown.
5. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid
electrical connector or the VCT seal may leak oil.
7. Connect the 2 LH VCT solenoid electrical connectors. Install a tie strap.
8. Install the CAC tube bracket and the 2 nuts.

z Tighten the M6 nut to 6 Nm (53 lb-in).
z Tighten the M10 nut to 48 Nm (35 lb-ft).
9. Connect the turbocharger wastegate hose.
10. Install the tie strap for the turbocharger wastegate hose.
12. Install the ignition coil-over-plugs. for additional information, refer to Section 303-07A .
13. Install the fuel injection pump. For additional information, refer to Section 303-04A .
14. Install the LH turbocharger-to- CAC tube. Install the LH ACL pipe-to-turbocharger pipe and the ACL
outlet pipe. For additional information, refer to Intake Air System Components — Exploded View, 3.5L
GTDI in Section 303-12 .

Valve Cover — RH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
205-142 (T80T-4000-J)

303-1247/2

303-1247/1
Material
Item Specification
TA-357
ZC-31-A
Remover
ZC-30
LSP12 (Canada)
Removal
2. Remove the Air Cleaner (ACL) outlet pipe and the RH ACL pipe-to-turbocharger pipe. Remove the
RH turbocharger-to-Charge Air Cooler (CAC) tube. For additional information, refer to Intake Air
System Components — Exploded View, 3.5L Gasoline Turbocharged Direct Injection (GTDI) in
Section 303-12 .
3. Remove the ignition coil-over-plugs. for additional information, refer to Section 303-07A .
4. Remove the PCV tube. Refer to Section 310-00 .

6. Remove the tie strap. Disconnect and position aside the turbocharger wastegate hose.
7. Remove the tie strap and disconnect the wire retainer from the valve cover.
8. Disconnect the PCM electrical connector. Disconnect the electrical connector and the 2 wire
retainers. Position aside the engine wire harness.
9. Disconnect the 2 RH Variable Camshaft Timing (VCT) solenoid electrical connectors. Remove the tie
strap for the turbocharger wastegate hose and engine wiring.
10. Disconnect the 2 Camshaft Position (CMP) sensor electrical connectors.
11. Remove the 2 bolts and the 2 CMP sensors.
12. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
13. NOTE: When removing the valve cover do not apply excessive force to the VCT oil control solenoid.
If the VCT solenoid seal sticks to the VCT oil control solenoid carefully wiggle the valve cover until the
seal breaks free. After the valve cover is removed, inspect and replace the VCT solenoids if
damaged. The plastic electrical connector on the VCT solenoid will normally rotate approximately 12
degrees inside the steel housing.
Loosen the 12 valve cover stud bolts and remove the RH valve cover.
z Discard the valve cover gasket.
Installation
4. Using a new gasket, install the RH valve cover, tighten the 12 valve cover stud bolts in the sequence
shown.
5. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid
electrical connector or the VCT seal may leak oil.
6. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
7. NOTE: Lubricate the 2 CMP sensor O-rings with clean engine oil.
Install the 2 CMP sensors and 2 bolts.

8. Connect the 2 CMP sensor electrical connectors.
9. Connect the 2 RH VCT solenoid electrical connectors. Install a tie strap for the turbocharger
wastegate hose and engine wiring.
10. Connect the PCM electrical connector. Connect the electrical connector and the 2 wire retainers.
11. Connect the wire retainer to the valve cover. Install a tie strap
12. Connect the turbocharger wastegate hose. Install a the tie strap
13. Position back the coolant hose to the valve cover stud. Install the CAC tube bracket and the 2 nuts.
14. Install the PCV tube. Refer to Section 310-00 .
15. Install the ignition coil-over-plugs. for additional information, refer to Section 303-07A .
16. Install the RH turbocharger-to- CAC tube. Install the RH ACL pipe-to-turbocharger pipe and the ACL
outlet pipe. For additional information, refer to Intake Air System Components — Exploded View, 3.5L
GTDI in Section 303-12 .

Valve Spring, Retainer and Seal
Special Tool(s)
Compressor, Valve Spring
303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-1249
Installer, Valve Stem Oil Seal

303–470 (T94P-6510–CH)
Material
Item Specification
LSP12 (Canada)
Removal
1. Remove the valve tappets from the cylinder being serviced. For additional information, refer to Valve
Tappets in this section.
2. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke.
3. NOTICE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air
pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support
the valve prior to removal or engine damage may occur.
NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the
NOTE: If a valve drops into the cylinder, remove the cylinder head. For additional information, refer to
Cylinder Head — RH or Cylinder Head — LH in this section.
Pressurize the cylinder using compressed air.
4. Using the Valve Spring Compressors, remove the keys, retainer and spring.
5. Remove and discard the valve stem seal.
Installation
1. NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.
Using the Valve Stem Oil Seal Installer, install a new valve stem seal.
2. Using the Valve Spring Compressors, install the valve spring, retainer and key.
3. Install the valve tappets. For additional information, refer to Valve Tappets in this section.

Valve Tappets
Material
Item Specification
LSP12 (Canada)
1. Depending on the valve tappets being serviced, remove the LH and/or the RH camshafts. For
additional information, refer to Camshaft — RH and/or the Camshaft — LH in this section.
Remove the valve tappets from the cylinder head.

Valve Train Components — Exploded View
Part
1 W500305 Valve train oil tube bolt (3 required)
2 6K602 Valve train oil tube
3 W710702 Camshaft cap bolt (8 required)

5 W500215 Exhaust camshaft Variable Camshaft Timing (VCT) oil
control solenoid bolt
8 6A258 Camshaft cap (4 required)
9 6A258 Camshaft cap
10 6279 Intake camshaft VCT assembly bolt
13 6250 Intake camshaft
14 6279 Exhaust camshaft VCT assembly bolt
16 6250 Exhaust camshaft
18 6518 Valve spring retainer key (24 required)
19 6514 Valve spring retainer (12 required)
20 6513 Valve spring (12 required)
21 6571 Valve stem seal (12 required)
removal.

Cylinder Head
Special Tool(s)
303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-1249

303-470 (T94P-6510-CH)
Material
Item Specification
LSP12 (Canada)
NOTE: RH cylinder head shown, LH cylinder head similar.

1 W701706 RH exhaust manifold nut (8 required)
5 6A968 Turbocharger coolant return fitting
6 6518 Intake valve spring retainer key (12 required)
7 6514 Intake valve spring retainer (6 required)
8 6513 Intake valve spring (6 required)
9 6571 Intake valve stem seal (6 required)
10 6518 Exhaust valve spring retainer key (12 required)
11 6514 Exhaust valve spring retainer (6 required)
12 6513 Exhaust valve spring (6 required)
13 6571 Exhaust valve stem seal (6 required)
15 W714090 Timing chain tensioner arm pin
16 6507 Intake valve (6 required)
17 6505 Exhaust valve (6 required)
Disassembly
All cylinder heads
1. Remove the 8 nuts and the exhaust manifold.

z Discard the nuts and gasket.
2. Clean and inspect the exhaust manifold. For additional information, refer to Section 303-00 .
3. Remove and discard the 8 exhaust manifold studs.
4. Remove the timing chain guide pin.
5. Remove the turbocharger coolant return fitting.
Using the Valve Spring Compressors, remove the keys, retainer and spring.
7. Remove the valve from the cylinder head.
9. Repeat the above steps for each valve.
RH cylinder head
10. Remove the timing chain tensioner arm pin.
Assembly
All cylinder heads
1. NOTE: If the components are to being reinstalled, they must be installed into their original location.
NOTE: Lubricate the valve stem and valve stem seal with clean engine oil prior to installation.
2. Install the valve.
5. Install the timing chain guide pin and tighten in 2 stages.

6. Install the turbocharger coolant return fitting.

LH cylinder head
7. Install the timing chain tensioner arm pin and tighten in 2 stages.
8. Install 8 new LH exhaust manifold studs.

sequence shown:
RH cylinder head
10. Install 8 new RH exhaust manifold studs.

Using a new gasket, install the RH exhaust manifold and 8 new nuts. Tighten in 2 stages in the
sequence shown:

Piston
Material
Item Specification
LSP12 (Canada)

1 — Piston compression upper ring (part of 6148)
2 — Piston compression lower ring (part of 6148)
3 — Piston oil control upper segment ring (part of 6148)
4 — Piston oil control spacer (part of 6148)
5 — Piston oil control lower segment ring (part of 6148)
6 6140 Piston pin retainer clip
8 6135 Piston pin
9 6200 Connecting rod

10 6110 Piston
Disassembly
1. Remove the piston rings from the piston.

z Discard the piston rings.
2. Remove the 2 piston pin retainers and the piston pin.

z Discard the 2 piston pin retainer clips.
3. NOTE: If the piston and/or connecting rod are being installed new, the piston rod orientation marks
block.
NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same
orientation. Mark the piston orientation to the connecting rod for reassembly.
Separate the piston from the connecting rod.
4. Clean and inspect the piston and connecting rod. For additional information, refer to Section 303-00 .
Assembly
1. Align the piston-to-connecting rod orientation marks and position the connecting rod in the piston.
2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the new piston pin retaining clips in the piston.
z The piston pin retaining clip gap orientation must be toward the top or dome of piston.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. NOTE: The piston compression upper and lower ring should be installed with the "O" mark on the ring
face pointing up toward the top of the piston.
Install the piston rings onto the piston as shown.

SECTION 303-01B: Engine — 3.7L 2014 F-150 Workshop Manual

Material
Capacity
Motorcraft® High Performance WSE- —
TA-357
ZC-31-A
Motorcraft® SAE 5W-20 WSS- 5.7L (6.0 qt)
Premium Synthetic Blend Motor M2C945-A includes
Oil (US); Motorcraft® SAE 5W- filter change
20 Super Premium Motor Oil
(Canada)
XO-5W20-QSP (US); CXO-
5W20-LSP12 (Canada)
VC-3-B (US); CVC-3-B2

(Canada)
Remover
ZC-30
Motorcraft® Multi-Purpose ESB-M1C93- —
Grease B
XL-5
TA-26 M2G351-A6
Motorcraft® Thread Sealant with WSK- —
PTFE M2G350-A2
TA-24
Item Specification
Engine
Displacement 3.7L (4V) (226 CID)
No. cylinders 6
Bore/stroke 95.5/86.7 mm (3.759/3.413 in)
Fire order 1-4-2-5-3-6
Spark plug 12405
Oil pressure Minimum 30 psi @ 1,500 rpm with engine at normal
operating temperature
Engine weight (without accessory drive 161 kg (355 lb)

components)
Engine and transaxle assembly weight (without 260.8 kg (575 lb)
accessory drive components)
Cylinder head gasket surface flatness Flat within 0.08 mm (0.003 in) length end to end;
area 150 mm (5.9 in) x 150 mm (5.9 in) (or full width)
should be less than 0.05 mm (0.002 in)
Combustion chamber volume 56.651 cc (3.46 CI)
Valve tappet clearance — intake 0.15-0.25 mm (0.006-0.01 in)
Valve tappet clearance — exhaust 0.360-0.460 mm (0.0142-0.0181 in)
Engine must be at room temperature before measuring

Valve guide bore inner diameter 5.519-5.549 mm (0.217-0.218 in)
Valve head diameter — intake 37.0 mm (1.46 in)
Valve head diameter — exhaust 31.0 mm (1.22 in)
Valve face angle 45.25-45.75°
Valve seat runout 0.04 mm (0.0001 in) MAX
Valve seat angle 44.5-45.5°
Valve spring free length (approx.) 48.0 mm (1.889 in)
Valve spring compression pressure (N @ spec. 525 N @ 27.0 mm (114.7 lb @ 1.06 in)
length)
Valve spring installed height 37.0 mm (1.45 in)
Valve spring installed height pressure (N @ 235 N @ 37.0 mm (53 lb @ 1.45 in)
spec. length)
Valve spring installed pressure — service limit 10% force loss @ specified height
Camshaft
Theoretical valve lift @ 0 lash — Intake 10.0 mm (0.39 in)
Theoretical valve lift @ 0 lash — Exhaust 9.6798 mm (0.38 in)
Allowable lobe lift loss 0.062 mm (0.0024 in)
Camshaft journal bore inside diameter — 1st 39.0375-39.0625 mm (1.536-1.537 in)
journal
Camshaft journal bore inside diameter — 25.9875-26.0125 mm (1.023-1.024 in)

Camshaft bearing outside diameter — 1st 38.99-39.01 mm (1.5350-1.5358 in)
journal
Camshaft bearing outside diameter — 25.937-25.963 mm (1.021-1.022 in)
Camshaft journal-to-bearing clearance, 1st 0.0725 mm (0.0029 in) MAX
journal — service limit
Camshaft journal-to-bearing clearance, 0.0755 mm (0.0029 in) MAX
intermediate journals — service limit
Runout camshaft journals 0.040 mm (0.0015 in) MAX
End play — standard 0.032-0.170 mm (0.0012-0.0066 in)
End play — service limit 0.190 mm (0.00748 in) MAX
Cylinder Block
Cylinder bore diameter — grade 1 95.500-95.520 mm (3.760-3.761 in)
Cylinder bore roundness 0.013 mm (0.0005 in)
Cylinder bore taper 0.010 mm (0.0004 in) per 25.4 mm (1 in)
Block main bore roundness 0.008 mm (0.003 in)
Head gasket surface flatness Flat within 0.150 mm (0.005 in) overall;
0.050 mm (0.001 in) per 150 mm (5.905 in) x 150 mm

(5.905 in);
0.025 mm (0.0009 in) per 25 mm (0.98 in) x 25 mm (0.98

in)
Crankshaft
Main bearing journal diameter 67.5 mm (2.657 in)
Main bearing journal maximum out-of-round 0.006 mm (0.00023 in)
Main bearing journal-to-main bearing clearance 0.026-0.041 mm (0.0010-0.0016 in)
Connecting rod journal maximum out-of-round 0.006 mm (0.00023 in)
Crankshaft maximum end play 0.051-0.291 mm (0.0020-0.0114 in)
Piston diameter — single grade 95.490-95.476 mm (3.7594-3.7589 in)
Piston-to-cylinder bore clearance 0.010 to 0.044 mm (0.0003-0.0017 in)
Piston ring end gap — compression (top, gauge 0.17-0.27 mm (0.0067-0.0106 in)
diameter)
Piston ring end gap — compression (bottom, 0.30-0.55 mm (0.0118-0.0216 in)
gauge diameter)
Piston ring end gap — oil ring (steel rail, gauge 0.15-0.45 mm (0.0059-0.0177 in)
diameter)
Piston ring groove width — compression (top) 1.230-1.25 mm (0.0484-0.0492 in)
Piston ring groove width — compression 1.530-1.55 mm (0.0602-0.0610 in)
(bottom)
Piston ring groove width — oil ring 2.53-2.55 mm (0.0996-0.1004 in)
Piston ring width — upper compression ring 1.17-1.19 mm (0.0460-0.0468 in)
Piston ring width — lower compression ring 1.47-1.49 mm (0.0578-0.0586 in)
Piston ring-to-groove clearance (upper and 0.040-0.080 mm (0.0015-0.0031 in)
lower compression rings)
Piston pin length 55.975 mm (2.203 in)
Piston pin-to-piston fit 0.004 to 0.011 mm (0.00015-0.00043 in)
Piston-to-connecting rod clearance 2.7 mm (0.1 in)
Connecting rod-to-pin clearance — standard 0.007-0.022 mm (0.0002-0.0009 in)
Connecting rod length (center-to-center) 152.68 mm (6.01 in)
1
2
3
crank) — standard
crank) — service limit
A/C compressor bolt, stud bolt and nut 25 18 —
A/C tube nut 15 — 133
Accessory drive belt tensioner bolts 25 18 —
Bellhousing-to-engine bolts and stud bolts 48 35 —
Bellhousing-to-oil pan bolts 48 35 —
Block coolant drain plug — RH a — — —
Block coolant drain plug — LH b — — —

Block oil gallery plug — LH c 48 35 —
Block oil gallery plug — rear c 85 63 —
Block oil gallery plug — RH c 32 24 —
Camshaft bearing and mega cap bolts d — — —
Camshaft Position (CMP) sensor bolts 10 — 89
Catalytic convertor support bracket bolts 90 66 —
Catalytic converter-to-exhaust intermediate pipe bolts d — — —
Catalytic converter-to-exhaust manifold nuts 45 35 —
Channel cover plate bolts d — — —
Connecting rod cap bolts d — — —
Coolant pump bolts d — — —

Crankcase rear seal retainer plate bolts d — — —
CKP sensor heat shield nut and bolt 10 — 89
CKP sensor wiring harness retainer stud bolt 10 — 89
Crankshaft pulley bolt d — — —
Crossmember brace nuts and bolts 90 66 —
Cylinder head bolts d — — —
Cylinder head M6 bolt 10 — 89
Engine front cover bolts d — — —
Engine lift eye 25 18 —
Engine support insulator bolts 175 129 —
Engine support insulator bracket bolts 63 46 —
Engine support insulator stud bolts 15 — 133
Engine oil filter e — — —
Engine-to-bellhousing bolt 45 35 —
Engine Oil Pressure (EOP) switch d — — —
Exhaust manifold heat shield bolts 12 — 106
Exhaust manifold nuts d — — —
Exhaust manifold studs 12 — 106
Flexplate bolts d — — —
Front air dam 20 — 177
Generator B+ terminal nut 17 — 150

Generator nut and bolt 48 35 —
Generator stud 8 — 71
Ground strap bolt 10 — 89
Heater hose bracket nut 8 — 71
Ignition coil-on-plug bolts 7 — 62
Knock Sensor (KS) bolts 20 — 177
Lower front axle carrier mounting bushing bolt 115 85 —
Lower intake manifold bolts d — — —
Main bearing bolts d — — —
d — — —
Main bearing cap support brace bolts
Oil cooler bolt 58 43 —
Oil filter adapter bolts d — — —
Oil pan bolts d — — —
Oil pan-to-bellhousing bolts 48 35 —
Oil pump bolts 10 — 89
Oil pump screen and pickup tube bolts 10 — 89
d — — —
Thermostat housing bolts
Timing chain guide pin d — — —
Timing chain tensioner arm pin d — — —

Timing chain tensioner bolts 10 — 89
Transmission cooler tube bracket bolt 12 — 106
Transmission cooler tube bracket nut 12 — 106
Transmission crossmember nuts 103 76 —
Upper front axle carrier mounting bushing bolt 115 85 —
Upper intake manifold bolts d — — —
Upper intake manifold support bracket bolt 10 — 89
Valve cover bolts and stud bolts d — — —
Valve train oil tube bolts d — — —
Variable Camshaft Timing (VCT) bolts d — — —
VCT oil control solenoid bolts d — — —
a
b
c Discard original plug and O-ring seal. Install a new plug and O-ring seal to specified torque, no sealer or
lubricant required.
d
Refer to the procedure in this section.
e Tighten to 5 Nm (44 lb-in) plus an additional 180 degrees.

Engine
The 3.7L (4V) is a (TiVct) V6 engine with the following features:

z Sequential Multi-Port Fuel Injection (SFI)
z A composite lower intake manifold and upper intake manifold
z An aluminum, 60-degree V-cylinder block
z Twin independent Variable Camshaft Timing (VCT) system
z The electronic ignition system with 6 ignition coils
z 305 horsepower
For quick identification, refer to the safety certification decal.
z The decal is located on the LH front door lock face panel.
The engine code information label, located on the front side of the valve cover, contains the following:
Item Description
2 Engine plant (Cleveland)
4 Engine configuration
5 Twin independent VCT system
6 Bar code
7 Bar code
8 Running number
10 Plant shift line
11 Derivative code
Exhaust Emission Control System
Operation and required maintenance of the exhaust emission control devices used on this engine is covered
in the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
Induction System
The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 6 solenoid-operated fuel
injectors:
z are mounted between the fuel rail and the intake manifold.
z meter fuel into the air intake stream in accordance with engine demand.
z are positioned so that their tips direct fuel just ahead of the engine intake valves.
Valve Train
The valve train uses Direct Acting Mechanical Buckets (DAMB). The camshaft lobes are positioned directly
above mechanical buckets which are positioned on top of the valves.
Twin IndependentVariable Camshaft Timing (VCT) System
PCV System
manifold.
Lubrication System
The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the
crankshaft, connecting rod bearings, timing chain tensioners and VCT solenoids. The flow of oil to the valve
tappets and valve train is controlled by a restricting orifice located in the cylinder head, valve train oil feed
tubes. Die cast aluminum deep sump oil pan for 10,000 mile oil change intervals.
Oil Pump
The lubrication system is designed to provide optimum oil flow to critical components of the engine through
its entire operating range.
The heart of the system is a positive displacement internal gear oil pump.
z Oil pump displacement has been selected to provide adequate volume to ensure correct oil pressure
both at hot idle and maximum speed.
z The relief valve calibration protects the system from excessive pressure during high-viscosity
conditions.
Engine Oil Flow Illustration
Engine Assembly
Part
1 6600 Oil pump
3 — Piston oil cool valve (part of 6010)
4 6303 Crankshaft
5 6C364 Engine main bearing cap support
6 6675 Oil pan
7 6731 Oil filter
8 6A642 Oil cooler
14 6A258 LH camshaft cap
15 6K602 LH valve train oil feed tube
17 6B280 LH camshaft mega cap

18 6M280 LH intake and exhaust camshaft Variable Camshaft
Timing (VCT) oil control solenoid
19 6C525 LH exhaust camshaft VCT
20 6256 LH intake camshaft VCT
21 6A280 RH camshaft cap
22 6K602 RH valve train oil feed tube
23 6C270 RH secondary timing chain tensioner
24 6B280 RH camshaft mega cap
25 6M280 RH intake and exhaust camshaft VCT oil control
solenoid
26 6C525 RH exhaust camshaft VCT
27 6256 RH intake camshaft VCT
Cooling System
The engine cooling system includes the following:
z Radiator
z Coolant pump
z Electric fan assembly(s)
z Degas bottle (aids in maintaining the correct volume of engine coolant)
z Coolant hoses
z Engine oil cooler
The channel cover plate is located under the engine front cover mounted to the block. It contains a timing
chain idler and press and place gaskets separating engine coolant and engine oil. A weep hole is provided
on the front left side of the engine behind the generator. If oil or coolant is leaking from the weep hole, then a
gasket has failed and must be replaced.

Engine

Valve Clearance Check
1. Remove the valve covers. For additional information, refer to Valve Cover — LH and Valve Cover —
RH in this section.
2. NOTE: Engine must be at room temperature before measuring. The valve clearance must be
measured with the camshaft at base circle. The engine will have to be rotated with the crankshaft
pulley bolt to bring each valve to base circle.
Use a feeler gauge to measure the clearance of each valve and record its location. A midrange
clearance is the most desirable:
z Intake: 0.15-0.25 mm (0.006-0.01 in)
z Exhaust: 0.360-0.460 mm (0.0142-0.0181 in)
3. NOTE: The number on the valve tappet reflects the thickness of the valve tappet. For example, a
tappet with the number 3.310 has the thickness of 3.31 mm (0.13 in).
If any of the valve clearances are out of specification, select new tappets using this formula: tappet
thickness = measured clearance + the base tappet thickness - most desirable thickness.
Select the tappets and mark the installation location.
4. If required, install the new selected valve tappets in the marked locations. For additional information,
refer to Valve Tappets in this section.

Engine
Special Tool(s)
300-OTC1819E

303-1454
Eye, Engine Lift

303-1245

303-F047 (014-00073)

307-346 (T97T-7902-A) or
equivalent
02 .
5. If equipped, disconnect the block heater electrical connector at the thermostat housing.
z Detach the block heater wiring harness retainer from the LH valve cover stud bolt, generator
wiring harness and position aside.
6. Remove the cooling module. For additional information, refer Section 303-03 .
7. Remove the Air Cleaner (ACL) upper tray. For additional information, refer to Intake Air System
Components — Exploded View, 3.7L in Section 303-12 .
8. Disconnect the Battery Junction Box (BJB) wiring harness and the A/C pressure transducer electrical
connectors.

z Discard the O-ring seal and gasket seal.

z Detach the A/C compressor wiring harness from the A/C compressor.
14. Remove the Air Conditioning (A/C) compressor belt. For additional information, refer to Section 303-
05 .
15. Disconnect the middle PCM electrical connector.

z Detach the wiring harness retainer from the fender splash shield.
16. Detach and disconnect the engine harness electrical connector.
17. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in this
section.
18. Disconnect the fuel supply tube quick connect coupling from the fuel rail. For additional information,
19. Remove the PVC tube quick connect coupling from RH valve cover. For additional information, refer
to Section 310-00 .
20. Remove the crankcase vent tube quick connect coupling from LH valve cover. For additional
21. Disconnect the 2 heater hose couplings at the rear of the engine.
22. Disconnect the 2 coolant hoses from the degas bottle.
23. Detach the wiring harness retainers from the rear of the RH valve cover stud bolt and the rear of the
RH cylinder head.
Remove the 4 torque converter nuts.
Disconnect the LH and RH Heated Oxygen Sensor (HO2S) electrical connectors.
separate.
37. If equipped, remove the 2 coolant hoses from the oil cooler.
38. NOTE: The 2 engine mount stud may come off with the nuts.
Remove and discard the 2 RH engine support insulator nuts and studs.
39. Remove the engine-to-bellhousing bolt.
40. Remove the oil pan-to-bellhousing bolt.
41. Remove the 2 LH bellhousing-to-engine bolts.
Remove and discard the LH engine mount through bolt.
45. Remove the 4 upper bellhousing-to-engine bolts.
46. Install the LH engine lift eye.
47. Using part of Engine Lifting Bracket and a chain, assemble the Engine Spreader Bar as shown.
48. Install the Engine Spreader Bar assembly into the Engine Lift Eyes.
49. NOTE: After removing the bolts leave the LH engine support insulator in place.
Remove the 3 bolts for the LH engine support insulator.
50. NOTE: The use of a ratchet strap may be needed to level the engine.
Using the Heavy Duty Floor Crane and Engine Spreader Bar assembly, raise the engine for
clearance to remove the LH engine support insulator.
53. Using the Heavy Duty Floor Crane and Engine Spreader Bar assembly, remove the engine.

Engine
Special Tool(s)
300-OTC1819E
3 Jaw Puller
303-D121

303-1454
Handle
205-153 (T80T-4000-W)

303-1530
205-142 (T80T-4000-J)

205-150 (T80T-4000-S)
Remover, Oil Seal

303-409 (T92C-6700CH)
Remover, VCT Spark Plug Tube

Seal
303-1247/1
Slide Hammer
307-005 (T59L-100-B)
Strap Wrench
303-D055 (D85L-6000-A)

303-1248
Material
Item Specification
ZC-31-A
Remover
ZC-30
NOTE: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.
All engines
2. Remove the spacer plate.
4. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil
pan.
Using the Heavy Duty Floor Crane and Spreader Bar, mount the engine on a suitable engine stand.
5. Remove the LH and RH engine lift eyes.
6. Remove the 3 bolts and the A/C compressor .
10. Remove the LH fuel rail insulator.
11. Remove the RH fuel rail insulator.
12. Disconnect the 3 RH ignition coil-on-plug electrical connectors.
13. Disconnect the Cylinder Head Temperature (CHT) sensor wiring harness jumper electrical connector.
14. Disconnect the 3 RH fuel rail electrical connectors.
15. Disconnect the 2 RH Variable Camshaft Timing (VCT) solenoid electrical connectors.
16. Disconnect the 2 RH Camshaft Position (CMP) sensors electrical connectors.
17. Detach all of the wiring harness retainers from the RH cylinder head, valve cover and stud bolts.
19. Disconnect the 3 LH ignition coil-on-plug electrical connectors.
20. Disconnect the 3 LH fuel rail electrical connectors.
21. Disconnect the 2 LH VCT solenoid electrical connectors.
22. Disconnect the Knock Sensor (KS) electrical connector.
23. Disconnect the 2 LH CMP sensors electrical connectors.

z Detach the wiring harness retainer from the rear of the cylinder head.
24. Remove the nut, the bolt and the heat shield.
28. Detach all of the wiring harness retainers from the LH cylinder head, valve cover and stud bolts.
z Discard the bolt.
33. Remove the LH cylinder block drain plug.

34. Remove the RH cylinder block drain plug.

35. Remove the nut and the heater hose bracket from the valve cover stud bolt.
36. Remove the 4 bolts and the thermostat housing.

z Discard the thermostat housing and coolant inlet tube O-ring seals.

z Discard the coolant pump gasket and coolant pump O-ring seal.
removal.
Remove the 3 bolts and the 3 LH ignition coil-on-plugs.
spark plugs.
Remove the 3 LH spark plugs.
Loosen the 7 stud bolts, 4 bolts and remove the LH valve cover.
45. Remove the 2 bolts and the LH exhaust manifold heat shield.

z Discard the nuts and exhaust manifold gaskets.
removal.
Remove the 3 bolts and the 3 RH ignition coil-on-plugs.
spark plugs.
Remove the 3 RH spark plugs.
Loosen the 8 stud bolts, 3 bolts and remove the RH valve cover.
55. Remove the 2 bolts and the RH exhaust manifold heat shield.

z Discard the nuts and exhaust manifold gaskets.
59. Remove the 2 bolts and the LH CMP sensors.
60. Remove the 2 bolts and the RH CMP sensors.
If equipped, remove the oil cooler mounting bolt and the oil cooler.

65. Using a pry tool, locate the 7 pry pads shown and pry the engine front cover loose and remove.
66. NOTE: Inspect front cover radial seal and replace if necessary.
If necessary, using the Spindle Bearing Installer and Handle, remove the front cover radial seal from
the rear side of the front cover.
guide may occur.
guide may occur.
Remove the bolt and the RH primary timing chain guide.
90. Remove the 9 bolts and the channel cover plate.
z Discard the gaskets.
All engines
may occur.
Verify the LH camshafts are in the neutral position.
original positions.
may occur.
Rotate the RH camshafts counterclockwise to the neutral position.
original positions.
Remove the valve tappets from the cylinder heads.
damage.
Remove the 10 bolts and the lower intake manifold.

106. Disconnect and remove the CHT sensor jumper harness.
Remove and discard the M6 bolt from each cylinder head.
Remove and discard the 8 bolts from each cylinder head.

z Remove the cylinder heads.
z Discard the cylinder head gaskets.
minutes.
111. Remove the 2 bolts and the KS .
Using a pry tool, locate the 2 pry pads at the LH and RH side of the oil pan and pry the oil pan loose
and remove.
114. Remove the 3 bolts and the oil pump screen and the pickup tube.
carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's
instructions.
118. NOTE: The main bearing cap support brace bolts must be discarded and new bolts must be installed.
They are a tighten-to-yield design and cannot be reused.
Remove the bolts in the sequence shown.

z Remove the main bearing cap support brace.
119. NOTE: The connecting rod cap bolts are a tighten-to-yield design. The original connecting rod cap
bolts will be used when measuring the connecting rod large end bore during assembly. The
connecting rod cap bolts will be discarded after measurement.
NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and
connecting rod bearings for reassembly.
Remove the connecting rod cap bolts and cap.
120. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Remove the piston/rod assembly from the engine block.
121. Repeat the previous 2 steps until all the piston/rod assemblies are removed from the engine block.
122. NOTE: The 8 main bearing cap side bolts must be discarded and new bolts must be installed. They
are a tighten-to-yield design and cannot be reused.
Remove the 8 main bearing cap side bolts in the sequence shown.
123. NOTE: The 8 main bearing cap bolts must be discarded and new bolts must be installed. They are a
Remove the 8 main bearing cap bolts in the sequence shown.

reassembly.
NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.
Remove the 4 main bearing caps.
125. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing
bulkhead.
Remove the crankshaft.
126. NOTE: Inside shown, outside similar.
Remove the 2 crankshaft thrust bearings from the rear main bearing bulkhead.
reassembly.
Remove the 4 crankshaft main bearings from the cylinder block.
reassembly.
Remove the 4 crankshaft main bearings from the main bearing caps.
129. Inspect the cylinder block, bearing cap support brace, pistons and connecting rods. For additional
sequence.
engine front cover and oil pan. Do not use metal scrapers, wire brushes or any other power
abrasive disk to clean the engine front cover and oil pan. These tools cause scratches and
gouges that make leak paths.
Clean the engine front cover and oil pan using a 3M™ Roloc® Bristle Disk (2-in white, part number
07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
z Thoroughly wash the engine front cover and oil pan to remove any foreign material, including
any abrasive particles created during the cleaning process.

Engine
Special Tool(s)
300-OTC1819E

303-1454

303-D032 (D81L-6002-C)

Fixture
100-002 (TOOL-4201-C)
Eye, Engine Lift

303-1245
Handle
205-153 (T80T-4000-W)

303-1530
205-142 (T80T-4000-J)

205-149 (T80T-4000-R)

Damper
303-102 (T74P-6316-B)

303-335

303-1251
Installer, VCT Spark Plug Tube

Seal
303-1247/2
Strap Wrench
303-D055 (D85L-6000-A)

303-1248
Material
Item Specification
TA-357
ZC-31-A
LSP12 (Canada)
Remover
ZC-30
Engine Upper

1 14A411 Engine control harness
2 9424 Upper intake manifold
3 9J444 Upper intake manifold support bracket
4 9F797 Fuel rail
5 9424 Lower intake manifold
6 8A586 Thermostat housing
7 12A699 Knock Sensor (KS)
Engine Upper — LH Cylinder Head
Part
4 6A258 LH camshaft cap (6 required)
control solenoid

9 6K297 LH secondary tensioner shoe
17 6B288 LH cylinder head Camshaft Position (CMP) sensor (2
required)
19 W712244 LH exhaust manifold stud (6 required)
Engine Upper — RH Cylinder Head
Part
3 6A258 RH camshaft cap (6 required)
control solenoid
9 6K297 RH secondary tensioner shoe

17 6B288 RH cylinder head Camshaft Position (CMP) sensor (2
required)
Engine Front

2 6378 Crankshaft pulley washer

5 8501 Coolant pump
7 6268 Timing chain
10 6K255 Primary timing chain tensioner arm
11 6B274 LH lower primary timing chain guide
12 8501 Channel cover plate
13 6M256 RH primary timing chain guide

1 6600 Oil pump

4 6675 Oil pan
6 6A642 Oil cooler
10 6K301 Crankshaft rear seal retainer
12 6375 Flexplate
Part
1 — Piston compression upper ring (part of 6148) (6
required)
2 — Piston compression lower ring (part of 6148) (6
required)
3 — Piston oil control upper segment ring (part of 6148) (6
required)
4 — Piston oil control spacer (part of 6148) (6 required)
5 — Piston oil control lower segment ring (part of 6148) (6
required)

10 6211 Connecting rod upper bearing (6 required)
12 6K868 Piston oil cool valve (6 required)
13 6211 Connecting rod lower bearing (6 required)
14 6200 Connecting rod cap (6 required)
15 6A341 Crankshaft upper thrust washer (2 required)
16 6D309 Cylinder block crankshaft main bearing (4 required)
17 6303 Crankshaft
18 6K302 Crankshaft lower thrust washer
19 6D309 Lower crankshaft main bearing (4 required)
20 6325 Lower crankshaft main bearing cap (4 required)
21 6C364 Main bearing cap support brace
NOTE: Assembly of the engine requires various inspections/measurements of the engine components.
These inspections/measurements will aid in determining if the engine components will require replacement.
All engines
1. NOTE: This procedure is for selecting bearings using a new crankshaft.
Select the crankshaft main bearings for each crankshaft journal.

z Read the code on the crankshaft flange.
z Read the code on the cylinder block face.
The first letter after the first asterisk makes up the code for main No. 1 and the next
letter for main No. 2. The first letter after the second asterisk makes up the code for
main No. 3 and the last letter for main No. 4.
main bearing code.
bearing.
z Repeat the above steps using the fourth letter of the block and crankshaft codes to select the
No. 4 bearing.
3. NOTE: This chart is for selecting main bearings 2 and 3 only.
bearing grade for the No. 2 crankshaft main bearing.
correct bearing grade for this main bearing is "1".
z Repeat the above steps using the third letter of the block and crankshaft codes to select the
No. 3.
Using the original connecting rod cap bolts, install the connecting rod caps and bolts.
z Tighten the bolts in 3 stages:
5. Measure the connecting rod large end bore in 2 directions.

z Remove the bolts and the rod cap.
Discard the connecting rod cap bolts.
6. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
7. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod
journal.
8. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and
Lubricate the upper crankshaft main bearings with clean engine oil and install the 4 crankshaft main
bearings in the cylinder block.
9. NOTE: Do not install the upper thrust bearings until the crankshaft is installed.
NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.
Install the crankshaft onto the upper main bearings.
surface.
No. 4 rear bulkhead.
surface.
Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No.
4 rear bulkhead.
12. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main
bearing caps. Visually check seating and squareness of the bearings to make sure of proper seating
in caps.
13. Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as
square as possible, alternately draw the caps down evenly using the new bolts until the main bearing
caps are seated.
surface.
NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the
tab aligned with the cutout in the main bearing cap.
15. Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible,
alternately draw the cap down evenly using the new bolts until the main bearing cap is seated.
16. Loosen the No. 4 main bearing cap bolts.
17. NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4
main bearing cap rearward to seat the crankshaft thrust washers.
Tighten the main bearing bolts in the sequence shown in 2 stages:

18. Install the new 8 main bearing cap side bolts. Tighten in the sequence shown in 2 stages:
19. Using the Dial Indicator Gauge with Holding Fixture, measure crankshaft end play.
z Position the crankshaft to the rear of the cylinder block.
z Zero the Dial Indicator Gauge.
z Move the crankshaft to the front of the cylinder block. Note and record the crankshaft end play.
Prepare the connecting rod and cap.

z Insert the new bolts in the rod cap.
z Insert the upper and lower rod bearings into the rod and cap.
21. Before installing the pistons into the cylinder block, verify proper ring gap location.
22. NOTICE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting
rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE: The next 3 steps are for all 6 connecting rods, rod caps and pistons. Only 1 connecting rod,
rod cap and piston is shown.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with
clean engine oil.
NOTE: Make sure the piston rings are positioned to specifications for installation. For additional
information, refer to Disassembly and Assembly of Subassemblies - Piston in this section.
NOTE: If the piston and/or connecting rod are being installed new, the piston rod orientation marks
block.
NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same
orientation as disassembled.
Using the Piston Ring Compressor, install the piston and connecting rod assemblies.
23. Seat the connecting rod on the crankshaft journal.
NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to
verify smooth operation.
Install the connecting rod cap and bolts.

z Tighten the bolts in 3 stages:
25. Repeat the previous 3 steps until all 6 piston, connecting rod and connecting rod cap assemblies are
installed.
26. Install the main bearing cap support brace and the new bolts. Tighten in the sequence shown in 2
steps.
z Stage 1: Tighten fasteners to 20 Nm (177 lb-in).
z Stage 2: Tighten fasteners an additional 180 degrees.
28. NOTE: Lubricate the crankshaft rear seal with clean engine oil.
NOTE: Use the 2 handles during installation to avoid touching the sealant.
Install the 8 crankshaft rear seal retainer plate bolts. Tighten in the sequence shown.

application.
35. Tighten bolts 10, 11, 13 and 14 in the sequence shown to 3 Nm (27 lb-in).
37. Install the Knock Sensor (KS) and the 2 bolts.

38. Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5
stages:
39. Install the RH M6 bolt.

40. Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5
stages:
41. Install the LH M6 bolt.

42. Connect the Cylinder Head Temperature (CHT) sensor jumper harness.
including valve or piston damage, check the intake manifold for metal debris. If metal debris if
damage.
Using new lower intake manifold gaskets, install the lower intake manifold and the 10 bolts and
tighten in the sequence shown.
Position the crankshaft dowel pin in the 9 o'clock position.
may occur.
original positions.

53. Rotate the RH camshafts to the Top Dead Center (TDC) position as shown.
may occur.
original positions.

64. Using new gaskets, install the channel cover plate and the 9 bolts. Tighten in the sequence shown in
2 stages:
65. Install the RH primary timing chain guide and the bolt.
bore.
assembly.
71. Install the 2 new RH VCT bolts and tighten in 4 stages:


bore.
assembly.
79. Install the 2 new LH VCT bolts and tighten in 4 stages:


chain.
assembly.
85. Install the 2 new RH VCT bolts and tighten in 4 stages:

assembly.
90. Install the 2 new LH VCT bolts and tighten in 4 stages:

All engines
93. Rotate the crankshaft clockwise 60 degrees to the Top Dead Center (TDC) position (crankshaft dowel
pin at 11 o'clock).

z Release the ratchet detent.
z Using a soft-jawed vise, compress the ratchet plunger.
z Align the hole in the ratchet plunger with the hole in the tensioner housing.
z Install a suitable lockpin.


sprocket links (3).
104. Install the RH valve train oil tube and the 3 bolts and tighten in 2 stages:
106. Install the LH valve train oil tube and the 3 bolts and tighten in 2 stages:
If removed, using the Spindle Bearing Installer, install the front cover radial seal from the rear side of
the front cover.
for at least 90 minutes after installing the engine front cover. Failure to follow these
instructions may cause engine oil leakage.
cover bolt bosses.
Install the engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 and tighten sequence
shown in 3 stages:
110. Install the remaining 12 engine front cover bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 16 and 22. Tighten all
of the engine front cover bolts in the sequence shown in 3 stages:
z Stage 1: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14 and 16 to 10 Nm (89 lb-in).
z Stage 2: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14 and 16 to 20 Nm (177 lb-in) then an
If equipped, install the new oil cooler and the mounting bolt.
113. Install the Crankshaft Position (CKP) sensor and install the bolt.
114. Install the 2 RH Camshaft Position (CMP) sensors and the bolts.
115. Install the 2 LH CMP sensors and the bolts.

sequence shown:
118. Install the RH exhaust manifold heat shield and the 2 bolts.
122. Using a new gasket, install the RH valve cover and tighten the 3 bolts and 8 stud bolts in the
sequence shown.
Install the 3 RH spark plugs.

126. Install the 3 RH ignition coil-on-plug assemblies and the 3 bolts.


sequence shown:
129. Install the LH exhaust manifold heat shield and the 2 bolts.
133. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts in the
sequence shown.
Install the 3 LH spark plugs.

137. Install the 3 LH ignition coil-on-plug assemblies and the 3 bolts.

Using new coolant pump gasket and coolant pump O-ring seal, install the coolant pump and the 7
bolts and tighten in the sequence shown in 2 stages:

140. NOTE: Lubricate the coolant inlet tube O-ring seal with clean engine coolant.
Install the thermostat housing and the 4 bolts and tighten in the sequence shown in 2 stages:
141. Install the heater hose bracket on the valve cover stud bolt and install the nut.
142. Install the RH cylinder block drain plug.

143. Install the LH cylinder block drain plug.

z Tighten the cylinder block drain plug to 10 Nm (89 lb-in) plus an additional 720 degrees.
crankshaft pulley.
148. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages:
149. Attach all of the wiring harness retainers to the LH cylinder head, valve cover and stud bolts.

153. Install the heat shield, the nut and the bolt.
154. Connect the 2 LH CMP sensors electrical connectors.

z Attach the wiring harness retainer to the rear of the cylinder head.
155. Connect the KS electrical connector.
156. Connect the 2 LH VCT solenoid electrical connectors.
157. Connect the 3 LH fuel rail electrical connectors.
158. Connect the 3 LH ignition coil-on-plug electrical connectors.
159. Connect the Engine Oil Pressure (EOP) switch electrical connector.
160. Attach all of the wiring harness retainers to the RH cylinder head, valve cover and stud bolts.
161. Connect the 2 RH CMP sensors electrical connectors.
162. Connect the 2 RH VCT solenoid electrical connectors.
163. Connect the 3 RH fuel rail electrical connectors.
164. Connect the CHT sensor wiring harness jumper electrical connector.
165. Connect the 3 RH ignition coil-on-plug electrical connectors.
166. Install the RH fuel rail insulator.
167. Install the LH fuel rail insulator.
169. Install the LH engine support insulator-to-cylinder block bracket and the 4 bolts.
170. Install the RH engine support insulator and the 4 bolts.


172. Install the LH and RH engine lift eyes.

173. Using the Heavy Duty Floor Crane and Spreader Bar, remove the engine from the stand.
175. Install the spacer plate.
176. Install the flexplate and the 8 bolts and tighten is sequence shown.

Engine
Special Tool(s)
300-OTC1819E

303-1454

303-F047 (014-00073)
Material
Item Specification
LSP12 (Canada)
XL-5 B
1. NOTICE: Prior to installation of the engine, the torque converter pilot hub must be lubricated
with multi-purpose grease or damage to the torque converter or the engine crankshaft can
occur
2. Align the torque converter stud and flexplate hole near the paint marks at the 12 o'clock position.
3. Using the Heavy Duty Floor Crane and Engine Spreader Bar, position the engine in the engine
compartment.
5. Using the Heavy Duty Floor Crane and Engine Spreader Bar, position the engine to the transmission.
6. Align the engine to the transmission and install LH bellhousing-to-engine bolt.

7. Install the engine-to-bellhousing bolt.

8. Install the oil pan-to-bellhousing bolt.

9. Tighten the engine-to-bellhousing bolt.

10. Using the Heavy Duty Floor Crane and Engine Spreader Bar, raise the engine for clearance for the
LH engine support insulator.
11. Install the LH engine support insulator.
12. NOTICE: Use only hand tools when installing the LH engine support insulator through bolt or
the engine support insulator may be damaged.
NOTE: Clean the LH and RH engine support insulator-to-frame mating surfaces of any dirt or foreign
Install the new LH engine support insulator and the through bolt.
14. Install the 3 LH engine support insulator bolts.

15. Install the 2 LH bellhousing-to-oil pan bolts.


17. Tighten LH bellhousing-to-engine bolt.

18. Install the 2 new RH engine support insulator studs.

19. NOTICE: Use only hand tools when installing the RH engine support insulator nuts or the
engine support insulator may be damaged.

20. NOTICE: Use only hand tools when tightening the LH engine support insulator through bolt or
Tighten the LH engine mount through bolt.

21. If equipped, install the 2 coolant hoses to the oil cooler.


new bolts.
63 Nm (46 lb-ft).
63 Nm (46 lb-ft).
Connect the LH and RH Heated Oxygen Sensor (HO2S) electrical connectors.
26. Install the 4 torque converter nuts.

31. Install the 4 upper bellhousing-to-engine bolts.


35. Attach the wiring harness retainers to the rear of the RH valve cover stud bolt and the rear of the RH
cylinder head.
36. Connect the 2 coolant hoses to the degas bottle.
37. Connect the 2 heater hose couplings at the rear of the engine.
38. Install the crankcase vent tube quick connect coupling to LH valve cover. For additional information,
39. Install the PVC tube quick connect coupling to RH valve cover. For additional information, refer to
Section 310-00 .
40. Connect the fuel supply tube quick connect coupling to the fuel rail. For additional information, refer to
Section 310-00 .
41. Install the upper intake manifold. For additional information, refer to Upper Intake Manifold in this
section.
42. Attach and connect the engine harness electrical connector.
43. Connect the middle PCM electrical connector.

z Attach the wiring harness retainer to the fender splash shield.
44. Install the Air Conditioning (A/C) compressor belt. For additional information, refer to Section 303-05 .

z Attach the A/C compressor wiring harness to the A/C compressor.
49. Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
50. Connect the Battery Junction Box (BJB) wiring harness and the A/C pressure transducer electrical
connectors.
52. Install the Air Cleaner (ACL) upper tray. For additional information, refer to Intake Air System
Components — Exploded View, 3.7L in Section 303-12 .
53. Install the cooling module. For additional information, refer Section 303-03 .
54. If equipped, connect the block heater electrical connector at the thermostat housing.
z Attach the block heater wiring harness retainer to the LH valve cover stud bolt.

Camshaft — LH
Special Tool(s)
303-1530

303-1248
Material
Item Specification
LSP12 (Canada)
Removal
NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.
Mark the 2 timing chain links that aligns with the timing mark on the crankshaft sprocket as shown.

z Remove the Secondary Chain Hold Down.
original positions.
Installation
Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
may occur.
original positions.

assembly.

16. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).



sprocket links (3).


Camshaft — RH
Special Tool(s)
303-1530

303-1248
Material
Item Specification
LSP12 (Canada)
Removal
NOTE: The following 3 steps are for primary timing chains when the colored links are not visible.
Mark the 2 timing chain links that aligns with the timing mark on the crankshaft sprocket as shown.

z Remove the Secondary Chain Hold Down.
original positions.
Installation
Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
may occur.
original positions.

9. Rotate the RH camshafts to the TDC position as shown.
chain.
assembly.

16. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).



sprocket links (3).


Special Tool(s)
Damper
303-102 (T74P-6316-B)

303-1251
Remover, Oil Seal

303-409 (T92C-6700CH)
Material
Item Specification
ZC-31-A
LSP12 (Canada)
Removal
02 .
Installation


2 N806165 Washer
removal.

Crankshaft Pulley
Special Tool(s)
3 Jaw Puller

303-335
Replacer, Crankshaft Vibration

Damper
303-102 (T74P-6316-B)
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent

Material
Item Specification
LSP12 (Canada)
Removal
02 .
2. Remove the accessory drive belt and the A/C belt. For additional information, refer to Section 303-
05 .
z Discard the bolt.

Installation
crankshaft pulley.
4. Install the accessory drive belt and the A/C belt. For additional information, refer to Section 303-05 .

Material
Item Specification
TA-357
ZC-31-A
LSP12 (Canada)
Remover
ZC-30
Removal
02 .
2. Remove the flexplate. For additional information, refer to Flexplate in this section.
4. Remove the engine-to-transmission spacer plate.
5. Remove the nut, the bolt and the heat shield.
10. If equipped, remove the bolts and the skid plate.
11. Remove the 2 oil pan-to-crankshaft rear seal retainer plate bolts.
Clean the sealing surfaces of the cylinder block and oil pan flange in the following sequence.
Installation
Apply a 5 mm (0.196 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 cylinder
block/oil pan joints.
3. NOTE: Lubricate the crankshaft rear seal with clean engine oil.
NOTE: Use the 2 handles during installation to avoid touching the sealant.
Install the crankshaft rear seal retainer at an angle above the oil pan flange to avoid scraping off the
sealer. Tilt the seal retainer up and onto the rear of the cylinder block.
4. Install the 8 crankshaft rear seal retainer plate bolts. Tighten in the sequence shown.
5. Install the 2 oil pan-to-crankshaft rear seal retainer plate bolts.

6. If equipped, install the skid plate and the bolts.

7. Install the CKP sensor and the bolt.


11. Install the heat shield, the nut and the bolt.
12. Install the engine-to-transmission spacer plate.
14. Install the flexplate. For additional information, refer to Flexplate in this section.

Cylinder Head — LH
Material
Item Specification
LSP12 (Canada)
Part
1 — Heated Oxygen Sensor (HO2S) electrical connector
(part of 14A411) (2 required)
2 W714265 Catalytic converter-to-exhaust manifold nuts (4
required) - 45 Nm (35 lb-ft)
3 5F250 Catalytic converter assembly (Y-pipe)
Part
1 W709818 LH upper primary timing chain guide bolt - 10 Nm (89
lb-in)
3 W707193 Ground strap bolt - 10 Nm (89 lb-in)
4 19A095 Ground strap
Removal
personal injury.
3. Detach and disconnect the RH and LH Heated Oxygen Sensor (HO2S) electrical connectors.
separate.
5. Remove and discard the LH and RH catalytic convertor-to-exhaust manifold nuts and lower the
catalytic convertor assembly.
6. Remove the LH camshafts. For additional information, refer to Camshaft — LH in this section.
7. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
guide may occur.
Remove the bolt and the LH upper primary timing chain guide.
9. Disconnect the 2 LH Camshaft Position (CMP) sensors electrical connectors.
10. Remove the 2 bolts and the 2 LH CMP sensors.
11. If equipped, remove the bolt and ground strap from the rear of the LH cylinder head.
12. Detach the wiring harness retainer from the rear of the LH cylinder head.

minutes.
Installation
installed.
Install a new gasket, the LH cylinder head and 8 new bolts. Tighten in the sequence shown in 5
stages:

2. Install the M6 bolt.

Install the LH valve tappets.
4. Attach the wiring harness retainer to the rear of the LH cylinder head.
5. If equipped, install the ground strap and bolt.

Install the 2 LH CMP sensors and the 2 bolts.

7. Connect the 2 LH CMP sensors electrical connectors.
8. Install the LH upper primary timing chain guide and the bolt.
9. Install the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
10. Install the LH camshafts. For additional information, refer to Camshaft — LH in this section.
11. Raise the catalytic convertor and install the new LH and RH catalytic convertor-to-exhaust manifold
nuts.
new bolts.
63 Nm (46 lb-ft).
63 Nm (46 lb-ft).
13. Connect and attach the RH and LH HO2S electrical connectors.

Cylinder Head — RH
Material
Item Specification
LSP12 (Canada)
Part
Part
1 — Cylinder Head Temperature (CHT) sensor electrical
connector (part of 14A411)
2 W715118 RH primary timing chain guide bolt - 10 Nm (89 lb-in)
3 6K297 RH upper primary timing chain guide
4 W705661 Ground wire bolt - 10 Nm (89 lb-in)
5 19A095 Ground wire
6 — Wiring harness retainer (part of 15525)
Removal
personal injury.
separate.
5. Remove and discard the LH and RH catalytic converter-to-exhaust manifold nuts and lower the
catalytic converter assembly.
6. Remove the RH camshafts. For additional information, refer to Camshaft — RH in this section.
7. Remove the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
8. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
guide may occur.
Remove the bolt and the RH upper primary timing chain guide.
10. Disconnect the 2 RH Camshaft Position (CMP) sensors electrical connectors.
11. Remove the 2 bolts and the 2 RH CMP sensors.
12. Remove the bolt and ground wire from the rear of the RH cylinder head.

minutes.
Installation
installed.
Install a new gasket, the RH cylinder head and 8 new bolts. Tighten in the sequence shown in 5
stages:
2. Install the M6 bolt.

Install the RH valve tappets.
4. Install the ground wire and bolt to the rear of the RH cylinder head.
Install the 2 RH CMP sensors and the 2 bolts.

6. Connect the 2 RH CMP sensors electrical connectors.
7. Install the RH upper primary timing chain guide and the bolt.
8. Connect the CHT sensor electrical connector.
9. Install the lower intake manifold. For additional information, refer to Lower Intake Manifold in this
section.
10. Install the RH camshafts. For additional information, refer to Camshaft — RH in this section.
11. Raise the catalytic converter and install the new LH and RH catalytic converter-to-exhaust manifold
nuts.
new bolts.
63 Nm (46 lb-ft).
63 Nm (46 lb-ft).

Engine Front Cover
Special Tool(s)
Handle
205-153 (T80T-4000-W)

205-149 (T80T-4000-R)

205-150 (T80T-4000-S)
Material
Item Specification
TA-357
ZC-31-A
LSP12 (Canada)
Remover
ZC-30

1 6730 Oil pan drain plug.
2 W520414 Generator nut
3 W714577 Generator bolt
4 10346 Generator
5 W714329 Generator stud

Removal
02 .
3. Remove the LH and RH valve covers. For additional information, refer to Valve Cover — LH and
Valve Cover — RH in this section.

5. Loosen the 4 coolant pump pulley bolts.
6. Remove the A/C belt. For additional information, refer to Section 303-05 .
8. Remove the nut, bolt and position the generator aside.
9. Remove the generator stud.
11. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal in this
section.
remove.
16. NOTE: Inspect front cover radial seal and replace if necessary.
If necessary, using the Spindle Bearing Installer and Handle, remove the front cover radial seal from
the rear side of the front cover.
Installation
engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk
to clean. These tools cause scratches and gouges that make leak paths.
Clean the engine front cover using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a
z Thoroughly wash the engine front cover to remove any foreign material, including any abrasive
particles created during the cleaning process.
material created while cleaning gasket surfaces) that enters the oil passages or the oil pan
sequence.
If removed, using the Spindle Bearing Installer, install the front cover radial seal from the rear side of
the front cover.
for at least 90 minutes after installing the engine front cover. Failure to follow these
instructions may cause engine oil leakage.
cover bolt bosses.
Install the engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 and tighten sequence
shown in 3 stages:
6. Install the remaining 12 engine front cover bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14, 16 and 22. Tighten all
of the engine front cover bolts in the sequence shown in 3 stages:
z Stage 1: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14 and 16 to 10 Nm (89 lb-in).
z Stage 2: Tighten bolts 3, 4, 5, 6, 9, 10, 11, 12, 13, 14 and 16 to 20 Nm (177 lb-in) then an
9. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal in this
section.
11. Install the generator stud.

12. Position the generator and install the nut and bolt.
13. Install the A/C belt. For additional information, refer to Section 303-05 .
15. Tighten the 4 coolant pump pulley bolts.

16. Install the LH and RH valve covers. For additional information, refer to Valve Cover — LH and Valve
Cover — RH in this section.

Skid Plate
NOTE: For vehicles equipped with skid plate.

1 W706894 Skid plate bolt (4 required)
2 5D032 Skid plate
Engine Lubrication Components
Part
(part of 14A411)
2 9278 EOP switch
4 — Oil cooler bolt (part of 6A642)
5 6A642 Oil cooler
9 6730 Oil pan drain plug

12 W708221 Oil pan bolt
13 6675 Oil pan
17 W500300 Primary timing chain tensioner bolt (2 required)
25 W503282 Oil pump bolt (3 required)
26 6600 Oil pump
removal.

Material
Item Specification
Motorcraft® Thread Sealant with WSK-M2G350-
PTFE A2
TA-24

z To install, tighten to 14 Nm (124 lb-in) then an additional 180 degrees.

z Apply thread sealant with PTFE to the EOP switch threads prior to installation.

Special Tool(s)
303-1454
Eye, Engine Lift

303-1245
Support Bar, Engine

303-F070
Engine Support Insulator — LH
Part
1 W713244 LH engine support insulator-to-frame bolt (3 required)
4 W714735 LH engine support insulator-to-cylinder block bracket
bolt (4 required)
5 6038 LH engine support insulator-to-cylinder block bracket
Engine Support Insulator — RH
Part
1 W707251 RH engine support insulator nut (2 required)
2 — RH engine support insulator stud bolt (part of 6038) (2
required)
6038)
5 W714735 RH engine support insulator-to-cylinder block bracket
bolt (4 required)
6 — RH engine support insulator-to-cylinder block bracket
(part of 6038)
Removal
All engine support insulator
02 .
section.
6. Install the LH engine lift eye.
separate.
05 .
Remove and discard the RH and LH engine support insulator through bolts.
17. NOTICE: Only use hand tools when removing or installing the engine support insulator nuts or
NOTICE: Only use hand tools when removing or installing the engine support insulator stud
bolts or damage to the engine support insulator can occur.
Remove and discard the 2 RH engine support insulator nuts and stud bolts.
Remove and discard the LH and RH engine support insulator through bolts.
Remove the 3 LH engine support insulator-to-frame bolts.
Four-Wheel Drive (4WD) — LH engine support insulator
24. Position a suitable hydraulic jack under the front axle. Securely strap the jack to the axle.
28. Lower the front axle to allow clearance to the LH engine support insulator.
NOTE: If necessary, the following 3 steps are to remove the LH engine support insulator-to-cylinder block
bracket.
z Detach the generator wiring harness retainer from the oil filter adapter.
Installation
NOTE: If removed, the following 3 steps are to install the LH engine support insulator-to-cylinder block
bracket.
2. Install the LH engine support insulator-to-cylinder block bracket and install the 4 bolts.

bolts.
4WD — LH engine support insulator
6. Raise the front axle carrier into position.



10. Tighten the LH engine support insulator-to-frame bolts to 175 Nm (129 lb-ft).

14. Position the RH engine support insulator-to-cylinder block bracket and install the 4 bolts.
Position the RH engine support insulator into the vehicle and install the 2 new stud bolts.



All vehicles
Tighten the transmission mount-to-crossmember nuts to 103 Nm (76 lb-ft).

new bolts.
63 Nm (46 lb-ft).
63 Nm (46 lb-ft).
27. Install the upper radiator air deflector and the 4 pushpins.
28. Remove the LH engine lift eye.
section.


Exhaust Manifold — LH
Material
Item Specification
ZC-31-A
Part
Part
1 W714133 LH exhaust manifold heat shield bolt (2 required) - 12
Nm (106 lb-in)
2 9Y427 LH exhaust manifold heat shield
3 W701706 LH exhaust manifold nut (6 required)
6 W712244 LH exhaust manifold stud (6 required) - 12 Nm (106
lb-in)
Removal
02 .
separate.
5. Remove the LH front wheel and tire. For additional information, refer to Section 204-04 .

means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak
paths. Use a plastic scraper to clean the sealing surfaces.
Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the
directions on the packaging.
Installation

sequence shown:

4. Install the LH front wheel and tire. For additional information, refer to Section 204-04 .
nuts.
new bolts.
63 Nm (46 lb-ft).
63 Nm (46 lb-ft).

Exhaust Manifold — RH
Material
Item Specification
ZC-31-A
Part
Part
1 W714133 RH exhaust manifold heat shield bolt (2 required) - 12
Nm (106 lb-in)
2 9A462 RH exhaust manifold heat shield
6 W712244 RH exhaust manifold stud (6 required) - 12 Nm (106
lb-in)
Removal
02 .
separate.
5. Remove the RH front wheel and tire. For additional information, refer to Section 204-04 .

Installation

sequence shown:

4. Install the RH front wheel and tire. For additional information, refer to Section 204-04 .
nuts.
new bolts.
63 Nm (46 lb-ft).
63 Nm (46 lb-ft).

Flexplate
Special Tool(s)
Removal
02 .
2. Remove the automatic transmission. For additional information, refer to Section 307-01 .
Installation
1. NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position.
Install the flexplate and the 8 bolts and tighten in sequence shown.
2. Install the automatic transmission. For additional information, refer to Section 307-01 .

Front Cover Radial Seal
Special Tool(s)
Remover/Installer, Water Tube
Seal
303-1528

Removal
05 .
3. Using the Water Tube Seal Remover, remove the front cover radial seal.
z Reset the Water Tube Seal Remover center bolt to its retracted position.
z Screw the Water Tube Seal Remover onto the front cover radial seal until it bottoms out.
z Using a brass hammer, give the Water Tube Seal Remover a slight tap inward to break the
front cover radial seal lose.
z Turn the Water Tube Seal Remover center bolt clockwise and remove the front cover radial
seal.
4. Clean the engine front cover radial seal area.
Installation
1. Using the Water Tube Seal Installer, install the front cover radial seal.
z Position the front cover radial seal on the Water Tube Seal Installer.
z Position the Water Tube Seal Installer into the engine front cover.
z Using a brass hammer, tap the Water Tube Seal Installer until the front cover radial seal
bottoms out.
2. Inspect the front cover radial seal for proper installation or damage.

Lower Intake Manifold
Lower Intake Manifold (View 1 of 3)
Part
1 — Fuel tube-to-fuel rail quick connect coupling (part of
9J280)
2 6P013 LH fuel rail noise insulator shield
3 6P013 RH fuel rail noise insulator shield
4 — Fuel injector electrical connector (part of 12C508) (6
required)

1 W714841 Thermostat housing bolt (4 required)
3 8A571 Thermostat housing gasket
4 9A425 Thermostat housing-to-coolant tube O-ring seal
5 18472 Heater hose-to-lower intake manifold

1 W503279 Lower intake manifold bolt (10 required)
3 9439 Lower intake manifold gasket (8 required)
Removal
personal injury.
3. Drain the cooling system. For additional information, refer to Section 303-03 .
section.
5. Disconnect the fuel tube-to-fuel rail quick connect coupling. For additional information, refer to
Section 310-00 .
6. Remove the LH and RH fuel rail noise insulator shields.
7. Disconnect the 6 fuel injector electrical connectors.
8. NOTICE: Cover the accessory drive belts to prevent coolant contamination of the belts.
Completely cover the accessory drive belts with waterproof plastic.
9. Remove the 4 bolts and remove the thermostat housing from the coolant tube.
z Remove and discard the thermostat housing gasket and coolant tube O-ring seal.
10. Disconnect the heater hose from the rear of the lower intake manifold.
11. Remove the 10 bolts and the lower intake manifold.

z Remove and discard the lower intake manifold gaskets.
Installation
damage.
Using new lower intake manifold gaskets, install the lower intake manifold and the 10 bolts and
tighten in the sequence shown.
2. Connect the heater hose to the lower intake manifold.
3. Using a new thermostat housing gasket and coolant tube O-ring seal, install the thermostat housing
and the 4 bolts and tighten in the sequence shown in 2 stages.
4. Connect the 6 fuel injector electrical connectors.
5. Install the LH and RH fuel rail noise insulator shields.
6. Connect the fuel tube-to-fuel rail quick connect coupling. For additional information, refer to Section
310-00 .
section.
9. Remove the waterproof plastic from accessory drive belts.
10. Fill and bleed the cooling system. For additional information, refer to Section 303-03 .

Oil Cooler
Removal
02 .
3. Using hose clamp pliers, clamp the 2 oil cooler coolant hoses and remove the 2 coolant hoses from
the oil cooler.
4. Loosen the oil cooler insert bolt and remove the oil cooler.
Installation
1. Align the oil cooler to the oil filter adapter and tighten the oil cooler insert bolt.
2. Connect the 2 coolant hoses to the engine oil cooler and remove the hose clamp pliers.

4. Inspect and adjust the coolant level in the degas bottle.

Oil Filter Adapter
Removal
All engines
02 .
3. Remove the Air Cleaner (ACL) outlet tube and the ACL upper tray. For additional information, refer to
Engine with oil cooler
5. Loosen the oil cooler insert bolt and position the oil cooler aside.
All engines
6. Disconnect the generator electrical connector.
7. Position the generator B+ protective boot aside, remove the B+ nut and position the B+ terminal
aside.
z Detach the generator wiring harness retainer from the oil filter adapter and position the
generator wiring harness aside.

Installation
All engines
2. Connect the EOP switch electrical connector.

z Attach the generator wiring harness retainer.
3. Position back the generator wiring harness and B+ terminal and install the nut.
z Position back the generator B+ protective boot.
4. Connect the generator electrical connector.
Engine with oil cooler
5. Position the oil cooler and tighten the oil cooler insert bolt.
All engines

7. Install the ACL outlet tube and the ACL upper tray. For additional information, refer to Intake Air

Oil Pan
Material
Item Specification
TA-357
ZC-31-A
LSP12 (Canada)
Remover
ZC-30
Removal
All vehicles
02 .
3. Remove the oil level indicator.
4. NOTE: This step does not apply if the engine front cover is removed.
Loosen the 4 upper bellhousing-to-engine bolts 5 mm (0.19 in).
5. If equipped, remove the bolts and the skid plate.
6. Remove the bolt for the transmission cooler tube bracket from the radiator support.

Remove the nut and the transmission cooler line bracket from the engine front cover stud bolt.
Detach the generator wiring harness from the engine front cover.
All vehicles
Loosen the engine-to-bellhousing bolt above the starter motor 5 mm (0.19 in).
20. Remove the oil pan-to-bellhousing bolt from below the starter motor.
Loosen the 2 LH bellhousing-to-engine bolts 5 mm (0.19 in).
Loosen the 2 transmission crossmember nuts.
Slide the transmission rearward 5 mm (0.19 in).
Remove the 4 lower engine front cover bolts.
27. NOTE: LH rear shown, RH front similar.
Using a suitable pry tool, locate the 2 pry pads at the LH and RH sides of the oil pan and pry the oil
28. NOTE: The generator wiring harness retainer is being removed for clearance to install the oil pan.
Detach the generator wiring harness retainer from the engine block.
29. NOTICE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the oil
pan. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean. These
tools cause scratches and gouges that make leak paths.
Clean the engine oil pan using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a
z Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles
created during the cleaning process.
white, part number 07528) to clean the cylinder block and engine front cover sealing surfaces.
These tools cause scratches and gouges that make leak paths. They also cause contamination
that causes premature engine failure. Remove all traces of the gasket.
Clean the sealing surfaces of the cylinder block and engine front cover in the following sequence.
Installation
All vehicles
Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 engine
front cover-to-cylinder block joint areas on the sealing surface of the oil pan.
for at least 90 minutes after installing the oil pan. Failure to follow these instructions may
cause engine oil leakage.
NOTE: Do not apply Motorcraft® High Performance Engine RTV Silicone to the front edge of the oil
pan, if the engine front cover is removed.
edge of the oil pan to the sealing surface of the oil pan-to-engine block and to the oil pan-to-engine
front cover mating surface.
application.
NOTE: Keep the oil pan as close as possible to the transmission while installing, then slide forward
towards the engine front cover to prevent wiping off of the sealant.
Tighten the 2 LH bellhousing-to-engine bolts.

Tighten the RH engine-to-bellhousing bolt.

7. Install and tighten the 2 LH bellhousing-to-oil pan bolts.

8. Install and tighten the RH oil pan-to-bellhousing bolt.

10. Tighten bolts 10, 11, 13 and 14 in the sequence shown to 3 Nm (27 lb-in).
Install the 4 lower engine front cover bolts finger tight.
Tighten the 4 lower engine front cover bolts to 24 Nm (18 lb-ft).
Tighten the 2 LH bellhousing-to-engine bolts to 48 Nm (35 lb-ft).
Tighten the RH engine-to-bellhousing bolt to 48 Nm (35 lb-ft).
16. Tighten the 2 LH bellhousing-to-oil pan bolts to 48 Nm (35 lb-ft).
17. Tighten the RH oil pan-to-bellhousing bolt to 48 Nm (35 lb-ft).
Tighten the 2 transmission crossmember nuts to 103 Nm (75 lb-ft).
19. Attach the generator wiring harness retainer to the engine block.
20. NOTICE: Use care when positioning the front axle housing, or the vacuum lines to the axle

All vehicles
Attach the generator wiring harness to the engine front cover.
Install the transmission cooler line bracket and nut to the engine front cover stud bolt.

30. Position the transmission cooler tube bracket to the radiator support and install the bolt.
31. If equipped, install the skid plate and the bolts.

Tighten the 4 upper bellhousing-to-engine bolts to 48 Nm (35 lb-ft).
33. Install the oil level indicator.

3. NOTE: Install a new O-ring seal.

Oil Pump
Special Tool(s)
303-1248
Removal
02 .
Installation

3. Install the crankshaft timing chain sprocket.
4. Install the oil pan. For additional information, refer to Oil Pan in this section.



z There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake
z There is 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft
sprocket links (3).
13. Remove the Camshaft Holding Tool.
15. Remove the Camshaft Holding Tool.


Special Tool(s)
303-1530

303-1248

1 6256 LH intake Variable Camshaft Timing (VCT) assembly
2 6C525 LH exhaust VCT assembly
3 6K297 LH secondary timing chain tensioner shoe
6 6306 Crankshaft timing chain sprocket
9 6K297 RH secondary timing chain tensioner shoe
10 6C525 RH exhaust VCT assembly

13 8501 Channel cover plate
14 6K297 LH primary timing chain guide
Removal
All engines
guide may occur.
guide may occur.
Remove the bolt and the RH primary timing chain guide.
25. Remove the 9 bolts and the channel cover plate.

Installation
All engines
1. Using new gaskets, install the channel cover plate and the 9 bolts. Tighten in the sequence shown in
2 stages:
2. Install the RH primary timing chain guide and the bolt.

bore.
assembly.


bore.
assembly.


chain.
assembly.

assembly.

All engines



sprocket links (3).


Upper Intake Manifold
Upper Intake Manifold (View 1 of 2)
Part
1 6A664 PCV tube quick connect coupling
2 — Throttle Body (TB) electrical connector (part of
14A411)
3 — TB electrical connector wiring harness pin-type retainer
(part of 14A411)
4 9J280 Evaporative Emission (EVAP) tube
5 — EVAP canister purge valve electrical connector (part of
14A411)
6 — EVAP canister purge valve electrical connector wiring
harness pin-type retainer (part of 14A411)
7 — Brake booster vacuum hose (part of 9C482)
8 — Wiring harness pin-type retainer (part of 14A411)
9 W503275 Upper intake manifold support bracket bolt
Upper Intake Manifold (View 2 of 2)

1 W715096 Upper intake manifold bolt
2 9Y450 Upper intake manifold bolt (6 required)
3 9424 Upper intake manifold
4 9H486 Upper intake manifold gasket
Removal
2. Disconnect the PCV tube quick connect coupling from the intake manifold. For additional information,
3. Disconnect the Throttle Body (TB) electrical connector.

z Detach the TB electrical connector wiring harness pin-type retainer from the TB .
4. Disconnect Evaporative Emission (EVAP) tube from the EVAP canister purge valve. For additional
z Detach the EVAP hose retainer from the intake manifold.
5. Disconnect the EVAP canister purge valve electrical connector.

z Detach the EVAP canister purge valve electrical connector wiring harness pin-type retainer.
6. Disconnect the brake booster vacuum hose from the engine.
7. Detach the wiring harness pin-type retainer from the rear of the upper intake manifold.
8. Remove the upper intake manifold support bracket bolt from the front of the RH cylinder head.
9. Loosen the 7 bolts and remove the upper intake manifold.

z Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
Installation
damage.
Using new gaskets, install the upper intake manifold and tighten the 7 bolts in the sequence shown in
2 stages.
2. Install the upper intake manifold support bracket bolt to the RH cylinder head.
3. Attach the wiring harness pin-type retainer to the rear of the upper intake manifold.
4. Connect the brake booster vacuum hose to the engine.
5. Connect the EVAP canister purge valve electrical connector.

z Attach the EVAP canister purge valve electrical connector wiring harness pin-type retainer.
6. Connect EVAP tube to the EVAP canister purge valve. For additional information, refer to Section
310-00 .
z Attach the EVAP hose retainer to the intake manifold.

z Attach the TB electrical connector wiring harness pin-type retainer to the TB .
8. Connect the PCV tube quick connect coupling to the intake manifold. For additional information, refer
to Section 310-00 .
9. Install the ACL outlet pipe. For additional information, refer to Section 303-12 .

Valve Cover — LH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
205-142 (T80T-4000-J)

303-1247/2

303-1247/1
Material
Item Specification
TA-357
ZC-31-A
Remover
ZC-30
Valve Cover — LH (View 1 of 2)
Part
(part of 14A411)
2 — EOP switch electrical connector wiring harness pin-
type retainer (part of 14A411)
3 6758 Crankcase ventilation tube
4 — LH Variable Camshaft Timing (VCT) electrical
connector (part of 14A411) (2 required)
5 — LH valve cover wiring harness pin-type retainer (part of
14A411) (2 required)
6 — LH valve cover stud bolt wiring harness retainer (part of
14A411)
14A411)
14A411)
Valve Cover — LH (View 2 of 2)
Part
2 6C519 Valve cover bolt (4 required)
3 6C519 Valve cover stud bolt (7 required)
required)
Removal
1. Remove the Air Cleaner (ACL) outlet tube and the ACL upper tray. For additional information, refer to
2. Disconnect and remove the crankcase ventilation tube quick connect coupling from the LH valve
cover. For additional information, refer to Section 310-00 .
4. Remove the LH ignition coils. For additional information, refer to Section 303-07A .
5. Disconnect the 2 LH Variable Camshaft Timing (VCT) solenoid electrical connectors.

Loosen the 7 stud bolts, 4 bolts and remove the LH valve cover.

Installation
4. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts in the
sequence shown.
7. Connect the EOP switch electrical connector.

8. Connect the 2 LH VCT solenoid electrical connectors.
9. Install the LH ignition coils. For additional information, refer to Section 303-07A .
11. Connect the crankcase ventilation tube quick connect coupling to the LH valve cover. For additional
12. Install the ACL outlet tube and the ACL upper tray. For additional information, refer to Intake Air

Valve Cover — RH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
205-142 (T80T-4000-J)

303-1247/2

303-1247/1
Material
Item Specification
TA-357
ZC-31-A
Remover
ZC-30
Valve Cover — RH (View 1 of 2)
Part
—
1 6A664 PCV tube
2 — RH valve cover stud bolt wiring harness retainer (part
of 14A411) (3 required)
3 — RH Variable Camshaft Timing (VCT) electrical
connector (part of 14A411) (2 required)
4 — RH valve cover wiring harness pin-type retainer (part of
14A411)
of 14A411)
of 14A411)
of 14A411)
Valve Cover — RH (View 2 of 2)
Part
1 6C519 Valve cover bolt (3 required)
2 6C519 Valve cover stud bolt (8 required)
4 6584 RH valve cover gasket
required)
Removal
1. Remove the RH ignition coils. For additional information, refer to Section 303-07B .
2. Disconnect and remove the PCV tube quick connect coupling from the RH valve cover. For additional
3. Disconnect the 2 RH Variable Camshaft Timing (VCT) solenoid electrical connectors.
4. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
5. Remove the nut and position the heater hose and bracket aside.
Loosen the 8 stud bolts, 3 bolts and remove the RH valve cover.

Installation
4. Using a new gasket, install the RH valve cover and tighten the 3 bolts and 8 stud bolts in the
sequence shown.
6. Position the heater hose and bracket on the valve cover stud bolt and install the nut.
7. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
8. Connect the 2 RH VCT solenoid electrical connectors.
9. Connect the PCV tube quick connect coupling to the RH valve cover. For additional information, refer
to Section 310-00 .
10. Install the RH ignition coils. For additional information, refer to Section 303-07B .

Valve Spring, Retainer and Seal
Special Tool(s)
303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-1249

303–470 (T94P-6510–CH)
Material
Item Specification
LSP12 (Canada)
Removal
1. Remove the valve tappets from the cylinder being serviced. For additional information, refer to Valve
Tappets in this section.
3. NOTICE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air
pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support
the valve prior to removal or engine damage may occur.
NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the
Cylinder Head — RH or Cylinder Head — LH in this section.
Installation
1. NOTE: Lubricate the valve stem seal with clean engine oil prior to installation.
3. Install the valve tappets. For additional information, refer to Valve Tappets in this section.

Valve Tappets
Material
Item Specification
LSP12 (Canada)
1. Depending on the valve tappets being serviced, remove the LH and/or the RH camshafts. For
additional information, refer to Camshaft — RH and/or the Camshaft — LH in this section.
Remove the valve tappets from the cylinder head.

Part
1 W500305 Valve train oil tube bolt (3 required)
2 6K602 Valve train oil tube
3 W500215 Exhaust camshaft Variable Camshaft Timing (VCT) oil

control solenoid bolt
5 6279 Intake camshaft VCT assembly bolt
6 6279 Exhaust camshaft VCT assembly bolt
12 6A258 Camshaft cap (12 required)
removal.

Cylinder Head
Special Tool(s)
303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-1249

303-470 (T94P-6510-CH)
Material
Item Specification
LSP12 (Canada)
NOTE: RH cylinder head shown, LH cylinder head similar.

1 W714133 RH exhaust manifold heat shield bolt (2 required)
8 W714090 Timing chain tensioner arm pin
9 W714090 Timing chain guide pin
10 6518 Intake valve spring retainer key (12 required)
11 6514 Intake valve spring retainer (6 required)
12 6513 Intake valve spring (6 required)
13 6571 Intake valve stem seal (6 required)
15 6518 Exhaust valve spring retainer key (12 required)
16 6514 Exhaust valve spring retainer (6 required)
17 6513 Exhaust valve spring (6 required)
18 6571 Exhaust valve stem seal (6 required)
Disassembly
All cylinder heads
1. Remove the 2 bolts and the exhaust manifold heat shield.
2. Remove the 6 nuts and the exhaust manifold.

3. Clean and inspect the exhaust manifold. For additional information, refer to Section 303-00 .
4. Remove and discard the 6 exhaust manifold studs.
5. Remove the timing chain guide pin.
Using the Valve Spring Compressors, remove the keys, retainer and spring.
RH cylinder head
10. Remove the timing chain tensioner arm pin.
11. Remove and discard the Cylinder Head Temperature (CHT) sensor.
12. Remove the 2 bolts and the engine lift eye.
Assembly
All cylinder heads
1. NOTE: If the components are to being reinstalled, they must be installed into their original location.
NOTE: Lubricate the valve stem and valve stem seal with clean engine oil prior to installation.
2. Install the valve.
5. Install the timing chain guide pin and tighten in 2 stages.

RH cylinder head
6. Install the engine lift eye and the 2 bolts.

7. Install a new CHT sensor.

8. Install the timing chain tensioner arm pin and tighten in 2 stages.

sequence shown:
LH cylinder head

sequence shown:

Piston
Material
Item Specification
LSP12 (Canada)

8 6135 Piston pin

10 6110 Piston
Disassembly

2. Remove the 2 piston pin retainers and the piston pin.

z Discard the 2 piston pin retainer clips.
3. NOTE: If the piston and/or connecting rod are being installed new, the piston rod orientation marks
block.
NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same
orientation. Mark the piston orientation to the connecting rod for reassembly.
Separate the piston from the connecting rod.
Assembly
1. Align the piston-to-connecting rod orientation marks and position the connecting rod in the piston.
4. Install the new piston pin retaining clips in the piston.
z The piston pin retaining clip gap orientation must be toward the top or dome of piston.
6. NOTE: The piston compression upper and lower ring should be installed with the "O" mark on the ring
face pointing up toward the top of the piston.
Install the piston rings onto the piston as shown.

SECTION 303-01C: Engine — 5.0L (4V) 2014 F-150 Workshop Manual

Material
Capacity
Motorcraft® Multi-Purpose Grease ESB-M1C93- —
XL-5 B
ZC-31-A
Motorcraft® SAE 5W-20 Premium WSS- 7.33 L
Synthetic Blend Motor Oil (US); M2C945-A (7.75 qt)
LSP12 (Canada)
Remover
ZC-30
Motorcraft® Silicone Brake Caliper ESE-M1C171- —
XG-3-A
Motorcraft® Silicone Gasket and WSE- —
Sealant M4G323-A4
TA-30
TA-26 M2G351-A6
Item Specification
Engine
Displacement 4.957 L (302 CID)
Number of cylinders 8
Bore 92.2 mm (3.629 in)
Stroke 92.7 mm (3.649 in)
Firing order 1-5-4-8-6-3-7-2
Spark plug 12405
Spark plug gap 1.25-1.35 mm (0.049-0.053 in)
Minimum oil pressure at idle (engine at normal 103 kPa (15 psi)
operating temperature, transmission in park)
file:///C:/TSO/tsocache/VDTOM2_10764/SE2~us~en~file=SE231C01.HTM~gen~ref.H...
Engine weight 197.3 kg (435 lb)

Combustion chamber volume 54.5-57.5 cc (3.33-3.51 cu in)

Valve head diameter — intake 37 mm (1.45 in)
Valve head diameter — exhaust 31 mm (1.22 in)
Valve face angle 45 degrees
Valve seat runout 0.04 mm (0.0016 in)
Valve seat angle 120/90/60 degrees
Valve spring free length — intake 51.32 mm (2.02 in)
Valve spring free length — exhaust 51.32 mm (2.02 in)
Valve spring perpendicularity — intake 3 mm (0.118 in)
Valve spring perpendicularity — exhaust 3 mm (0.118 in)
Valve spring compression force — intake 650 N
Valve spring compression force — exhaust 650 N
Valve spring installed height — intake 40 mm (1.5748 in)
Valve spring installed height — exhaust 40 mm (1.5748 in)
Valve spring installed force — intake 265 N
Valve spring installed force — exhaust 265 N
Roller follower ratio 2:1
Head gasket surface flatness 0.025 mm (0.001 in) in any 25 mm (1 in) x 25 mm
(1 in) area;
0.050 mm (0.002 in) in any 150 mm (6 in) x 150

mm (6 in) area; 0.1 mm (0.004 in) overall
Hydraulic Lash Adjuster
Diameter — intake 11.89-12.00 mm (0.4681-0.472 in)
Diameter — exhaust 11.89-12.00 mm (0.4681-0.472 in)
Clearance-to-bore 0.018-0.050 mm (0.0007-0.0019 in)
Hydraulic leakdown rate — intake 0.45-3 seconds a
Hydraulic leakdown rate — exhaust 0.45-3 seconds a
Collapsed lash adjuster gap 0.35-0.85 mm (0.0137-0.0334 in)
Camshaft
file:///C:/TSO/tsocache/VDTOM2_10764/SE2~us~en~file=SE231C01.HTM~gen~ref.H... 2014-03-01

Journal diameter 28.607-28.633 mm (1.1262-1.1272 in)
Journal bore inside diameter 28.682-28.657 mm (1.1292-1.1282 in)
Journal-to-bearing clearance 0.025-0.075 mm (0.001-0.002 in)
Runout 0.04 mm (0.0016 in) (4 places)
End play 0.15 mm (0.0059 in)
Cylinder Block
Cylinder bore diameter 92.200-92.220 mm (3.6299-3.6307 in)
Cylinder bore maximum taper 0.013 mm (0.0005 in)
Cylinder bore maximum out-of-round 0.010 mm (0.0004 in)
Head gasket surface flatness 0.0254 mm (0.001 in) across any 38.1 mm (1.5 in)
square
Crankshaft
Main bearing journal diameter 67.481-67.505 mm (2.657-2.658 in)
Main bearing journal maximum out-of-round 0.008 mm (0.0003 in) between cross sections
Main bearing journal-to-main bearing clearance 0.025-0.045 mm (0.0009-0.0018 in)
Crankshaft maximum end play 0.28 mm (0.011 in)
Piston diameter 92.161-92.175 mm (3.6283-3.6289 in)
Piston-to-cylinder bore clearance (at grade size) b 0.025-0.059 mm (0.0009-0.0023 in)
Piston ring end gap — top 0.15-0.25 mm (0.0059-0.0098 in)
Piston ring end gap — intermediate 0.30-0.55 mm (0.0118-0.0216 in)
Piston ring gap — oil control 0.15-0.45 mm (0.0059-0.0177 in)
Piston ring groove width — top 1.220-1.250 mm (0.0480-0.0492 in)
Piston ring groove width — intermediate 1.220-1.240 mm (0.0480-0.0488 in)
Piston ring groove width — oil control 2.530-2.550 mm (0.0996-0.1003 in)
Piston ring width — top 1.17-1.19 mm (0.0460-0.0468 in)
Piston ring width — intermediate 1.17-1.19 mm (0.0460-0.0468 in)
Piston ring-to-groove clearance — top 0.030-0.080 mm (0.0019-0.0031 in)
Piston ring-to-groove clearance — intermediate 0.030-0.070 mm (0.0019-0.0028 in)
Piston pin length 60.7-61.0 mm (2.3897-2.4015 in)
Piston pin-to-piston fit (clearance) 0.004-0.013 mm (0.0002-0.0005 in)
Connecting rod-to-pin clearance 0.003-0.018 mm (0.0001-0.0007 in)

Connecting rod length (centerline bore-to-bore) 150.7 mm (5.933 in)
Connecting rod side clearance (as assembled to 0.325 mm (0.0128 in)
crank) — standard play
Connecting rod side clearance (as assembled to 0.500 mm (0.0197 in)
crank) — max. play
a Time required for the plunger to leak down 1.6 mm of travel with 222 N force and leakdown fluid in the lash
adjuster.
b
Before Grafal coating.
lb-
Description Nm lb-ft in
Accessory drive belt tensioner bolt 48 35 —
A/C compressor stud bolts 25 18 —
Camshaft bearing cap bolts a — — —
Camshaft bearing mega cap bolts a — — —

Camshaft Position (CMP) sensor bolt 10 — 89
Catalytic convertor-to-exhaust manifold nuts 40 30 —
Connecting rod cap bolts a — — —
Coolant outlet bolts 10 — 89
Coolant outlet pipe bolt 10 — 89
Coolant pump bolts 20 — 177
Coolant pump pulley bolts 20 — 177
a — — —
Crankshaft main bearing cap bolts
Crankshaft pulley bolt a — — —
Crankshaft rear seal retainer plate bolts a — — —
Cylinder head bolts a — — —

a — — —
Engine front cover bolts
Engine front cover-to-oil filter adapter jackscrew a — — —
Engine oil filter b — — —
Engine Oil Pressure (EOP) c — — —

Engine support insulator bracket bolts 63 46 —

Engine support insulator bolts a — — —
Engine support insulator studs 15 — 133
Engine-to-transmission bolts and stud bolts 48 35 —
Exhaust H-pipe clamp nuts 48 35 —
Exhaust manifold nuts a — — —
Exhaust manifold studs 25 18 —
Flexplate a — — —
Flexplate inspection cover bolts 35 26 —
Fuel rail bolts a — — —
Generator B+ wire terminal nut 17 — 150
Generator bolt and nut 48 35 —
Ground strap-to-cowl bolt 10 — 89
Ground strap-to-frame bolt 12 — 106
Ignition coil-on-plug bolt 6 — 53
Intake manifold assembly bolts a — — —
Knock Sensor (KS) 20 — 177
Oil filter adapter bolts a — — —
Oil pan bolts a — — —
Oil pan stud bolts a — — —
Oil pump bolts and stud bolts a — — —
Oil pump screen and pickup tube bolts a — — —
Oil pump screen and pickup tube spacer 25 18 —
Piston cooling jet bolts a — — —
Primary timing chain tensioner bolts 10 — 89
Skid plate 48 35 —
Thermostat housing bolts 10 — 89
Transmission fluid cooler tube bracket-to-flexplate inspection cover stud bolt nut 13 — 115
Transmission fluid cooler tube bracket-to-RH engine support insulator bracket stud bolt 48 35 —
nut
Transmission mount-to-crossmember nut 25 18 —
a — — —
Valve cover bolts
VCT assembly bolts a — — —

Wiring harness-to-frame bracket bolt 20 — 177
b
Do not lubricate O-ring seal, tighten to 16 Nm (142 lb-in).
c Tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.

Engine
The 5.0L (302 CID) is a V-8 engine with the following features:

z Sequential Multi-Port Fuel Injection (SFI)
z Aluminum, 90-degree V-cylinder block
z Individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain
z Electronic ignition system with 8 ignition coils
z Engine oil cooler
Always refer to these labels when installation of new parts is necessary or when checking engine
calibrations. The engine parts often differ within a CID family. Verification of the identification codes will
make sure that the correct parts are obtained. These codes contain all the pertinent information relating to
the dates, optional equipment and revisions. The Ford Master Parts Catalog contains a complete listing of
the codes and their applications.
The engine code information label, located on the valve cover, contains the following:
Item Description
1 Essex engine plant
3 Transmission
4 Vehicle line
5 Sequential number

7 Essex engine plant
8 Bar code
Induction System
The SFI provides the fuel/air mixture needed for combustion in the cylinders. The 8 solenoid-operated fuel
injectors:
z are mounted in the fuel injection supply manifold and the intake manifold above the cylinder heads.
z meter fuel into the air intake stream in accordance with engine demand.
z are positioned so that their tips direct fuel just ahead of the engine intake valves.
z supply fuel from the fuel tank by a fuel pump mounted in the fuel tank.
Crankshaft
The crankshaft is supported on the bottom of the cylinder block by 5 crankshaft main bearings.
Camshafts
The camshafts:
z are arranged in pairs, one each (intake and exhaust) on each cylinder head.
z are synchronized through a secondary timing chain.
z depress the roller followers to actuate the valves.
Valve Train
The valves are actuated by a hydraulic lash adjuster and roller follower. The hydraulic lash adjusters and
roller followers:
z provide hydraulic lash adjustment.

z ride on the camshaft lobes.
Twin IndependentVariable Camshaft Timing (VCT) System
PCV System
manifold.
Engine Lubrication System
The engine lubrication system is of the force-feed type in which oil is supplied under full pressure to the:
z crankshaft main bearings.

z crankshaft thrust main bearing.
z connecting rod bearings.
z oil galleries.
z piston cooling jets.
All other parts are lubricated by splash of the oil.
Oil Pump
The lubrication system of the 5.0L (4V) engine is designed to provide optimum oil flow to critical components
of the engine through its entire operating range. The heart of the system is a positive displacement internal
gear oil pump using top seal rotors.
z Oil pump displacement has been selected to provide adequate volume to make sure of correct oil
pressure both at hot idle and maximum speed.
z The relief valve calibration protects the system from excessive pressure during high viscosity
conditions.
Engine Oil Flow Illustration
Engine Assembly

1 6714 Oil filter
2 6A642 Oil filter cooler
5 6049 Cylinder head — LH
6 6L266 Timing chain tensioner — LH

9 6256 Exhaust camshaft Variable Camshaft Timing (VCT)
10 6256 Intake camshaft VCT
12 6049 Cylinder head — RH
13 6L266 Timing chain tensioner — RH
14 6600 Oil pump
16 6710 Oil pan gasket
17 6675 Oil pan
18 6K868 Piston cooling jet (4 required)

Engine

Engine
Special Tool(s)
3 Jaw Puller
Handle
205-153 (T80T-4000-W)
Holding Tool, Crankshaft

303-448 (T93P-6303-A)
Installer, Connecting Rod

303-442 (T93P-6136-A)
205-142 (T80T-4000-J)
Remover, Crankshaft Rear Oil

Seal
303-519 (T95P-6701-EH)
Remover, Oil Seal

303-409 (T92C-6700-CH)

303-1247/1
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
ZC-31-A
Remover
ZC-30
NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in
engine damage.
NOTE: If the components are to be reinstalled, they must be installed in their original location. Mark the
components for installation into their original location.
1. Remove the engine. For additional information, refer to Engine in this section.
2. NOTE: The flexplate bolts are torque-to-yield design and are not reusable.
Remove the 8 bolts and the flexplate.

3. Remove the engine separator plate.
4. NOTE: Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped
or has any visual damage, it must be discarded.
5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the
crankshaft rear seal.
6. Mount the engine on a work stand.
7. Remove the 3 bolts and the LH engine support insulator bracket.


15. Clean and inspect the RH and LH exhaust manifolds. For additional information, refer to Section 303-
00 .
Disconnect the 8 ignition coil electrical connectors.
NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease
removal. RH shown, LH similar.
Remove the 8 bolts and the 8 ignition coils.
18. Disconnect the 2 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
z Detach the 10 wiring harness retainers from the RH valve cover.
19. Disconnect the 2 VCT variable force solenoid electrical connectors.

z Detach the 10 wiring harness retainers from the LH valve cover.
20. Remove the bolt, stud bolt and heat shield from the RH cylinder head.
21. Disconnect the RH intake and exhaust Camshaft Position (CMP) sensor electrical connectors.
z Remove the 2 bolts and the RH intake and exhaust CMP sensors.
22. Disconnect the Cylinder Head Temperature (CHT) sensor and the Crankshaft Position (CKP) sensor
electrical connectors.
23. Remove the 2 bolts and the heat shield from the LH cylinder head.
24. Disconnect the LH intake and exhaust Camshaft Position (CMP) sensor electrical connectors.
z Remove the 2 bolts and the LH intake and exhaust CMP sensors.
25. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 3 wiring harness
retainers.
26. Detach the wiring harness retainer from the engine front cover stud bolt.
27. Remove the nut and the ground wire from the engine front cover stud bolt.
28. Disconnect the 2 Knock Sensor (KS) electrical connectors.

z Remove the wiring harness from the engine.
means to clean the sealing surfaces. These tools cause scratches and gouges which make
leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Loosen the 14 fasteners and remove the RH valve cover and gasket.
z Clean the valve cover mating surface of the cylinder head with silicone gasket remover and
metal surface prep. Follow the directions on the packaging.
z Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a
suitable solvent.
Loosen the 14 fasteners and remove the LH valve cover and gasket.
suitable solvent.
Inspect the 2 VCT variable force solenoid seals. Remove any damaged seals.
Inspect the spark plug tube seals. Remove any damaged seals.
34. Remove the 2 bolts and position the thermostat housing and lower radiator hose aside.
z Remove and discard the thermostat housing O-ring seal.
35. Release the 2 clamps and disconnect the coolant hoses from the oil cooler.
37. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
38. Rotate the A/C compressor belt tensioner clockwise and remove the A/C compressor belt.

41. Remove the bolt and the accessory drive belt tensioner.
42. Disconnect the A/C compressor electrical connector and the 2 wiring harness retainers.
43. Detach the 3 wiring harness retainers.
44. Remove the 2 bolts and the generator.
45. Remove the crankshaft pulley bolt and washer.
46. Using the 3 Jaw Puller and the crankshaft pulley bolt, remove the crankshaft pulley.
z Discard the crankshaft pulley bolt.
47. NOTICE: Use care not to damage the engine front cover or the crankshaft when removing the
seal.
Using the Oil Seal Remover, remove the crankshaft front oil seal.
48. Remove the 2 front oil pan stud bolts and 2 front oil pan bolts.
49. Remove the engine front cover-to-oil filter adapter bolt.
50. Using a 10 mm (0.393 in) Hex Bit loosen the engine front cover-to-oil filter adapter jack screw.
51. Remove the 13 engine front cover bolts and the 2 stud bolts.
Remove the engine front cover.

z Remove and discard the engine front cover gaskets.
z Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the
z Inspect the mating surfaces.
53. Using the crankshaft holding tool, rotate the crankshaft clockwise until the keyway is at the 12 o'clock
position.
54. Verify the data matrix on the camshafts is facing up, if not, rotate the crankshaft clockwise one
revolution.
55. Remove the 2 bolts and the RH primary timing chain tensioner.
56. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to
remove the RH timing chain tensioner arm. Return the crankshaft keyway to the 12 o'clock position
after removing the RH timing chain tensioner arm.
Remove the RH timing chain tensioner arm.
remove the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after
removing the RH timing chain guide.
Remove the bolt and the RH timing chain guide.
58. Remove the RH primary timing chain.
59. Remove the 3 RH intake Variable Camshaft Timing (VCT) assembly bolts and the 3 RH exhaust VCT
assembly bolts.
60. Slide the RH VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
61. Depress the RH secondary timing chain tensioner and turn the tensioner 90 degrees.
62. Remove the RH VCT assemblies and the RH secondary timing chain.
63. NOTICE: The front camshaft bearing mega cap must be removed first and then the remaining
camshaft bearing caps. Failure to follow this direction may result in damage to the engine.
Remove the 4 bolts and the RH front camshaft bearing mega cap.
64. Remove the 16 bolts and the 8 camshaft bearing caps.
65. NOTE: Intake camshaft shown, exhaust camshaft similar.
Remove the VCT system oil filter from the intake and exhaust camshafts.
66. Remove the RH intake and exhaust camshafts.
67. Remove the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
68. Remove the bolt and the coolant outlet pipe from the RH cylinder head.
69. Remove the CHT sensor.
70. NOTICE: The cylinder head must be cool before removing it from the engine. Cylinder head
warpage can result if a warm or hot cylinder head is removed.
NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels
so foreign material is not dropped into the engine.
NOTICE: The cylinder head bolts must be discarded and new bolts must be installed. They are
a tighten-to-yield design and cannot be reused.
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive
NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder
Remove the 10 bolts and the RH cylinder head.

z Discard the bolts and the cylinder head gasket.
NOTE: Observe all warnings or notices and follow all application directions contained on the
Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder
2. Apply silicone gasket remover, following package directions and allow to set for several
minutes.
72. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant.
The cylinder head surface must be clean and dry before running a flatness check.
NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002
in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge
must be flat within 0.010 mm (0.0004 in) from end to end.
Support the cylinder head on a bench with the head gasket side up. Check the cylinder head
distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area.
73. Using the crankshaft holding tool, rotate the crankshaft counterclockwise until the crankshaft keyway
is at the 9 o'clock position.
74. Remove the 2 bolts and the LH primary timing chain tensioner.
remove the LH timing chain tensioner arm. Return the crankshaft keyway to the 9 o'clock position
after removing the LH timing chain tensioner arm.
Remove the LH timing chain tensioner arm.
remove the LH timing chain guide. Return the crankshaft keyway to the 9 o'clock position after
removing the LH timing chain guide.
Remove the bolt and the LH timing chain guide.
77. Remove the LH primary timing chain.
78. Remove the crankshaft sprocket.
79. Remove the 3 LH intake Variable Camshaft Timing (VCT) assembly bolts and the 3 LH exhaust VCT
assembly bolts.
80. Slide the LH VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
81. Depress the LH secondary timing chain tensioner and turn the tensioner 90 degrees.
82. Remove the LH VCT assemblies and the LH secondary timing chain.
Remove the 4 bolts and the LH front camshaft bearing mega cap.
86. Remove the LH intake and exhaust camshafts.
88. Remove the 2 bolts and the coolant outlet from the LH cylinder head.
z Remove and discard the gasket.
Remove the 10 bolts and the LH cylinder head.

minutes.
92. Remove the 2 bolts and the 2 KS .
93. Remove the bolt and the Crankshaft Position (CKP) sensor.
Remove the oil cooler threaded insert and the oil cooler.
z Discard the oil cooler.

96. Remove the 3 bolts and the A/C compressor.
Remove the bolts and the oil pan.

z Clean and inspect the sealing surface.
99. Remove the oil pump screen and pickup tube spacer.
z NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other
abrasive means to clean the sealing surfaces. These tools cause scratches and gouges
which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Clean and inspect the sealing surfaces.
101. Remove the 2 bolts, the 2 stud bolts and the oil pump.
carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer's
instructions.
103. NOTICE: Verify that the connecting rod and rod cap have orientation numbers cast into them.
If not, number the connecting rod and rod cap for correct orientation. Failure to do so can
result in engine damage.
Remove the bolts and the connecting rod cap. Discard the bolts.
104. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or
engine damage may occur.
Use the Connecting Rod Installer to push the piston through the top of the cylinder block.
105. Repeat the previous 2 steps for each of the remaining pistons.
106. Disassemble the 8 pistons. For additional information, refer to Piston in this section.
107. Remove the main bearing cap fasteners.

1. Remove and discard the cross-mounted main cap bolts.
2. Remove and discard the main bearing cap bolts and stud bolt.
108. Remove the main bearing caps (1), the lower crankshaft main bearings (2) and the lower thrust
bearing (3).
109. Remove the crankshaft (1), the upper crankshaft main bearings (2) and the upper thrust washer (3)
from the cylinder block.
110. Remove the 4 bolts and 4 piston cooling jets from the cylinder block.

Engine
Special Tool(s)
300-OTC1819E
Alignment Pins, Cylinder Head

303-1040 (SR-015486)

303-D032 (D81L-6002-C) or
equivalent
Handle
205-153 (T80T-4000-W)

303-448 (T93P-6303-A)
Installer, Connecting Rod

303-442 (T93P-6136-A)
205-142 (T80T-4000-J)

303-335 (T88T-6701-A2 plate
only)
Installer, Front Crank Seal and

Damper
303-1531
Installer, Rear Main Seal

303-1250

303-1247/2

303-F047 (014-00073) or
equivalent
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent
Material
Item Specification
ZC-31-A

LSP12 (Canada)
Motorcraft® SAE 5W-50 Full WSS-
Synthetic Motor Oil M2C931-B
XO-5W50-QGT or equivalent
Remover
ZC-30
Motorcraft® Specialty Orange WSS-
Engine Coolant M97B44-D
VC-3-B (US); CVC-3-B (Canada)
Silicone Brake Caliper Grease and ESE-M1C171-
Dielectric Compound A
XG-3-A
Silicone Gasket and Sealant WSE-
TA-30 M4G323-A4
Engine — Upper End
Part
3 6L266 Primary timing chain tensioner (2 required)
5 6B288 Intake Camshaft Position (CMP) sensor (2 required)
6 18801 Radio capacitor (2 required)
7 12K073 Exhaust CMP sensor (2 required)
8 18696 Heater supply tube

10 6C683 Camshaft engine oil filter (4 required)
13 6766 Oil filler cap
14 6A666 PCV valve
15 6578 Crankcase vent hose
17 12029 Ignition coil on plug (8 required)
18 9F991 Throttle Body (TB)
19 9F624 Heat control inlet tube
20 9C915 Fuel vapor purge valve
22 9F792 Fuel rail
23 9F593 Fuel injector (8 required)
24 6P013 RH fuel injector insulator shield
25 6P013 LH fuel injector insulator shield
26 6762 Crankcase vent valve
28 6754 Oil indicator tube
29 6750 Oil indicator
34 8594 Coolant outlet connector
36 6K297 Secondary tensioner shoe (2 required)
37 6K254 Secondary tensioner (2 required)
38 — Camshaft bearing cap (part of 6049) (2 required)
39 — Camshaft bearing cap (part of 6049) (16 required)
40 6500/6564 Hydraulic lash adjuster/camshaft roller follower (32
required)
43 6268 Secondary timing chain (2 required)
44 6256 Intake camshaft Variable Camshaft Timing (VCT) (2
required)
45 6256 Exhaust camshaft VCT (2 required)

Engine — Lower End
Part
2 6700 Crankshaft front oil seal

4 6B297 Variable Camshaft Timing (VCT)variable force
solenoid (4 required)
5 6K255 RH timing chain tensioner arm
6 6268 RH primary timing chain
7 6K255 LH timing chain tensioner arm
8 6268 LH primary timing chain
9 6306 Crankshaft sprocket
10 6B274 LH timing chain guide
11 6M256 RH timing chain guide
12 8566 Coolant bypass tee
13 8A586 Thermostat housing
14 18663 Heater outlet tube
15 8509 Coolant pump pulley
16 8501 Coolant pump
17 6600 Oil pump
19 12A699 KS (2 required)
20 14A411 KS wiring harness
21 6214 Connecting rod cap bolt (16 required)
22 — Connecting rod cap (part of 6200) (8 required)
23 6211 Connecting rod bearing (16 required)
28 — Outer oil control ring (part of 6148) (16 required)
29 — Lower compression ring (part of 6148) (8 required)
30 — Upper compression ring (part of 6148) (8 required)
32 N806180 Oil pump screen and pickup tube spacer
33 6675 Oil pan
35 — Crankshaft main bearing cap (part of 6010) (5
required)
36 6D309 Crankshaft lower main bearing
37 6D309 Crankshaft lower main bearing (4 required)
38 6303 Crankshaft
39 6D309 Crankshaft upper main bearing (5 required)

40 6A341 Thrust washer
41 6K868 Piston cooling jets (4 required)
42 6010 Engine block
44 6701 Crankshaft rear seal
46 6375 Flexplate
47 6731 Oil filter
48 6A642 Oil cooler
NOTICE: During engine assembly do not allow the piston connecting rods to come in contact with
the piston cooling jets or engine damage may occur.
NOTE: During engine assembly it may become necessary to check bearing clearances and end play. For
1. Record the main bearing code found on the front of the engine block.
2. Record the main bearing code found on the rear of the crankshaft.
main bearing code.
bearing.
z Repeat the above steps using the fifth letter of the block and crankshaft codes to select the No.
5 bearing.
4. NOTE: This chart is for selecting main bearings 2, 3 and 4 only.
required bearing grade for main bearings 2, 3 and 4.
bearing.
z Repeat the above steps using the third and fourth letters of the block and crankshaft codes to
select the No. 3 and No. 4 bearings.
NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and
5. Install the 4 piston cooling jets and 4 bolts. Tighten in 2 stages.

6. Install the crankshaft main bearings.

z Install the crankshaft upper main bearings into the cylinder block.
z Install the crankshaft lower main bearings and thrust bearing into the bearing caps.
z Make sure all oil passages are aligned.
z Lubricate all main bearings with clean engine oil.
7. NOTE: Lubricate the crankshaft bearing journals with clean engine oil.
Install the crankshaft into the cylinder block.
8. NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the
crankshaft thrust surface).
No. 5 main boss.
9. Install the main bearing caps and fasteners on the cylinder block and, keeping the caps as square as
possible, alternately draw the caps down evenly using the cap fasteners.
10. Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward
position.
11. Tighten the vertical main bearing cap fasteners in the sequence shown, in 4 stages.
z Stage 1: Tighten fasteners 1 through 20 to 20 Nm (177 lb-in).
12. Install the cross-mounted main bearing cap fasteners and tighten in the sequence shown, in 3 stages.
13. Check the crankshaft end play. For additional information, refer to Section 303-00 .
14. Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
15. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to
Section 303-00 .
16. Assemble the pistons. For additional information, refer to Piston in this section.
17. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around
the circumference of the piston.
18. Make sure the dimple in the piston faces the front of the engine.
NOTICE: Do not allow the piston connecting rods to come in contact with the piston cooling
jets or engine damage may occur.
Use the Piston Ring Compressor and the Connecting Rod Installers to install the connecting rod with
the upper connecting rod bearing in place.
z Lubricate the piston and ring with clean engine oil.
z Lubricate the rod bearings with clean engine oil.
Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installers.
NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod
ends. Excessive bearing clearance will result if not mated correctly.
Position the lower bearing and connecting rod and install the new bolts loosely.
22. Repeat the previous 5 steps for each of the remaining pistons.
23. NOTE: Main bearing caps are removed for clarity.
Tighten the bolts in the sequence shown in 3 stages.

24. Rotate the inner rotor of the oil pump assembly to align the flats on the crankshaft and slip the oil
pump over the crankshaft until seated against the block.
z Rotate the oil pump until the bolt holes are aligned to the block and install the fasteners.
25. NOTE: Oil pump must be held against the cylinder block until all bolts are tightened.
Tighten the fasteners in the sequence shown in 3 stages:

z Stage 1: Hand tighten.
z Stage 2: Tighten the bolt (1) to 10 Nm (89 lb-in), the stud bolt (2) to 25 Nm (18 lb-ft), the bolt
(3) to 10 Nm (89 lb-in) and the stud bolt (4) to 20 Nm (177 lb-in).
z Stage 3: Tighten the bolt (1) an additional 45 degrees, the stud bolt (2) an additional 75
degrees, the bolt (3) an additional 45 degrees and the stud bolt (4) an additional 60 degrees.
26. Install the oil pump screen and pickup tube spacer.
27. NOTE: The 2 oil pump screen and pickup tube-to-oil pump bolts must be tightened prior to tightening
the oil pump screen and pickup tube-to-spacer bolt.
Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts.
1. Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts in 2 stages.
Stage 1: Tighten to 10 Nm (89 lb-in).
Stage 2: Tighten an additional 45 degrees.
2. Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
28. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be
removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow
the directions on the packaging. Allow to dry until there is no sign of wetness, or 5 minutes, whichever
is longer. Failure to follow this procedure may cause future oil leaks.
Apply a 3.75 mm (0.147 in) bead of silicone gasket and sealant to the rear crankshaft seal retainer
mating surface on the engine block.
29. Install the crankshaft rear seal retainer plate and the 6 bolts, tighten in the sequence shown in 2
stages.
means to clean the sealing surfaces. These tools cause scratches and gouges, which make
Inspect the oil pan and engine sealing surfaces. Clean the mating surfaces of the engine and oil pan
with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
31. NOTE: If the oil pan is not installed and the fasteners tightened within 5 minutes, the sealant must be
removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and
metal surface prep. Failure to follow this procedure can cause future oil leakage. If this timing cannot
be met, tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer and
final torque all of the fasteners within 1 hour of applying the sealer.
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the crankshaft rear seal retainer plate-
to-cylinder block sealing surfaces and the engine front cover-to-cylinder block sealing surfaces.
32. NOTE: Fastener location 7 is a stud bolt.
Using a new gasket, install the oil pan and tighten the fasteners in sequence in 3 stages.
z Stage 1: Tighten to 2 Nm (18 lb-in)

34. NOTE: Install a new oil filter adapter gasket.
Using a new gasket, install the oil filter adapter and the 3 bolts. Tighten the bolts in 2 stages.
z Stage 1: Tighten the bolts to 20 Nm (177 lb-in).
Install a new oil cooler and the threaded fitting.

36. NOTICE: The Crankshaft Position (CKP) sensor must be positioned into the fitting on the
crankshaft rear seal retainer plate and be flush against the boss on the engine block before
the bolt is installed. If the CKP sensor is installed incorrectly, the CKP sensor can be
damaged.
Position the CKP sensor and install the bolt.

37. Install the 2 Knock Sensor (KS) and 2 bolts.

38. Verify the crankshaft keyway is in the 9 o'clock position and install the crankshaft sprocket with the
flange facing forward.
39. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface
and cylinder bore. Failure to follow these instructions may result in engine damage.
NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted.
The gasket must be installed dry. Failure to follow these instructions may result in future oil
leakage.
NOTICE: The cylinder head bolts must be discarded and new bolts installed. They are a
NOTE: Do not turn the crankshaft until instructed to do so.
Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over
the dowels and install the cylinder head bolts loosely.
40. Tighten the new RH cylinder head bolts in 4 stages in the sequence shown.
leak paths. Use a plastic scraper to clean the sealing surfaces.
42. Install the Cylinder Head Temperature (CHT) sensor.

43. NOTICE: Lubricate the O-ring seal with clean engine coolant prior to installing.
Using a new O-ring seal, install the coolant outlet pipe.

44. Tighten the new LH cylinder head bolts in 4 stages in the sequence shown.
46. Using a new gasket, install the coolant outlet and 2 bolts.
47. NOTE: Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean
engine oil prior to installation.
Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
48. NOTE: Lubricate the camshafts with clean engine oil prior to installation.
Install the LH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the
illustration.
49. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.
50. Install the LH front camshaft bearing mega cap and the 4 bolts. Do not tighten the bolts at this time
51. Tighten the bolts in the sequence shown in 2 stages.

Install the Variable Camshaft Timing (VCT) system oil filter in the intake and exhaust camshafts.
53. Install the secondary timing chain onto the LH VCT assemblies. Align the colored links on the
secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
1. The timing mark on the intake VCT assembly should align between the 2 consecutive colored
links.
2. The timing mark on the exhaust VCT assembly should align with the single colored link.
54. Install the LH VCT assemblies and the secondary timing chain onto the LH camshafts to a position 2
mm (0.078 in) from fully seated. The timing mark on the exhaust VCT assembly should be in the 11
o'clock position.
55. NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the
camshaft) to seat the VCT assemblies onto the camshafts.
Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and
fully seat the VCT assemblies onto the camshafts.
z If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies
until they are fully seated on the camshafts.
56. NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT
assembly bolts.
Install the 3 LH intake VCT assembly bolts and the 3 LH exhaust VCT assembly bolts.
57. Install the LH primary timing chain.

z Align the colored link on the timing chain with the timing mark on the LH VCT assembly.
58. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.
install the LH timing chain guide. Return the crankshaft keyway to the 9 o'clock position after installing
the LH timing chain guide.
Install the LH timing chain guide and bolt.

install the LH timing chain tensioner arm. Return the crankshaft keyway to the 9 o'clock position after
installing the LH timing chain tensioner arm.
Install the LH timing chain tensioner arm.
NOTE: Complete the following 3 steps on both the LH and RH primary timing chain tensioners.
61. NOTICE: Do not compress the ratchet assembly or damage to the tensioner will occur.
Compress the primary timing chain tensioner plunger, using an edge of a vise.
62. Using a small screwdriver or pick, push back and hold the ratchet mechanism, then push the ratchet
arm back into the tensioner housing.
63. Install a suitable pin into the hole of the tensioner housing to hold the ratchet assembly and plunger in
place during installation.
64. Install the LH primary timing chain tensioner and 2 bolts.

z Remove the holding pin from the tensioner.
65. Using the crankshaft holding tool, rotate the crankshaft clockwise until the crankshaft keyway is at the
12 o'clock position.
Install the RH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the
illustration.
69. Install the RH front camshaft bearing mega cap and the 4 bolts. Do not tighten at this time

Install the VCT system oil filter in the intake and exhaust camshafts.
72. Install the secondary timing chain onto the RH VCT assemblies. Align the colored links on the
links.
73. Install the RH VCT assemblies and the secondary timing chain onto the RH camshafts to a position 2
o'clock position.
assembly bolts.
Install the 3 RH intake VCT assembly bolts and the 3 RH exhaust VCT assembly bolts.
76. Install the RH primary timing chain.

z Align the colored link on the timing chain with the timing mark on the RH VCT assembly.
install the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after
installing the RH timing chain guide.
Install the RH timing chain guide and bolt.

install the RH timing chain tensioner arm. Return the crankshaft keyway to the 12 o'clock position
after installing the RH timing chain tensioner arm.
Install the RH timing chain tensioner arm.
80. Install the RH primary timing chain tensioner and 2 bolts.

81. With the crankshaft keyway still at the 12 o'clock position, verify the timing mark alignment is correct.
82. NOTICE: The Variable Camshaft Timing (VCT) variable force solenoid pins must be fully
depressed to avoid interference with the VCT valve tips when installing the engine front cover.
Failure to follow these instructions can result in damage to the engine.
Fully depress the VCT variable force solenoid pins.
83. NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of
applying the sealer. If this cannot be accomplished, install the engine front cover and tighten
fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the
fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is
exceeded, all sealant must be removed and the sealing area cleaned. To clean the sealing area, use
silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to
Apply a bead of silicone gasket and sealant to the cylinder head-to-cylinder block joints and the oil
pan-to-cylinder block joints as illustrated.
84. NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before
installation.
Using new gaskets, position the engine front cover onto the dowels.
z Install the 13 engine front cover bolts, 2 stud bolts, 2 oil pan-to-engine front cover bolts and 2
oil pan-to-engine front cover stud bolts finger-tight.

z Stage 1: Tighten bolts 1-15 to 25 Nm (18 lb-ft) and bolts 16-19 to 10 Nm (89 lb-in).
z Stage 2: Tighten bolts 1-15 an additional 60 degrees and bolts 16-19 an additional 45 degrees.
86. Using a 10 mm Hex Bit, rotate the engine front cover jackscrew into contact with the oil filter adapter
to 5 Nm (44 lb-in).
87. Install the engine front cover-to-oil filter adapter bolt and tighten to 25 Nm (18 lb-ft) plus an additional
60 degrees.
88. NOTE: Lubricate the engine front cover bore and the crankshaft front oil seal inner lip with clean
engine oil.
Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only),
install the crankshaft front oil seal.
89. NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned
with silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future
oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
90. Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
91. Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only),
install the crankshaft pulley.
92. Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt
in 4 stages:
z Stage 2: Loosen 360 degrees.
93. Install the generator and the 2 bolts.

94. Attach the 3 wiring harness retainers.
95. Connect the A/C compressor electrical connector and the 2 wiring harness retainers.
96. Install the accessory drive belt tensioner and the bolt.
97. NOTE: Lubricate the new coolant pump O-ring seal with clean engine coolant.
Using a new O-ring seal, install the coolant pump and the 4 bolts.
99. Rotate the A/C compressor belt tensioner clockwise and install the A/C compressor belt.
100. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
101. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft).
102. Connect the 2 coolant hoses to the oil cooler.
103. NOTE: Lubricate the new thermostat housing O-ring seal with clean engine coolant.
Using a new thermostat housing O-ring seal, install the thermostat housing and the 2 bolts.
Using the Differential Bearing Cone Installer and Handle, install new VCT variable force solenoid seal
(s).
106. NOTE: If the valve cover is not installed and the fasteners tightened within 5 minutes, the sealant
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-LH cylinder
head joints.
107. Position the LH valve cover and new gasket on the cylinder head.
z Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
(s).
Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the engine front cover-to-RH cylinder
head joints.
112. Position the RH valve cover and new gasket on the cylinder head.
113. Position the wiring harness on the engine.

z Connect the 2 KS electrical connectors.
114. Install the ground wire and nut to the engine front cover stud bolt.
115. Attach the wiring harness retainer to the engine front cover stud bolt.
116. Connect the Engine Oil Pressure (EOP) switch electrical connector and the 3 wiring harness
retainers.
117. If removed, install the LH intake and exhaust Camshaft Position (CMP) sensors and the 2 bolts.
z Connect the LH intake and exhaust CMP sensor electrical connectors.
118. Install the heat shield and the 2 bolts to the LH cylinder head.
119. Connect the CHT sensor and the CKP sensor electrical connectors.
120. Install the RH intake and exhaust CMP sensors and the 2 bolts.
z Connect the RH intake and exhaust CMP sensor electrical connectors.
121. Install the heat shield, the bolt and the stud bolt on the RH cylinder head.
122. Connect the 2 VCT variable force solenoid electrical connectors.

z Attach the 10 wiring harness retainers to the LH valve cover.
123. Connect the 2 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
z Attach the 10 wiring harness retainers to the RH valve cover.
125. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before
attaching to the spark plugs. RH shown, LH similar.
Install the 8 ignition coils and 8 bolts.

Connect the 8 ignition coil electrical connectors.

128. Install a new gasket, the RH exhaust manifold and 8 new nuts.
z Tighten the nuts in the sequence shown in 2 stages.

131. Install a new gasket, the LH exhaust manifold and 8 new nuts.
z Tighten in the sequence shown in 2 stages.
133. Install the RH engine support insulator and the 3 bolts.

134. Install the LH engine support insulator bracket and the 3 bolts.
135. Install the Engine Lifting Bracket
136. Using the Floor Crane, remove the engine from the work stand.
137. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear
seal onto the tool.
138. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
140. Install the engine separator plate.
Install the engine separator plate, the flexplate and 8 new bolts.

Cylinder Head
Special Tool(s)
303-1418

303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-1249
Material
Item Specification
Synthetic Blend Motor Oil M2C930-A
XO-5W20-QSP (US); Motorcraft®
SAE 5W-20 Super Premium Motor
Oil CXO-5W20-LSP12 (Canada); or
equivalent
NOTE: LH cylinder head shown, RH cylinder head similar.

4 6571 Valve seal (16 required)
Disassembly
NOTE: If the components are to be reinstalled, they must be installed in their original locations. Mark the
2. Remove and discard the valve seal.
4. Repeat the previous steps for each of the remaining valves.
Assembly
NOTE: Apply clean engine oil to the valve seals and the inside diameter of the valve guides prior to
assembling the cylinder head components.
1. NOTE: The valve seal must be bottomed out on the cylinder head spring seat.
Install the valve seal.
2. Install the valve into the cylinder head.
3. Using the Valve Spring Compressors, install the spring, retainer and keys.
4. Repeat the previous steps for each of the remaining valves.

Piston
Material
Item Specification
equivalent

6 6140 Piston pin retainer
7 6140 Piston pin retainer
8 6135 Piston pin

10 6110 Piston
Disassembly
with a hand or shop rag when removing the ring. Wear eye protection. Failure to follow these
instructions may result in serious personal injury.

2. Mark the piston and the connecting rod on the same side for assembly reference.
3. Remove the piston pin retainers and the piston pin.
4. Separate the piston from the connecting rod.
Assembly
1. NOTE: The connecting rod must be installed into the piston with the marks made during disassembly
on the same side. If a new piston or connecting rod is being installed, it can be installed in either
direction.
Position the connecting rod in the piston.
4. Install the piston pin retaining clips in the piston.
6. Install the piston rings onto the piston.

Camshaft — LH
Special Tool(s)
303-448 (T93P-6303-A)
Material
Item Specification
LSP12 (Canada)
Part
1 6256 RH exhaust Variable Camshaft Timing (VCT)
assembly
7 6L266 LH primary timing chain tensioner
8 6256 LH intake VCT assembly

12 6256 LH exhaust VCT assembly
17 6L266 RH primary timing chain tensioner
Camshafts
Part

2 — Front camshaft bearing mega cap (part of 6049)
3 N806183 Front camshaft bearing mega cap bolt (4 required)
4 — Intake camshaft bearing cap (part of 6049) (4
required)
5 — Exhaust camshaft bearing cap (part of 6049) (4
required)
6 N806183 Intake/exhaust camshaft bearing cap bolt (16
required)
Removal
NOTE: If the RH camshafts are being serviced at the same time as the LH camshafts, remove the RH
camshafts first. For additional information, refer to Camshaft — RH in this section.
position.
revolution.
assembly bolts.
Installation
illustration.

links.
o'clock position.
assembly bolts.







Camshaft — RH
Special Tool(s)
303-448 (T93P-6303-A)
Material
Item Specification
LSP12 (Canada)
Part
1 6256 RH exhaust Variable Camshaft Timing (VCT)
assembly
9 6L266 RH primary timing chain tensioner
Camshafts
Part
2 — Intake camshaft bearing cap (part of 6049) (4
required)
3 — Front camshaft bearing mega cap (part of 6049)
4 N806183 Front camshaft bearing mega cap bolt (4 required)
5 N806183 Intake/exhaust camshaft bearing cap bolt (16
required)
6 — Exhaust camshaft bearing cap (part of 6049) (4
required)
Removal
revolution.
assembly bolts.
Installation
illustration.

links.
o'clock position.
assembly bolts.




Camshaft Roller Follower
Material
Item Specification
equivalent
1. Remove the camshaft for the camshaft roller follower being serviced. For additional information, refer
to Camshaft — RH and/or Camshaft — LH in this section.
2. Remove the camshaft roller follower and hydraulic lash adjuster as an assembly.
3. Separate the hydraulic lash adjuster from the spring clip on the camshaft roller follower.

z Lubricate the camshaft roller follower and hydraulic lash adjuster assembly with clean engine
oil prior to installation.

Special Tool(s)
303-335 (T88T-6701-A2 plate
only)

Damper
303-1531
Remover, Oil Seal

303-409 (T92C-6700-CH)
Material
Item Specification
equivalent
Removal
02 .
seal.
Installation
engine oil.


2 N807033 Crankshaft pulley washer
removal.

Crankshaft Pulley
Special Tool(s)
3 Jaw Puller

303-335 (T88T-6701-A2 plate
only)

Damper
303-1531
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent

Material
Item Specification
ZC-31-A
LSP12 (Canada)

Remover
ZC-30
TA-30 M4G323-A4
Removal
02 .
2. Remove the accessory drive and A/C compressor belts. For additional information, refer to Section
303-05 .
Installation
oil leakage.
Apply silicone sealer to the Woodruff key slot in the crankshaft pulley.
in 4 stages:
5. Install the accessory drive and A/C compressor belts. For additional information, refer to Section 303-
05 .
Correction procedure, following the on-screen instructions.

Special Tool(s)
Handle
205-153 (T80T-4000-W)

303-1250

Seal
303-519 (T95P-6701-EH)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
ZC-31-A
Remover
ZC-30
TA-30 M4G323-A4
Removal
1. Remove the flexplate. For additional information, refer to Flexplate or Flywheel and Crankshaft Rear
Seal — Exploded View and Flexplate .
4. Remove the oil pan. For additional information, refer to Engine Lubrication Components — Exploded
View and Oil Pan in this section.
Installation
NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the
Clean and inspect the mating surface.
Apply a 3.75 mm (0.147 in) bead of silicone sealant to the rear crankshaft seal retainer mating
surface on the engine block.
3. Install the crankshaft rear seal retainer plate and the 6 bolts, tighten in the sequence shown in 2
stages.
seal onto the tool.
damaged.

8. Install the oil pan. For additional information, refer to Engine Lubrication Components — Exploded
11. Install the flexplate. For additional information, refer to Flexplate or Flywheel and Crankshaft Rear
Seal — Exploded View and Flexplate .

Crankshaft Rear Seal
Special Tool(s)
Handle
205-153 (T80T-4000-W)

303-1250

Seal
303-519 (T95P-6701-EH)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
ZC-31-A
equivalent
Removal
02 .
2. Remove the flexplate. For additional information, refer to Flexplate or Flywheel and Crankshaft Rear
Seal — Exploded View and Flexplate in this section.
Installation
seal onto the tool.
5. Install the flexplate. For additional information, refer to Flexplate or Flywheel and Crankshaft Rear
Seal — Exploded View and Flexplate in this section.

Engine Front Cover
Special Tool(s)
3 Jaw Puller

303-335 (T88T-6701-A2 plate
only)

Damper
303-1531
Remover, Oil Seal

303-409 (T92C-6700-CH)
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent

Material
Item Specification
ZC-31-A

LSP12 (Canada)
Remover
ZC-30
TA-30 M4G323-A4
Part
1 W503304 Engine front cover-to-oil filter adapter bolt
2 W715209 Engine front cover-to-oil filter adapter jackscrew (part
of 6019)
5 W704919 Engine front cover stud bolt (2 required)
7 6020 Engine front cover gasket (3 required)
8 W714963 Oil pan stud bolt (2 required)
Removal
02 .
3. Drain the engine cooling system. For additional information, refer to Section 303-03 .
4. Remove the RH and LH valve covers. For additional information, refer to Valve Cover — RH and
Valve Cover — LH in this section.
6. Remove the accessory drive and A/C compressor belts. For additional information, refer to Section
303-05 .
7. Release the clamp and disconnect the lower radiator hose from the thermostat housing assembly.
8. Release the clamp and disconnect the degas coolant hose.
9. Remove the 2 thermostat housing bolts.
10. Release the clamp and position the upper radiator hose T-connector/thermostat housing assembly
aside.
11. Disconnect the heater hose.

14. Disconnect the throttle body and Evaporative Emission (EVAP) purge valve electrical connectors.
18. Remove the 2 bolts and position the generator aside.
seal.
23. Remove the 3 bolts and the oil drain gutter.
26. Detach the wiring harness retainer from the oil pan stud bolt.

32. Drain the engine oil.

Installation
3. NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before
installation.
z Install the 13 engine front cover bolts, 2 stud bolts, the 2 oil pan-to-engine front cover bolts and
the 2 oil pan-to-engine front cover stud bolts finger-tight.

to 5 Nm (44 lb-in).
60 degrees.
7. Position the wiring harness and install the wiring harness retainer to the oil pan stud bolt.
9. Install the transmission cooler line bracket and the nut to the engine front cover stud bolt.
10. Install the oil drain gutter and the 3 bolts.


engine oil.
oil leakage.
in 4 stages:

18. Install the accessory drive belt tensioner and bolt.

21. Connect the throttle body and EVAP purge valve electrical connectors.
24. Connect the heater hose.
Using a new thermostat housing O-ring seal, install the upper radiator hose T-connector/thermostat
housing assembly and clamp.
26. Install the 2 thermostat housing bolts.

27. Connect the degas coolant hose and clamp.
28. Connect the lower radiator hose and clamp to the thermostat housing assembly.
29. Install the accessory drive and A/C compressor belts. For additional information, refer to Section 303-
05 .
31. Install the RH and LH valve covers. For additional information, refer to Valve Cover — RH and Valve
Cover — LH in this section.
32. Fill the crankcase with clean engine oil.
33. Connect the battery ground cable. For additional information, refer Section 414-01 .
34. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03 .

Oil Pan and Gasket

1 W714963 Oil pan stud bolt (3 required)

3 — Oil drain plug (part of 6675) - 26 Nm (19 lb-ft)
4 6675 Oil pan
Oil Pump, Oil Filter Adapter, Oil Pump Screen and Pickup Tube and Oil Level Indicator and Tube
Part
1 W714251 Oil pump stud bolt

2 N806183 Oil pump bolt (2 required)
4 6600 Oil pump
5 6731 Oil filter
6 — Coolant hoses (2 required)
7 W503304 Engine front cover-to-oil filter adapter bolt
8 W715209 Engine front cover-to-oil filter adapter jackscrew (part
of 6019)
9 6A642 Oil cooler - 57 Nm (42 lb-ft)
13 W503306 Oil filter adapter bolt
16 N605904 Oil pump screen and pickup tube bolt
18 N806180 Oil pump screen and pickup tube spacer - 25 Nm (18
lb-ft)
19 6750 Oil indicator
20 6754 Oil indicator tube
removal.

Engine Support Insulators — LH
Special Tool(s)
303-050 (T70P-6000)
Support Bar, Engine

303-F070
Material
Item Specification
Threadlock 262 WSK-M2G351-A6
TA-26
Part
1 W715211 LH engine support insulator through bolt - 350 Nm
(258 lb-ft)
2 W713244 LH engine support insulator bolt (3 required)
4 W714735 LH engine support insulator bracket bolt (3 required) -
63 Nm (46 lb-ft)
5 — LH engine support insulator bracket (part of 6038)
Removal
NOTE: Apply threadlock to the LH and RH engine support insulator through bolt threads prior to installation.
All vehicles
02 .
2. Remove the 4 pin-type retainers and the upper radiator air deflector.
3. Remove the Air Cleaner (ACL) outlet pipe and ACL cover as an assembly. For additional information,
4. NOTE: It may be necessary to install washers between the Engine Lifting Bracket and the cylinder
head to prevent the Engine Lifting Bracket from contacting the valve cover while supporting the
engine.
Install an Engine Lifting Bracket on the side of the LH cylinder head.

z Attach a length of chain and a connecting link to the Engine Lifting Bracket.

z Attach the chain installed in the previous step to the Engine Support Bar hook to support the
engine.
separate.
Remove the LH engine support insulator through bolt.
Loosen the RH engine support insulator through bolt.
12. Raise the LH side of the engine 50 mm (1.968 in).
Remove the 3 LH engine support insulator-to-frame bolts.
18. NOTICE: Use care when positioning the front axle housing or the vacuum lines to the axle
Lower the front axle to allow clearance to the LH engine support insulator.
All vehicles
21. If necessary, remove the 3 bolts and the LH engine support insulator-to-cylinder block bracket.
Installation
All vehicles
2. If removed, install the LH engine support insulator-to-cylinder block bracket and install the 3 bolts.
bolts.
z Do not tighten at this time.



All vehicles
8. Tighten the 3 LH engine support insulator bolts in the sequence shown to 175 Nm (129 lb-ft).
NOTE: Apply threadlock to the bolt threads prior to installation.
Install the LH engine support insulator through bolt.

Remove the RH engine support insulator through bolt and apply threadlock to the bolt threads.
z Install the through bolt and tighten to 350 Nm (258 lb-ft).
new bolts.
1. Tighten the inner exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to
63 Nm (46 lb-ft).
2. Tighten the outer exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolt to
63 Nm (46 lb-ft).
16. Install the Air Cleaner (ACL) outlet pipe and ACL cover assembly. For additional information, refer to
Section 303-12 .
17. Install the upper radiator air deflector and the 4 pin-type retainers.

Engine Support Insulators — RH
Special Tool(s)
Engine Lifting Bracket
(D94T-6000-C) 303-D099
Support Bar, Engine

303-F070
Material
Item Specification
TA-26
Part
6038) - 350 Nm (258 lb-ft)
2 W707251 RH engine support insulator nut (2 required) - 175 Nm
(129 lb-ft)
3 — RH engine support insulator stud (part of 6038) (2
required) - 15 Nm (133 lb-in)
5 W714735 RH engine support insulator bracket bolt (3 required) -
63 Nm (46 lb-ft)
6 — RH engine support insulator bracket (part of 6038)
02 .
2. Remove the 4 pin-type retainers and the upper radiator air deflector.
3. Remove the Air Conditioning (A/C) compressor belt . For additional information, refer to Section 303-
05 .
4. Remove the exhaust manifold nut and install the Engine Lifting Bracket and nut on the RH exhaust
manifold stud.
z Attach a length of chain and a connecting link to the Engine Lifting Bracket.

z Attach the chain installed in the previous step to the Engine Support Bar hook to support the
engine.
9. NOTICE: The upper bolt cannot be completely removed and will remain with the A/C
compressor.
Remove the 3 bolts and lower the A/C compressor.
10. NOTICE: Only use hand tools when removing or installing the engine support insulator nuts or
NOTICE: Only use hand tools when removing or installing the engine support insulator stud
bolts or damage to the engine support insulator can occur.
NOTE: If during nut removal the stud is extracted from the engine support insulator, separate the nut
from the stud bolt prior to stud installation.
Remove the 2 RH engine support insulator nuts and studs.
separate.
Loosen the LH engine support insulator through bolt.
14. Raise the RH side of the engine 50 mm (1.968 in).
15. Position the A/C compressor aside to access the 2 front engine support insulator bracket bolts.
16. Remove the 3 RH engine support insulator bracket-to-engine bolts.
z Remove the RH engine support insulator and bracket as an assembly.
Installation
1. Clean the engine support insulator bracket-to-cylinder block and engine support insulator-to-frame
mating surfaces of any dirt or foreign material prior to installation.
2. NOTE: If a new RH engine support insulator is installed, remove the 2 studs prior to positioning the
assembly in the vehicle.
Install the RH engine support insulator and bracket assembly and install the 3 bolts.
3. Position the A/C compressor below the RH side of the engine.
5. NOTICE: Only use hand tools when installing the engine support insulator studs or damage to
the engine support insulator can occur.
Install the 2 RH engine support insulator studs.

Install the 2 RH engine support insulator nuts.

Remove the LH engine support insulator through bolt and apply threadlock to the bolt threads.
z Install the through bolt and tighten to 350 Nm (258 lb-ft).
new bolts.
63 Nm (46 lb-ft).
63 Nm (46 lb-ft).

16. Remove the nut, the Engine Lifting Bracket, the connecting link and chain.
17. Remove and discard the exhaust manifold stud.

z Install a new exhaust manifold stud and tighten to 25 Nm (18 lb-ft).
18. Install a new exhaust manifold nut and tighten in 2 stages.

19. Install the upper radiator air deflector and the 4 pin-type retainers.

Material
Item Specification
ZC-31-A
Part
1 W714133 LH exhaust manifold heat shield bolts (3 required) -
12 Nm (106 lb-in)
2 9Y427 LH exhaust manifold heat shield
3 W714870 LH exhaust manifold nuts (8 required)
6 W714869 LH exhaust manifold studs (8 required) - 25 Nm (18
lb-ft)
Removal
02 .
2. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).
Using a suitable holding device, hold the steering wheel in the straight-ahead position.
3. Remove the air cleaner outlet pipe and air cleaner cover as an assembly. For additional information,
4. Remove the 2 bolts and remove the lower steering column shaft.
6. Remove the 2 catalytic converter-to-LH exhaust manifold nuts.
7. Loosen the LH catalytic converter-to-RH catalytic converter Torca® clamp.
z Lower the catalytic converter to disengage the catalytic converter flange from the LH exhaust
manifold studs.
8. Remove the 8 LH exhaust manifold nuts.
9. Working from under the hood, remove the LH exhaust manifold and gasket.
Installation


3. Position the LH catalytic converter onto the LH exhaust manifold and loosely install the 2 nuts.
4. Tighten the LH catalytic converter-to-RH catalytic converter Torca® clamp to 55 Nm (41 lb-ft).
5. Tighten the 2 new LH catalytic converter-to-exhaust manifold nuts in the following sequence.
1. Tighten the LH outer catalytic converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
2. Tighten the LH inner catalytic converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
7. Install the lower steering column shaft and the 2 bolts.

1. Tighten the upper bolt to 48 Nm (35 lb-ft).
2. Tighten the lower bolt to 30 Nm (22 lb-ft).
8. Install the air cleaner outlet pipe and air cleaner cover assembly. For additional information, refer to
Section 303-12 .

Material
Item Specification
ZC-31-A
Part
1 W714133 RH exhaust manifold heat shield bolts (3 required) -
12 Nm (106 lb-in)
3 W714870 RH exhaust manifold nuts (8 required)
5 W714869 RH exhaust manifold studs (8 required) - 25 Nm (18
lb-ft)
Removal
02 .
2. Remove the A/C compressor. For additional information, refer to Section 412-01 .
separate.
6. Remove the 2 catalytic converter-to-LH exhaust manifold nuts.
7. Remove the 2 catalytic converter-to-RH exhaust manifold nuts.

z Separate the exhaust Y-pipe dual catalytic converter from the exhaust manifolds.
8. Remove the 4 lower RH exhaust manifold nuts.
9. Remove the 4 top RH exhaust manifold nuts.

z Remove and discard the 4 top RH exhaust manifold studs.
10. Working from under the hood, remove the RH exhaust manifold and gasket.
12. Remove and discard the 4 lower RH exhaust manifold studs.
Installation
1. Install 4 new lower RH exhaust manifold studs.

2. Install a new gasket, the RH exhaust manifold and 4 new lower exhaust manifold nuts.
z Do not tighten the nuts at this time.
3. Install 4 new upper RH exhaust manifold studs.

4. Install 4 new upper RH exhaust manifold nuts.

z Do not tighten the nuts at this time.
5. Tighten the nuts in the sequence shown in 2 stages.

6. Position the exhaust Y-pipe dual catalytic converter onto the exhaust manifolds and loosely install 2
new RH catalytic converter-to-exhaust manifold nuts.
7. Loosely install 2 new LH catalytic converter-to-exhaust manifold nuts.
8. Tighten the 2 new RH catalytic converter-to-exhaust manifold nuts in the following sequence.
1. Tighten the RH lower catalytic converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
2. Tighten the RH upper catalytic converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
9. Tighten the 2 new LH catalytic converter-to-exhaust manifold nuts in the following sequence.
1. Tighten the LH outer catalytic converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
2. Tighten the LH inner catalytic converter-to-exhaust manifold nut to 40 Nm (30 lb-ft).
new bolts.
63 Nm (46 lb-ft).
63 Nm (46 lb-ft).
13. Install the A/C compressor. For additional information, refer to Section 412-01 .

Flexplate or Flywheel and Crankshaft Rear Seal — Exploded View

1 6379 Flexplate bolt (8 required)
2 6375 Flexplate
4 6A373 Separator plate
6 W714962 Crankshaft rear seal retainer plate bolt (6 required)
removal.

Flexplate
Special Tool(s)
1. Remove the transmission. For additional information, refer to Section 307-01 .
Remove the 8 bolts and the flexplate.

z To install, tighten in the sequence shown in 2 stages.

z After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile

Hydraulic Lash Adjuster
Material
Item Specification
equivalent
1. Remove the camshaft for the hydraulic lash adjuster being serviced. For additional information, refer
to Camshaft — RH and/or Camshaft — LH in this section.
2. Remove the camshaft roller follower and hydraulic lash adjuster as an assembly.
3. Separate the hydraulic lash adjuster from the spring clip on the camshaft roller follower.

z Lubricate the camshaft roller follower and hydraulic lash adjuster assembly with clean engine
oil prior to installation.

Intake Manifold
Material
Item Specification
ZC-31-A

1 6P013 Fuel rail insulator (2 required)
2 W714864 Fuel rail bolt (4 required)
3 9Y450 Intake manifold bolt (part of 9424) (6 required)
Removal
4. Disconnect the Evaporative Emission (EVAP) canister purge valve tube and electrical connector. For
additional information, refer to the quick connect coupling procedure in Section 310-00 .
z Detach the EVAP tube retainer from the fuel rail.
5. Remove the crankcase ventilation tube. For additional information, refer to the quick connect coupling
6. Disconnect the fuel supply tube. For additional information refer to the quick connect procedure in
Section 310-00 .
7. Release the clamp and disconnect the vacuum tube from the intake manifold.
8. Remove the LH and RH fuel rail insulators.
9. NOTE: The 4 LH fuel injector electrical connectors are shown, the 4 RH fuel injector electrical
connectors are similar.
Disconnect the 8 fuel injector electrical connectors.
10. Detach the 4 wiring harness retainers from the rear of the intake manifold.
11. Detach the heater hose retainer and position the heater hose aside.
12. NOTE: It is not necessary to remove the fuel rail from the intake manifold assembly.
Remove the 4 fuel rail bolts.
13. Loosen the 6 bolts and remove the intake manifold.

Installation
damage.
NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
Inspect the mating surfaces.
Using new gaskets, install the intake manifold.

z Tighten the 6 intake manifold bolts in the sequence shown in 2 stages.
2. Install the 4 fuel rail bolts.

Stage 1: Hand tighten.
3. Position the heater hoses and attach the heater hose retainer.
4. Attach the 4 wiring harness retainers to the rear of the intake manifold.
5. NOTE: The 4 LH fuel injector electrical connectors are shown, the 4 RH fuel injector electrical
connectors are similar.
Connect the 8 fuel injector electrical connectors.
6. Install the LH and RH fuel rail insulators.
7. Connect the vacuum tube to the intake manifold.
8. Connect the fuel supply tube. For additional information, refer to the quick connect coupling
9. Install the crankcase ventilation tube. For additional information, refer to the quick connect coupling
10. Connect the Evaporative Emission (EVAP) purge valve tube and electrical connector. For additional
information, refer to the quick connect coupling procedure in Section 310-00 .
z Attach the EVAP tube retainer to the fuel rail.
12. Install the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .

Oil Cooler
Removal
02 .
3. Using hose clamp pliers, clamp the 2 oil cooler coolant hoses.
z Disconnect the 2 coolant hoses from the oil cooler.
4. NOTICE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist.
Failure to correct these concerns may cause engine failure. To diagnose mechanical
concerns, refer to Section 303-00 .
Remove the oil cooler threaded insert and the oil cooler.
Installation
1. Install the oil cooler and threaded insert.

2. Connect the 2 coolant hoses.

z Release the hose clamp pliers.
3. NOTE: Do not lubricate the O-ring seal.
Install a new oil filter.


Oil Filter Adapter
Removal
NOTICE: The engine front cover-to-oil filter adapter bolt must be removed and the engine front
cover-to-oil filter adapter jackscrew loosened before removing the oil filter adapter
02 .
Remove the oil cooler threaded insert and position the oil cooler and hoses aside.
7. Disconnect the engine oil pressure switch electrical connector.
8. NOTE: On 4x4 vehicles, the rear bolt must be removed with the oil filter adapter.
Remove the 3 oil filter adapter bolts .

z Position the oil filter adapter aside and detach the wiring harness retainer.
z Remove the oil filter adapter and discard the gasket.
Installation
1. NOTE: Install a new oil filter adapter gasket.
NOTE: On 4x4 vehicles, the rear bolt must be positioned with the oil filter adapter.
Using a new gasket, position the oil filter adapter and attach the wiring harness retainer.
z Install the 3 bolts and tighten to 20 Nm (177 lb-in) plus an additional 60 degrees.
2. Connect the engine oil pressure switch electrical connector.
to 5 Nm (44 lb-in).
4. Tighten the engine front cover-to-oil filter adapter bolt to 25 Nm (18 lb-ft) plus an additional 60
degrees.
Position the oil cooler and hoses and install the oil cooler threaded insert.


Oil Level Indicator and Tube
Removal
1. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
2. Depress the 4 tabs and remove the oil level indicator tube.
Installation
1. Install the oil level indicator tube.

z Push the oil level indicator tube into the valve cover until it clicks into place.
2. Install the LH valve cover. For additional information, refer to Valve Cover — LH in this section.

Oil Pan
Material
Item Specification
ZC-31-A
Remover
ZC-30
TA-30 A4
Removal
All vehicles
02 .

7. Position a suitable hydraulic jack under the front axle.

z Securely strap the jack to the axle.
All vehicles
12. Remove the 3 bolts and the oil drain gutter.
14. Remove the bolt and the transmission cooler tube bracket from the bellhousing.
16. Detach the 2 wiring harness retainers from the oil pan stud bolts.
17. Disconnect the oil level sensor electrical connector and wiring harness retainer.
18. Remove the 3 stud bolts, the 13 bolts and the oil pan.
Installation
All vehicles
Inspect the oil pan and engine sealing surfaces. Clean the mating surfaces of the engine and oil pan
with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
2. NOTE: If the oil pan is not installed and the fasteners tightened within 5 minutes, the sealant must be
removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and
metal surface prep. Failure to follow this procedure can cause future oil leakage. If this timing cannot
be met, tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer and
final torque all of the fasteners within 1 hour of applying the sealer.
NOTE: If the engine front cover has been removed, it is only necessary to apply sealant to the
crankshaft rear seal retainer plate-to-cylinder block sealing surfaces.
Apply an 8 mm (0.31 in) bead of silicone sealant to the crankshaft rear seal retainer plate-to-cylinder
block sealing surfaces and the engine front cover-to-cylinder block sealing surfaces.
3. NOTE: Fastener locations 7, 13 and 16 are stud bolts.
Using a new gasket, install the oil pan and tighten the fasteners in sequence in 3 stages.
4. Connect the oil level sensor electrical connector and wiring harness retainer.
5. Attach the 2 wiring harness retainers to the oil pan stud bolts.
7. Install the transmission cooler tube bracket and the bolt onto the bellhousing.
8. Install the transmission cooler tube bracket and the nut onto the engine front cover stud bolt.
9. Install the oil drain gutter and the 3 bolts.

10. NOTICE: Use care when positioning the front axle housing, or the vacuum tubes to the axle

All vehicles


Removal
02 .
2. Remove the oil pan. For additional information, refer to Engine Lubrication Components — Exploded
3. Remove the 3 bolts and the oil pump screen and pickup tube assembly.
Installation
1. NOTE: The 2 oil pump screen and pickup tube-to-oil pump bolts must be tightened prior to tightening
the oil pump screen and pickup tube-to-spacer bolt.
Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten the 2 oil
pump screen and pickup tube-to-oil pump bolts in 2 stages.
2. Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
3. Install the oil pan. For additional information, refer to Engine Lubrication Components — Exploded

Oil Pump
Special Tool(s)
303-448 (T93P-6303-A)
Removal
02 .
position.
revolution.
15. Remove the oil pump screen and pickup tube. For additional information, refer to Engine Lubrication
Components — Exploded View and Oil Pump Screen and Pickup Tube in this section.
16. Remove the 2 bolts, the 2 stud bolts and the oil pump.
Installation
1. Rotate the inner rotor of the oil pump assembly to align the flats on the crankshaft and slip the oil
pump over the crankshaft until seated against the block.
z Rotate the oil pump until the bolt holes are aligned to the block and install the fasteners.
2. NOTE: Oil pump must be held against the cylinder block until all bolts are tightened.
Tighten the fasteners in the sequence shown in 3 stages:

z Stage 2: Tighten the bolt (1) to 10 Nm (89 lb-in), the stud bolt (2) to 25 Nm (18 lb-ft), the bolt
(3) to 10 Nm (89 lb-in) and the stud bolt (4) to 20 Nm (177 lb-in).
z Stage 3: Tighten the bolt (1) an additional 45 degrees, the stud bolt (2) an additional 75
degrees, the bolt (3) an additional 45 degrees and the stud bolt (4) an additional 60 degrees.
3. Install the oil pump screen and pickup tube. For additional information, refer to Engine Lubrication
Components — Exploded View and Oil Pump Screen and Pickup Tube in this section.
4. Install the crankshaft sprocket with the flange facing forward.







Special Tool(s)
303-448 (T93P-6303-A)
Part
1 6256 RH exhaust camshaft Variable Camshaft Timing
(VCT)
2 6K254 RH secondary tensioner
3 6256 RH intake camshaft VCT
7 6L266 LH primary tensioner
8 6256 LH intake camshaft VCT

10 6K254 LH secondary tensioner
12 6256 LH exhaust camshaft VCT
15 6268 RH timing chain
17 6L266 RH primary tensioner
Removal
position.
revolution.
assembly bolts.
assembly bolts.
Installation
1. Install the crankshaft sprocket with the flange facing forward.
links.
o'clock position.
assembly bolts.



links.
o'clock position.
assembly bolts.




Valve Cover — LH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
205-142 (T80T-4000-J)

303-1247/2

303-1247/1
Material
Item Specification
ZC-31-A
Remover
ZC-30
TA-30 A4
Part
required)
4 6754 Oil level indicator tube
5 6C519 Valve cover bolt (part of 6582) (14 required)
Removal
1. Remove the Air Cleaner (ACL) outlet pipe and the ACL cover as an assembly. For additional
3. Remove the LH ignition coils. For additional information, refer to Section 303-07C .
4. Disconnect the 2 LH Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
z Detach the 10 wiring harness retainers.
Loosen the 14 bolts and remove the LH valve cover and gasket.
suitable solvent.
7. Depress the 4 tabs and remove the oil level indicator tube.
8. Inspect the 2 VCT variable force solenoid seals. Remove any damaged seals.
Installation
(s).
head joints.
5. Install the oil level indicator tube.

z Push the oil level indicator tube into the valve cover until it clicks into place.
7. Connect the 2 LH VCT variable force solenoid electrical connectors.

z Attach the 10 wiring harness retainers.
8. Install the LH ignition coils. For additional information, refer to Section 303-07C .
10. Install the Air Cleaner (ACL) outlet pipe and ACL cover assembly. For additional information, refer to
Section 303-12 .

Valve Cover — RH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
205-142 (T80T-4000-J)

303-1247/2

303-1247/1
Material
Item Specification
ZC-31-A
Remover
ZC-30
TA-30 A4
Part
required)
3 — Valve cover bolt (part of 6582) (14 required)
Removal
1. Remove the RH ignition coils. For additional information, refer to Section 303-07C .
3. Disconnect the 2 RH Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
z Detach the 10 wiring harness retainers.
suitable solvent.
5. Inspect the 2 VCT variable force solenoid seals. Remove any damaged seals.
Installation
(s).
head joints.
z Tighten the fasteners in the sequence shown to 10 Nm (89 lb-in).
5. Connect the 2 RH VCT variable force solenoid electrical connectors.

z Attach the 10 wiring harness retainers.
7. Install the RH ignition coils. For additional information, refer to Section 303-07C .

Valve Seals
Special Tool(s)
303-1418

303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-1249
Material
Item Specification
equivalent
1. Remove the camshaft for the valve seal being serviced. For additional information, refer to Camshaft
— RH and/or Camshaft — LH in this section.
2. Remove the roller follower and hydraulic lash adjuster assembly for the valve seal being serviced.
3. NOTICE: If air pressure must be removed, support the valve prior to removal or engine
damage may occur.
Cylinder Head in this section.
5. Remove and discard the valve seal.

z Lubricate the valve seal and the roller follower and hydraulic lash adjuster assembly with clean

Valve Springs
Special Tool(s)
303-1418

303-300 (T87C-6565-A)

303-350 (T89P-6565-A)

303-1249
Material
Item Specification
equivalent
1. Remove the camshaft for the valve spring being serviced. For additional information, refer to
Camshaft — RH and/or Camshaft — LH in this section.
2. Remove the roller follower and hydraulic lash adjuster assembly for the valve spring being serviced.
3. NOTICE: If air pressure must be removed, support the valve prior to removal or engine
damage may occur.
Cylinder Head in this section.

z Lubricate the roller follower and hydraulic lash adjuster assembly with clean engine oil prior to
installation.

NOTE: LH cylinder head shown, RH cylinder head similar.

1 6500 Hydraulic lash adjuster (32 required)
2 6564 Camshaft roller follower (32 required)
6 6571 Valve seal (32 required)
removal.

Cylinder Head
Special Tool(s)
Alignment Pins, Cylinder Head
303-1040 (SR-015486)
Handle
205-153 (T80T-4000-W)

303-448 (T93P-6303-A)
205-142 (T80T-4000-J)

303-335 (T88T-6701-A2 plate
only)

Damper
303-1531

303-1247/2
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent
Material
Item Specification
ZC-31-A
LSP12 (Canada)
Motorcraft® SAE 5W-50 Full WSS-
Synthetic Motor Oil M2C931-B
XO-5W50-QGT or equivalent
Remover
ZC-30
XG-3-A
TA-30 M4G323-A4
Installation
NOTE: The Boss® 302 requires Motorcraft® SAE 5W-50 Full Synthetic Motor Oil, all other 5.0L (4V)
engines require Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil.
All cylinder heads
1. Verify the crankshaft keyway is in the 9 o'clock position.
2. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface
and cylinder bore. Failure to follow these instructions may result in engine damage.
NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted.
The gasket must be installed dry. Failure to follow these instructions may result in future oil
leakage.
NOTICE: The cylinder head bolts must be discarded and new bolts installed. They are a
NOTE: Do not turn the crankshaft until instructed to do so.
Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over
the dowels and install the cylinder head bolts loosely.
RH cylinder head
3. Tighten the new RH cylinder head bolts in 4 stages in the sequence shown.

6. Install a new gasket, the RH exhaust manifold and 8 new nuts.

z Tighten the nuts in the sequence shown in 2 stages.

8. Install the Cylinder Head Temperature (CHT) sensor.

9. Connect the Cylinder Head Temperature (CHT) sensor electrical connector.
10. Install the heat shield, the bolt and the stud bolt on the RH cylinder head.
11. NOTICE: Lubricate the O-ring seal with clean engine coolant prior to installing.
Using a new O-ring seal, install the coolant outlet pipe.

LH cylinder head
12. Tighten the new LH cylinder head bolts in 4 stages in the sequence shown.

17. Attach the wiring harness retainer to the LH cylinder head.
18. Install the heat shield and the 2 bolts to the LH cylinder head.
19. Using a new gasket, install the coolant outlet and 2 bolts.
illustration.

Install the Variable Camshaft Timing (VCT) system oil filter in the intake and exhaust camshafts.
links.
o'clock position.
assembly bolts.



39. With the crankshaft keyway at the 12 o'clock position, verify the timing mark alignment is correct.
RH cylinder head
illustration.

links.
o'clock position.
assembly bolts.
All cylinder heads



58. NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before
installation.
z Install the 13 engine front cover bolts, 2 stud bolts, 2 oil pan-to-engine front cover bolts and 2
oil pan-to-engine front cover stud bolts finger-tight.

to 5 Nm (44 lb-in).
60 degrees.
62. Position the wiring harness and install the wiring harness retainer to the oil pan stud bolt.
engine oil.
oil leakage.
in 4 stages:

69. Connect the wiring harness connector to the generator.

z Install the B+ wire and nut onto the generator.
Tighten to 17 Nm (150 lb-in).
72. Install the accessory drive belt tensioner and the bolt.
75. Rotate the A/C compressor belt tensioner clockwise and install the A/C compressor belt.
76. Rotate the accessory drive belt tensioner counterclockwise and install the accessory drive belt.
Using a new thermostat housing O-ring seal, install the thermostat housing and the 2 bolts.
(s).
head joints.
z Tighten the fasteners in the sequence shown to 10 Nm (89 lb-in).
84. If removed, install the LH intake and exhaust Camshaft Position (CMP) sensors and the 2 bolts.
z Connect the LH intake and exhaust CMP sensor electrical connectors.
(s).
head joints.
89. If removed, install the RH intake and exhaust CMP sensors and the 2 bolts.
z Connect the RH intake and exhaust CMP sensor electrical connectors.
90. Connect the 2 VCT variable force solenoid electrical connectors.

z Attach the 10 wiring harness retainers to the LH valve cover.
91. Connect the 2 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
z Attach the 10 wiring harness retainers to the RH valve cover.
NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before
attaching to the spark plugs. RH shown, LH similar.
Install the 8 ignition coils and 8 bolts.

Connect the 8 ignition coil electrical connectors.
95. Install the engine. For additional information, refer to Engine in this section.

Engine
Special Tool(s)
300-OTC1819E

303-F047 (014-00073)

Material
Item Specification
LSP12 (Canada)
Threadlock 262 WSK-
TA-26 M2G351-A6
1. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, position the engine in the engine
compartment leaving access to the LH engine support insulator bolts.
2. NOTE: Clean the LH and RH engine support insulator-to-frame mating surfaces of any dirt or foreign
Install the LH engine support insulator from under the vehicle.
3. NOTE: Apply threadlock to the bolt threads prior to installation.
Using a suitable floor crane, raise the engine assembly to gain access to install the 3 LH engine
support insulator bolts.
z Tighten the 3 LH engine support insulator bolts in the sequence shown to 175 Nm (129 lb-ft).
5. NOTICE: Use only hand tools when installing the LH engine support insulator through bolt or
NOTE: Apply threadlock to the bolt threads prior to installation.
Install the LH engine mount through bolt.

6. NOTICE: Use only hand tools when installing the RH engine support insulator studs or the
NOTE: Apply threadlock to the stud threads prior to installation.
Install the 2 RH engine support insulator studs.

7. NOTICE: Use only hand tools when installing the RH engine support insulator nuts or the
NOTE: Apply threadlock to the nut threads prior to installation.

8. NOTE: The 2 upper transmission-to-engine bolt will be installed later.
Install the lower transmission-to-engine bolt.

9. Install the 2 lower transmission-to-engine bolts.

10. Install the lower transmission-to-engine bolt.

11. Install the transmission cooler tube support bracket and the transmission-to-engine bolt.
12. Tighten the 2 transmission mount-to-crossmember nuts.

new bolts.
63 Nm (46 lb-ft).
63 Nm (46 lb-ft).
14. Install 2 new RH catalytic converter-to-exhaust manifold nuts.

15. Install 2 new LH catalytic converter-to-exhaust manifold nuts.

16. Install 4 new torque converter-to-flexplate nuts.

z Tighten to 35 Nm (26 Ib-ft).
17. Install the cylinder block opening cover.
18. Install the flexplate inspection cover and the 2 bolts.
z Tighten to 35 Nm (26 Ib-ft).

20. Connect the oil level sensor electrical connector.
23. Install the 2 upper transmission-to-engine bolts.

24. Attach the PCM wiring harness retainer to the valve cover bolt stud.
25. Attach and connect the engine harness electrical connector.
26. Connect the middle PCM electrical connector.

29. If equipped, attach and connect the block heater electrical connector and the 2 wiring harness
retainers.
30. Connect the 2 heater hose quick connect couplings. For additional information, refer to Section 412-
00 .
31. Connect the 2 coolant hoses.
32. Install the spring clip, the clamp and connect the coolant bypass T assembly to the engine.
33. Connect the 2 wiring harness connectors and attach the 3 wiring harness retainers.
34. Attach the 5 wiring harness retainers.
35. Connect the B+ wire and nut.

z Attach the wiring harness retainer to the battery tray.
36. Install the wiring harness bracket and the bolt to the RH frame rail.
37. Install the ground wire and the bolt to the RH frame rail.
38. Install the transmission cooler line bracket and the nut to the engine front cover stud bolt.
39. Using a new O-ring seal and gasket, install the A/C tube and the nut.
40. Connect the wiring harness electrical connector and pin-type retainer.
z Position the Power Distribution Box (PDB) and wiring harness toward the engine.
41. Connect the A/C pressure transducer electrical connector.
42. Install the cooling module. For additional information, refer to Section 303-03 .
43. Install the Air Cleaner (ACL) element and ACL upper tray. For additional information, refer to Section
303-12
44. Connect the Mass Air Flow (MAF) sensor electrical connector.
damage.
Install the intake manifold. For additional information, refer to Intake Manifold in this section.
Install the hood and the 4 bolts.


Cylinder Head
Special Tool(s)
3 Jaw Puller
Handle
205-153 (T80T-4000-W)

303-448 (T93P-6303-A)
205-142 (T80T-4000-J)
Remover, Oil Seal

303-409 (T92C-6700-CH)

303-1247/1
Material
Item Specification
ZC-31-A

Remover
ZC-30
Removal
All cylinder heads
1. Remove the engine. For additional information, refer to Engine in this section.
2. Mount the engine on a work stand.
Disconnect the 8 ignition coil electrical connectors.
NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease
removal. RH shown, LH similar.
Remove the 8 bolts and the 8 ignition coils.
5. Disconnect the 2 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
z Detach the 10 wiring harness retainers from the RH valve cover.
6. Disconnect the 2 VCT variable force solenoid electrical connectors.

z Detach the 10 wiring harness retainers from the LH valve cover.
suitable solvent.
suitable solvent.
Inspect the 2 VCT variable force solenoid seals. Remove any damaged seals.
Inspect the spark plug tube seals. Remove any damaged seals.
12. Remove the 2 bolts and position the thermostat housing and lower radiator hose aside.
14. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
15. Rotate the A/C compressor belt tensioner clockwise and remove the A/C compressor belt.

21. Remove the nut and the B+ wire from the generator.
z Disconnect the wiring harness connector from the generator.
22. Remove the 2 bolts and the generator.
seal.
26. Detach the wiring harness retainer from the oil pan stud bolt.

position.
revolution.
RH cylinder head
38. Remove the bolt and the coolant outlet pipe from the RH cylinder head.
39. Remove the bolt, stud bolt and heat shield from the RH cylinder head.
40. Disconnect the RH intake and exhaust Camshaft Position (CMP) sensor electrical connectors.
z Remove the 2 bolts and the RH intake and exhaust CMP sensors.
42. Remove the CHT sensor.

assembly bolts.
Remove the 10 bolts and the RH cylinder head.

minutes.
LH cylinder head
59. Remove the 2 bolts and the coolant outlet from the LH cylinder head.
z Remove and discard the gasket.
60. Remove the 2 bolts and the heat shield from the LH cylinder head.
61. Disconnect the LH intake and exhaust Camshaft Position (CMP) sensor electrical connectors.
z Remove the 2 bolts and the LH intake and exhaust CMP sensors.
62. Detach the wiring harness retainer from the LH cylinder head.

assembly bolts.
Remove the 10 bolts and the LH cylinder head.

minutes.

Engine
Special Tool(s)
300-OTC1819E

303-F047 (014-00073)
02 .
damage.
Remove the intake manifold. For additional information, refer to Intake Manifold in this section.
6. Disconnect the Mass Air Flow (MAF) sensor electrical connector.
7. Remove the Air Cleaner (ACL) upper tray and the ACL element. For additional information, refer to
Section 303-12 .
8. Remove the cooling module. For additional information, refer to Section 303-03 .
9. Disconnect the A/C pressure transducer electrical connector.
10. Disconnect the wiring harness electrical connector and pin-type retainer.
z Position the Power Distribution Box (PDB) and wiring harness aside.

z Discard the O-ring seal and gasket.
13. Remove the bolt and the ground wire from the RH frame rail.
14. Remove the bolt and the wiring harness bracket from the RH frame rail.
15. Remove the nut and disconnect the B+ wire.

z Detach the wiring harness retainer from the battery tray.
16. Detach the 5 wiring harness retainers.
17. Disconnect the 2 wiring harness connectors and detach the 3 wiring harness retainers.
18. Disconnect the middle PCM electrical connector.
19. Detach and disconnect the engine harness electrical connector.
20. Detach the PCM wiring harness retainer from the valve cover bolt stud.
22. Disconnect the 2 heater hose quick connect couplings. For additional information, refer to Section
412-00 .
23. Disconnect the 2 coolant hoses and position aside.
24. Remove the spring clip, the clamp and disconnect the coolant bypass T assembly from the engine.
25. If equipped, disconnect the block heater electrical connector and the 2 wiring harness retainers.
28. Remove the 2 bolts and the flexplate inspection cover.
29. Remove the cylinder block opening cover.
Remove the 4 torque converter-to-flexplate nuts.

z Discard the nuts.
31. NOTE: The 2 upper transmission-to-engine bolts will be removed later.
Remove the transmission-to-engine bolt and transmission cooler tube support bracket.
32. Remove the lower transmission-to-engine bolt.
33. Remove the 2 lower transmission-to-engine bolts.
34. Remove the lower transmission-to-engine bolt.
37. Remove and discard the 2 LH catalytic converter-to-exhaust manifold nuts.
38. Remove and discard the RH catalytic converter-to-exhaust manifold nut.
separate.
40. NOTICE: Only use hand tools when removing the engine support insulator nuts or the engine
support insulator may be damaged.
NOTE: If during nut removal the stud is extracted from the engine support insulator, separate the nut
from the stud prior to installing the stud.
Remove the 2 RH engine support insulator nuts.
41. NOTICE: Only use hand tools when removing the engine support insulator stud or the engine
Remove the 2 RH engine support insulator studs.
42. NOTICE: Only use hand tools when loosening the engine support insulator through bolt or the
Remove the LH engine support insulator bolt.
43. Loosen the 2 transmission mount-to-crossmember nuts.
44. Disconnect the oil level sensor electrical connector.
45. Disconnect the quick connect coupling and remove the crankcase ventilation tube. For additional
47. NOTE: On Four-Wheel Drive (4WD) vehicles, it may be necessary to reposition the transfer case vent
hose to access the bolts.
Remove the upper 2 transmission-to-engine bolts.
48. Install the Engine Lifting Bracket.
49. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, raise the engine assembly to gain
access to the 3 LH engine support insulator bolts.
50. Remove the LH engine support insulator from under the vehicle.
51. Using the Heavy Duty Floor Crane and the Engine Lifting Bracket, remove the engine assembly from
the vehicle.
SECTION 303-01D: Engine — 6.2L (2V) 2014 F-150 Workshop Manual

Camshaft — LH
Material
Item Specification
LSP12 (Canada)
Removal
1. Remove the timing drive components. For additional information, refer to Timing Drive Components in
this section.
2. NOTICE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or
used as a lifting or leveraging device.
NOTICE: Only use hand tools to remove the camshaft phaser and sprocket assembly or
damage may occur to the camshaft or camshaft phaser and sprocket.
Using a 26 mm (1.023 in) wrench on the flats of the camshaft to secure the camshaft, remove the 3
LH camshaft phaser and sprocket bolts and the camshaft phaser and sprocket.
z Discard the 3 camshaft phaser and sprocket bolts.
3. Remove and discard the Variable Camshaft Timing (VCT) system oil filter.
file:///C:/TSO/tsocache/VDTOM2_10764/SE2~us~en~file=SE231D13.HTM~gen~ref.H... 2014-03-01
4. NOTICE: The camshaft bearing caps must be installed in their original locations. Record
camshaft bearing cap locations. Failure to follow these instructions may result in engine
damage.
Remove the 10 bolts and remove the 5 camshaft bearing caps.
5. Remove the camshaft.

z Inspect the camshaft. For additional information, refer to Section 303-00 .
Installation
1. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
2. Position the 5 camshaft bearing caps in their original locations and install the 10 bolts in the sequence
shown, in 2 stages.
3. Install a new VCT system oil filter with the open end facing the front of the engine.
file:///C:/TSO/tsocache/VDTOM2_10764/SE2~us~en~file=SE231D13.HTM~gen~ref.H...
Position the camshaft phaser and sprocket with the alignment pin in the alignment slot of the
camshaft and install 3 new camshaft phaser and sprocket bolts finger-tight.
NOTICE: Only use hand tools to install the camshaft phaser and sprocket bolt or damage may
occur to the camshaft or camshaft phaser and sprocket.
Using a 26 mm (1.023 in) wrench on the flats of the camshaft to secure the camshaft, tighten the 3
new LH camshaft phaser and sprocket bolts in 2 stages.
6. Install the timing drive components. For additional information, refer to Timing Drive Components in
this section.

Camshaft — RH
Material
Item Specification
LSP12 (Canada)
Removal
this section.
RH camshaft phaser and sprocket bolts and the camshaft phaser and sprocket.
4. NOTICE: The camshaft bearing caps must be installed in their original locations. Record
camshaft bearing cap locations. Failure to follow these instructions may result in engine
damage.
Remove the 10 bolts and remove the 5 camshaft bearing caps.
5. Remove the camshaft.

z Inspect the camshaft. For additional information, refer to Section 303-00 .
Installation
1. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
2. Position the 5 camshaft bearing caps in their original locations and install the 10 bolts in the sequence
shown, in 2 stages.
this section.

Camshaft Phaser and Sprocket — LH
Removal
this section.
LH camshaft phaser and sprocket bolts and the camshaft phaser and sprocket.
Installation
this section.

Camshaft Phaser and Sprocket — RH
Removal
this section.
RH camshaft phaser and sprocket bolts and the camshaft phaser and sprocket.
Installation
this section.

Special Tool(s)
3-Jaw Puller or equivalent
303-D121
Adapter Set, Step Plate

205-DS011 or equivalent
Installer, Crankshaft Damper and

303-1508

303-335 (T88T-6701-A)
Remover, Oil Seal

303-409 (T92C-6700-CH)
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent

Material
Item Specification
ZC-31-A
LSP12 (Canada)
Remover
ZC-30
TA-30 M4G323-A4
Removal
02 .
2. Rotate the tensioner clockwise and remove the accessory drive belt from the crankshaft pulley.
3. Remove and discard the crankshaft pulley bolt.
4. Using the 3 Jaw Puller and Step Plate, remove the crankshaft pulley.
seal.
Installation
1. Lubricate the engine front cover and the new crankshaft seal inner lip with clean engine oil.
2. Using the Crankshaft Damper and Crankshaft Front Seal Installer and the Front Cover Oil Seal
Installer, install the new crankshaft front seal into the engine front cover.
with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or
5 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
4. Lubricate the crankshaft pulley sealing area with clean engine oil prior to installation.
5. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
in 2 stages:
7. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley.


1 8620 Accessory drive belt
2 6A340 Crankshaft pulley bolt and washer
removal.

Crankshaft Pulley
Special Tool(s)
3-Jaw Puller

Installer, Crankshaft Damper

303-1508
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent

Material
Item Specification
ZC-31-A
LSP12 (Canada)

Remover
ZC-30
TA-30 M4G323-A4
Removal
02 .
2. Rotate the tensioner clockwise and remove the accessory drive belt from the crankshaft pulley.
3. Remove the crankshaft pulley bolt.

Installation
in 2 stages:
5. Rotate the tensioner clockwise and install the accessory drive belt onto the crankshaft pulley.

Special Tool(s)
Handle
205-153 (T80T-4000-W)

303-1250

Seal
303-519 (T95P-6701-EH)
Slide Hammer
100-001 (T50T-100-A)

Material
Item Specification
ZC-31-A
LSP12 (Canada)

TA-30 M4G323-A4
Remover
ZC-30
Removal
3. Remove the engine rear cover plate.
4. NOTE: Inspect the ignition pulse ring for damage. If the ignition pulse ring has been dropped or has
any visual damage, it must be discarded.
Remove the crankshaft ignition pulse ring.
Installation
NOTE: Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the
Clean and inspect the mating surface.
Apply a bead of silicone gasket and sealant around the groove along the rear of crankshaft rear seal
retainer plate sealing surface.
3. Install the crankshaft rear seal retainer plate and the 8 bolts in the sequence shown, in 2 stages.
4. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.
Using the Rear Main Seal Installer and Handle, install a new crankshaft rear seal.
damaged.

With the inset hole on the crankshaft ignition pulse ring aligned with the inset hole on the crankshaft
flange, install the crankshaft ignition pulse ring.
8. Install the engine rear cover plate.
11. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the
on-screen instructions.

Crankshaft Rear Seal
Special Tool(s)
Handle
205-153 (T80T-4000-W)

303-1250

Seal
303-519 (T95P-6701-EH)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
LSP12 (Canada)
Removal
2. Remove the engine rear cover plate.
Remove the crankshaft ignition pulse ring.
Installation
1. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.
Using the Rear Main Seal Installer and Handle, install a new crankshaft rear seal.
With the inset hole on the crankshaft ignition pulse ring aligned with the inset hole on the crankshaft
flange, install the crankshaft ignition pulse ring.
3. Install the engine rear cover plate.

Engine Front Cover
Special Tool(s)
3 Jaw Puller or equivalent
303-D121

Installer, Crankshaft Damper and

303-1508

303-335 (T88T-6701-A)
Remover, Oil Seal

303-409 (T92C-6700-CH)
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent

Material
Item Specification
MERCON® V Automatic MERCON® V
Transmission Fluid
XT-5-QM (or XT-5-QMC) (US);
CXT-5-LM12 (Canada)
ZC-31-A
LSP12 (Canada)
Remover
ZC-30
TA-30 M4G323-A4
Front End Accessory Drive (FEAD), Crankshaft Pulley and Crankshaft Front Seal

5 N808920 Accessory drive belt tensioner bolt (3 required)
7 N808102 RH accessory drive belt idler pulley bolt
8 19A216 RH accessory drive belt idler pulley
9 N808102 LH accessory drive belt idler pulley bolt
10 19A216 LH accessory drive belt idler pulley
Coolant Pump Pulley, Power Steering Pump and Front Oil Pan Bolts

1 N806282 Coolant pump pulley bolt (4 required)
2 8A528 Coolant pump pulley
4 — Power steering pump bolts (3 required)
5 — Power steering pump
Engine Front Cover and Gaskets
Part
1 W713461 Engine front cover stud
3 W713462 Engine front cover stud (2 required)
4 6C086 Engine front cover
5 — Engine front cover gasket (part of 6C086) (3
required)
Removal
02 .
2. Remove the RH and LH Variable Camshaft Timing (VCT) variable force solenoids. For additional
3. Remove the nut and the position the radio ignition interference capacitor aside.
5. Rotate the tensioner clockwise and remove the accessory drive belt.
8. Remove the nut and position aside the transmission cooler tube support bracket and the starter wiring
harness support bracket.
9. Remove the crankshaft pulley bolt.

seal.
12. Remove the 2 bolts and the 2 accessory drive idler pulleys.
14. Remove the 4 front oil pan bolts.
15. Remove the power steering pump. For additional information, refer to Section 211-02 .
16. Remove the 17 bolts and the 3 studs.
17. Remove the engine front cover from the front cover-to-cylinder block dowel.
Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions
on the packaging.
Installation
NOTE: If the engine front cover is not secured within 5 minutes, the sealant must be removed and the
sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep.
Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Follow the directions
on the packaging. Failure to follow this procedure can cause future oil leakage.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before
installation.
Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the
oil pan-to-cylinder block surface, at the locations shown.
2. Install new engine front cover gaskets on the engine front cover. Position the engine front cover onto
the dowels. Install the fasteners finger-tight.
3. Tighten the 20 engine front cover fasteners in the sequence shown in 2 stages.
Stage 1: Tighten all fasteners to 10 Nm (89 lb-in).
Stage 2: Tighten all fasteners to 20 Nm (177 lb-in).
Stage 3: Tighten all fasteners an additional 45 degrees.

1 W713261 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 33
9 W713462 Stud, Hex Head Pilot, M8 x 33 + M10 x 30
4. Loosely install the 4 bolts, then tighten in 2 stages, in the sequence shown.

5. Position the starter wiring harness support bracket and the transmission fluid cooler tube support
bracket and tighten the nut.
6. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
7. Using the Crankshaft Damper and Crankshaft Front Seal Installer and the Front Cover Oil Seal
Installer, install a new crankshaft front seal into the engine front cover.
in 2 stages:
13. Install the 2 accessory drive idler pulleys and the 2 bolts.
14. Position the coolant pump pulley and install the 4 bolts finger-tight.
15. Install the power steering pump. For additional information, refer to Section 211-02 .
16. Rotate the tensioner clockwise and install the accessory drive belt.

18. Position the radio ignition interference capacitor and install the nut.
19. Install the RH and LH VCT variable force solenoids. For additional information, refer to Section 303-
14 .
20. Fill the crankcase with clean engine oil.

Part
2 6675 Oil pan

4 N503276 Oil pump screen and pickup tube-to-oil pump bolts (2
required)
5 W701706 Oil pump screen and pickup tube support bracket nut
9 W713655 Oil pump stud
10 N806183 Oil pump bolts (2 required)
11 6621 Oil pump
1. For additional information, refer to the procedures in this section.

Part
(part 12C508)
2 — EOP switch wiring harness retainer (part 12C508)
3 9278 EOP switch
Removal
02 .
2. Disconnect the Engine Oil Pressure (EOP) switch wiring harness retainer and the electrical
connector.
Installation
1. Install the EOP switch.

2. Connect the EOP switch electrical connector and attach the wiring harness retainer.

Special Tool(s)
Support Bar, Engine
303-F070
Support Brackets, Engine

Material
Item Specification
TA-26
LH Engine Support Insulator
Part
1 W712805 LH engine support insulator-to-frame bolt (3 required)
3 6B032 LH engine support insulator
4 W711141 LH engine support insulator-to-cylinder block bracket
bolt (3 required)
5 6061 LH engine support insulator-to-cylinder block bracket
RH Engine Support Insulator
Part
1 W707251 RH engine support insulator-to-frame nut (2 required)
2 W711144 RH engine support insulator-to-frame stud bolt (2
required)
3 W711142 RH engine support insulator through bolt
4 6H028 RH engine support insulator
5 W711141 RH engine support insulator-to-cylinder block bracket
bolt (3 required)
6 — RH engine support insulator-to-cylinder block bracket
Removal
All engine support insulators
02 .
4. Remove the front drive shaft. For additional information, refer to Section 205-01 .
5. Install the Engine Support Bar and Engine Support Bracket.
6. Remove the 4 Y-pipe flange nuts (2 RH and 2 LH).
8. NOTICE: Only use hand tools when loosening the engine support insulator through bolts or
damage to the engine support insulator-to-cylinder block bracket can occur.
Loosen the LH engine support insulator through bolt.
9. NOTICE: Only use hand tools when removing the engine support insulator through bolts or
Remove the RH engine support insulator through bolt.
10. NOTICE: Only use hand tools when removing the engine support insulator nuts or damage to
the engine support insulator can occur.
NOTE: If during nut removal the stud bolt is extracted from the engine support insulator, separate the
nut from the stud bolt prior to stud bolt installation.
11. NOTICE: Only use hand tools when removing the engine support insulator stud bolts or
Remove the 2 RH engine support insulator stud bolts.
13. NOTE: Rotate the steering column so the pinch bolt for the steering column coupling allows
clearance for the isolator bolt.
Remove the upper front axle carrier mounting bushing bolt.
16. NOTICE: Use care when lowering the front axle housing or when vacuum lines to the axle
Lower the axle to allow clearance to the RH lower front mount bracket bolt.
17. Disconnect the A/C compressor electrical connector and the wiring harness retainer.
19. Using the Engine Support Bar and Engine Support Bracket, raise the engine.
22. NOTICE: Only use hand tools when loosening the engine support insulator through bolts or
Loosen the RH engine support insulator through bolt.
23. NOTICE: Only use hand tools when removing the engine support insulator through bolts or
Remove the LH engine support insulator through bolt.
25. NOTICE: Only use hand tools when removing the engine support insulator-to-frame bolts or
damage to the engine support insulator-to-frame nut plate can occur.
Remove the 3 engine support insulator-to-frame bolts.

Installation
Position the RH engine support insulator into the vehicle and install the 2 stud bolts.
3. Position the RH engine support insulator-to-cylinder block bracket and install the 3 bolts.





10. Connect the A/C compressor electrical connector and the wiring harness retainer.
bolts.
13. Position the LH engine support insulator-to-cylinder block bracket and install the 3 bolts.
All engine support insulators
14. Using the Engine Support Bar and Engine Support Bracket, lower the engine into position.
15. NOTICE: Only use hand tools when installing the engine support insulator through bolt or
Install the LH and RH engine support insulator through bolts.

z Apply threadlock to the bolt threads prior to installation.
Install the transmission mount-to-crossmember nuts.

17. Position the Y-pipe and install the 4 nuts (2 RH and 2 LH).
18. Remove the Engine Support Bar and Engine Support Bracket.
20. Install the front driveshaft. For additional information, refer to Section 205-01 .

Special Tool(s)
Support Bar, Engine
303-F070 or equivalent

Material
Item Specification
ZC-31-A
TA-26

1 W705443 Exhaust Y-pipe flange nuts (2 required)
2 W714870 LH exhaust manifold nut (8 required)
4 9448 LH exhaust manifold gasket (2 required)
5 W714869 Exhaust manifold-to-cylinder head stud (8 required)
Removal
All vehicles
02 .
3. Remove the LH inner fenderwell. For additional information, refer to Section 501-02 .
4. Install the Engine Support Bar and the Engine Support Bracket.
5. NOTICE: Do not allow the steering column shaft to rotate while the intermediate shaft is
disconnected or damage to the clockspring can result. If there is evidence that the shaft has
rotated, the clockspring must be removed and recentered. For additional information, refer to
Section 501-20B .
Remove the bolt and disconnect the steering shaft and position aside.
6. Remove the 4 exhaust manifold-to-catalytic converter nuts (2 LH and 2 RH).
9. Remove the front driveshaft. For additional information, refer to Section 205-01 .
All vehicles
10. NOTICE: Only use hand tools when removing the engine support insulator through bolt or the
12. Remove the 2 bolts and the exhaust shield.
13. Remove the 8 exhaust manifold nuts, the 8 studs, the exhaust manifold and the 2 exhaust manifold
gaskets.
z Discard the exhaust manifold nuts, studs and gaskets.
Remove and discard the 2 exhaust manifold gaskets. Clean the sealing surfaces with metal surface
prep.
15. Inspect the exhaust manifold. For additional information, refer to Section 303-00 .
Installation
All vehicles
1. Using 2 new exhaust manifold gaskets and 8 new studs, position the 2 gaskets and exhaust manifold
and install the 8 studs.
2. Using new exhaust manifold nuts, install the 8 nuts in 2 stages in the sequence shown.
3. Position the exhaust manifold heat shield and install the 2 bolts.
4. Using the Engine Support Bar and Engine Support Bracket, lower the engine.
5. NOTICE: Only use hand tools when tightening the engine support insulator through bolt or the
Apply threadlock to the bolt threads and install the LH engine support insulator bolt.
6. Install the front driveshaft. For additional information, refer to Section 205-01 .
All vehicles
7. NOTICE: Only use hand tools when tightening the engine support insulator nuts or the engine
NOTE: Make sure the RH engine support insulator mating surfaces and the washer mating surface
are free of foreign material and corrosion before installation. Install a new washer.
Apply threadlock to the stud threads and install the RH engine support insulator washer and nuts.
8. Tighten the 2 transmission mount nuts.

9. Install the 4 exhaust Y-pipe flange nuts (2 RH and 2 LH).

10. NOTICE: Do not allow the steering column shaft to rotate while the intermediate shaft is
disconnected or damage to the clockspring can result. If there is evidence that the shaft has
rotated, the clockspring must be removed and recentered. For additional information, refer to
Section 501-20B .
Connect the steering shaft and install the bolt.

11. Install the LH inner fenderwell. For additional information, refer to Section 501-02 .

Special Tool(s)
Support Bar, Engine
303-F070 or equivalent

Material
Item Specification
ZC-31-A
TA-26

1 W705443 Exhaust Y-pipe flange nuts (2 required)
2 W701706 Exhaust manifold nut (8 required)
3 9430 Exhaust manifold
4 9Y431 Exhaust manifold gasket (2 required)
5 W707747 Exhaust manifold stud (8 required)
Removal
All vehicles
02 .
3. Remove the RH inner fenderwell. For additional information, refer to Section 501-02 .
4. Install the Engine Support Bar and the Engine Support Bracket.
6. Remove the 4 exhaust manifold-to-catalytic converter nuts (2 LH and 2 RH).
9. Remove the front drive shaft. For additional information, refer to Section 205-01 .
All vehicles
10. NOTICE: Only use hand tools when removing the engine support insulator through bolt or the
11. Disconnect the A/C compressor electrical connector and the wiring harness retainer.
14. Remove the 2 bolts and the exhaust shield.
15. Remove the 8 exhaust manifold nuts, the 8 studs, the exhaust manifold and the 2 exhaust manifold
gaskets.
z Discard the exhaust manifold nuts, studs and gaskets.
Remove and discard the 2 exhaust manifold gaskets. Clean the sealing surfaces with metal surface
prep.
17. Inspect the exhaust manifold. For additional information, refer to Section 303-00 .
Installation
All vehicles
1. Using 2 new exhaust manifold gaskets and 8 new studs, position the 2 gaskets and exhaust manifold
and install the 8 studs.
2. Using new exhaust manifold nuts, install the 8 nuts in 2 stages in the sequence shown.
3. Position the exhaust manifold heat shield and install the 2 bolts.
4. Using the Engine Support Bar and Engine Support Bracket, lower the engine.
5. NOTICE: Only use hand tools when tightening the engine support insulator through bolt or the
Apply threadlock to the bolt threads and install the LH engine support insulator bolt.
6. Install the front drive shaft. For additional information, refer to Section 205-01 .
All vehicles
7. NOTICE: Only use hand tools when tightening the engine support insulator nuts or the engine
NOTE: Make sure the RH engine support insulator mating surfaces and the washer mating surface
are free of foreign material and corrosion before installation. Install a new washer.
Apply threadlock to the stud threads and install the RH engine support insulator washer and nuts.
8. Tighten the 2 transmission mount nuts.

9. Install the 4 exhaust Y-pipe flange nuts (2 RH and 2 LH).


11. Connect the A/C compressor electrical connector and the wiring harness retainer.
13. Install the RH inner fenderwell. For additional information, refer to Section 501-02 .

Flexplate or Flywheel and Crankshaft Rear Seal — Exploded View
Part
1 6379 Flexplate bolt (8 required)
2 6375 Flexplate
3 6A373 Rear cover plate
4 12A227 Ignition pulse ring

6 — Crankshaft Position (CKP) sensor electrical connector
(part of 12C508)
7 W503276 CKP sensor bolt
8 6C315 CKP sensor
9 W503276 Crankshaft rear seal retainer plate bolt (6 required)

Flexplate
1. Remove the transmission. For additional information, refer to Section 307-01 .
2. Rotate the engine clockwise until the 2 slotted holes on the flexplate are at the 6 o'clock position as
shown.

z Discard the 8 flexplate bolts.
Installation
1. With the offset hole on the crankshaft ignition pulse ring aligned with the offset hole on the flexplate,
position the flexplate and install 8 new bolts finger-tight.
2. Tighten the 8 new bolts in 6 stages.

z Stage 1: Tighten fasteners 1 through 4 in sequence to 20 Nm (177 lb-in).
z Stage 2: Tighten fasteners 1 through 4 in sequence to 35 Nm (26 lb-ft).
z Stage 3: Tighten fasteners 1 through 4 sequence an additional 60 degrees.
z Stage 4: Tighten fasteners 5 through 8 in sequence to 20 Nm (177 lb-in).
z Stage 5: Tighten fasteners 5 through 8 in sequence to 35 Nm (26 lb-ft).
z Stage 6: Tighten fasteners 5 through 8 in sequence an additional 60 degrees.
3. Verify that the 2 flexplate slotted holes are at the 6 o'clock position as shown prior to transmission
installation.
4. Install the transmission. For additional information, refer to Section 307-01 .

Intake Manifold
Material
Item Specification
ZC-31-A
Evaporative Emission (EVAP) Tube Quick Connect Fitting, Fuel Supply Tube Quick Connect Fitting,
Throttle Body (TB), PCV Tube and Electrical Connectors
Part
1 — Electronic Throttle Control (ETC) electrical connector
(part of 12C508)
2 W709168 TB bolt (4 required)
3 9F991 TB
4 9E936 TB O-ring seal
5 — ETC wiring harness retainer (part of 12C508)
6 6A664 PCV tube
7 — Evaporative Emission (EVAP) tube quick connect
coupling
8 — Fuel supply tube quick connect coupling
Crankcase Ventilation Tube and Generator Support Bracket
Part
1 W503300 Generator support bracket bolt (4 required)
2 10239 Generator support bracket
3 — Brake booster vacuum hose
4 — Evaporative Emission (EVAP) purge valve electrical
connector (part of 12C508)
Wiring Harness Retainers, Intake Manifold and Gaskets
Part
2 9Y450 Intake manifold bolt (12 required)
4 9439 Intake manifold gasket (8 required)
5 — Engine wiring harness retainers (part of 12C508) (4
required)
Removal
2. Drain the cooling system. For additional information, refer to Section 303-03 .
4. Remove the 2 bolts, position aside the thermostat housing.

5. Remove the 8 ignition coils. For additional information, refer to Section 303-07D .
6. Remove the 4 bolts and the generator support bracket.
7. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to Section
310-00 .
8. Disconnect the Electronic Throttle Control (ETC) electrical connector and wiring harness retainer.
9. Remove the 4 bolts and the Throttle Body (TB).

z Inspect the TB O-ring seal and install a new O-ring seal if necessary.
10. Disengage the clamp and disconnect the brake booster vacuum hose from the intake manifold.
11. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling from the EVAP canister
purge valve. For additional information, refer to Section 310-00 .
12. Disconnect the EVAP canister purge valve electrical connector and detach wiring harness retainer.
13. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to
Section 310-00 .
15. NOTE: The fuel rail is removed with the intake manifold as an assembly.
Remove the 4 fuel rail bolts.
16. Disconnect the 4 wiring harness retainers from the rear of the intake manifold.
17. Loosen the 12 intake manifold bolts.
Remove the intake manifold.

z Clean and inspect the cylinder head sealing surfaces with metal surface prep. Follow the
z Inspect the 8 intake manifold gaskets for damage and install new gaskets if necessary.
Installation
damage.
Position the intake manifold onto the engine.
2. Loosely install the 4 fuel rail bolts.
3. Tighten the 12 intake manifold bolts and install the 4 fuel rail bolts in 4 stages in the sequence shown.
z Stage 1: Tighten the 12 intake manifold bolts to 10 Nm (89 lb-in).
z Stage 2: Tighten the 12 intake manifold bolts an additional 45 degrees.
z Stage 3: Tighten the 4 fuel rail bolts to 10 Nm (89 lb-in).
z Stage 4: Tighten the 4 fuel rail bolts an additional 90 degrees.
4. Connect the 4 wiring harness retainers to the rear of the intake manifold.
6. Position the PCV tube and connect the quick connect couplings. For additional information, refer to
Section 310-00 .
7. Attach wiring harness retainer, connect the electrical connector and the EVAP tube quick connect
coupling to the EVAP canister purge valve. For additional information, refer to Section 310-00 .
8. Position the TB and tighten the 4 bolts in 2 stages.

9. Connect the ETC electrical connector and wiring harness retainer.
10. Connect the brake booster vacuum hose to the intake manifold and install the clamp.
11. Connect the fuel supply tube quick connect coupling. For additional information, refer to Section 310-
00 .
12. Position the generator support bracket and install the 4 bolts.
z Stage 1: Tighten to 20 Nm.
z Stage 2: Tighten an addition 45 degrees.
13. Install the 8 ignition coils. For additional information, refer to Section 303-07D .
14. Position back thermostat housing.

z Install a new O-ring seal.
16. Fill and bleed the cooling system. For additional information, refer to Section 303-03 .

Oil Cooler
Material
Item Specification
LSP12 (Canada)
Part
1 6714 Oil filter
2 — Oil cooler coolant hose quick connect couplings (part
of 8B273)
3 6L626 Oil cooler threaded shaft
4 6A642 Oil cooler
02 .
2. Drain the engine cooling system. For additional information, refer to Section 303-03 .
3. Remove and discard the oil filter.
4. Disconnect the oil cooler coolant hose quick connect couplings and position aside. For additional
5. NOTICE: If metal foreign material is present in the oil cooler, mechanical concerns exist. To
diagnose mechanical concerns, refer to Section 303-00 .
Remove the threaded shaft and the oil cooler. Inspect the engine oil cooler.
Installation
1. Position the oil cooler and install the threaded shaft.

2. Connect the oil cooler coolant hose quick connect couplings. For additional information, refer to
Section 310-00 .
3. Install a new oil filter in 2 stages.

4. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03 .

Oil Filter Adapter
Material
Item Specification
ZC-31-A
LSP12 (Canada)
Remover
ZC-30
Part
(part of 12B637)
2 — EOP switch wiring harness retainer (part of 12B637)
3 8B273 Lower radiator hose

Removal
02 .
2. Remove the engine oil cooler. For additional information, refer to Oil Cooler in this section.

4. Disconnect the Engine Oil Pressure (EOP) switch wiring harness retainer and the electrical
connector.
5. Disconnect the lower radiator hose and position it aside.
Inspect the 3 gaskets for damage and install new gaskets if necessary.
z Clean and inspect the cylinder block sealing surfaces with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.
Installation
1. Position the oil filter adapter and install the 4 bolts in 2 stages.
2. Connect the EOP switch electrical connector and attach the wiring harness retainer.
3. Connect the lower radiator hose.
4. Install the engine oil cooler. For additional information, refer to Oil Cooler in this section.

Oil Level Indicator and Tube
Material
Item Specification
LSP12 (Canada)

1 W503276 Oil level indicator and tube bolt
2 6B667 Oil level indicator tube
3 — Oil level indicator tube O-ring seal (part of 6B667)
4 — Oil level indicator
1. Remove the RH exhaust manifold. For additional information, refer to Exhaust Manifold — RH in this
section.
2. Remove the oil level indicator from the oil level indicator tube.
3. Remove the oil level indicator and tube bolt.

4. Remove the oil level indicator tube from the cylinder block.
5. NOTE: Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to installation.


Oil Pan
Material
Item Specification
ZC-31-A
LSP12 (Canada)
TA-30 M4G323-A4
Remover
ZC-30
Removal
All vehicles
02 .
2. Remove the 4 bolts and the skidplate.
All vehicles
3. Remove the oil drain plug and drain the engine oil. Install the drain plug when finished.
4. Remove the 4 nuts, the 4 bolts and the crossmember.
6. NOTE: Rotate the steering column so the pinch bolt for the steering column coupling allows
clearance for the isolator bolt.
9. NOTICE: Use care when lowering the front axle housing or the vacuum lines to the axle
All vehicles
10. Remove the bolt and position the transmission fluid cooling tubes rear support bracket aside.
11. Remove the starter wiring harness rear support bracket pushpin.
12. Remove the nut and position the starter wiring harness and the transmission fluid cooler tubes aside.
13. Remove and discard the 4 stabilizer bar bracket nuts and allow the stabilizer bar to swing downward.
14. Remove the 20 bolts, the oil pan and the gasket.
Inspect the oil pan. Clean the gasket mating surfaces of the oil pan and engine block with silicone
gasket remover and metal surface prep. Follow the directions on the packaging.
Installation
All vehicles
with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to
dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure
can cause future oil leakage.
Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing
surface and at the engine front cover-to-cylinder block sealing surface.
2. Position a new gasket and the oil pan and install the 20 bolts.
z Tighten the bolts in the sequence shown in 3 stages.
3. Postion the swaybar and install the 4 new stabilizer bar brackets nuts.
4. Position the transmission fluid cooler tube support bracket, the starter wiring harness support bracket
and install the nut.
5. Position the starter wiring harness and install the starter wiring harness rear support bracket pushpin.
6. Install the transmission fluid cooling tubes rear support bracket bolt.


11. Install the skid plate and 4 bolts.

All vehicles
12. Position the crossmember and Install the 4 bolts and the 4 nuts.

Material
Item Specification
LSP12 (Canada)
Removal
2. Remove the oil pump screen and pickup tube support bracket nut.
Installation
1. NOTICE: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can
cause foam in the lubrication system, low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with
clean engine oil prior to installation.
Position the oil pump screen and pickup tube and install the 2 front bolts.
2. Install the oil pump screen and pickup tube support bracket nut.

Oil Pump
Material
Item Specification
ZC-31-A
LSP12 (Canada)
Removal
this section.
3. Remove the oil pump screen and pickup tube support bracket nut.
5. Remove the 2 upper bolts, the 2 lower stud bolts and the oil pump.
Installation
Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect
the mating surfaces.
2. Position the oil pump and install the 2 upper bolts and the 2 lower stud bolts in 5 stages.
z Stage 1: Tighten all fasteners to 2 Nm (18 lb-in).
z Stage 2: Tighten the 2 upper bolts to 10 Nm (89 lb-in).
z Stage 3: Tighten the 2 lower stud bolts to 20 Nm (177 lb-in).
z Stage 4: Tighten the 2 upper bolts an additional 45 degrees.
z Stage 5: Tighten the 2 lower stud bolts an additional 60 degrees.
3. NOTICE: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can
cause foam in the lubrication system, low oil pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with
clean engine oil prior to installation.
Position the oil pump screen and pickup tube and install the 2 front bolts.
4. Install the oil pump screen and pickup tube support bracket nut.
this section.

Rocker Arm
Material
Item Specification
LSP12 (Canada)
XG-3-A
Removal
LH cylinder head rocker arm shafts
NOTICE: If the components are to be reinstalled, they must be installed in the same positions. Mark
the components for installation into their original locations. Failure to follow these instructions may
result in engine damage.
1. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
2. Disconnect the 4 LH ignition wires from the LH cylinder head 4 lower spark plugs.
3. NOTICE: Only use hand tools when removing or installing the spark plugs or damage can
occur to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material from the spark plug well before removing
the spark plugs.
Remove the 4 lower spark plugs from the LH cylinder head.
4. Rotate the engine clockwise until the No. 6 cylinder camshaft intake valve is open.
5. Remove the 10 bolts and the LH intake rocker arm shaft assembly.
6. Rotate the engine clockwise until the No. 6 cylinder camshaft exhaust valve is open.
7. Remove the 10 bolts and the LH exhaust rocker arm shaft assembly.
RH cylinder head rocker arm shafts
8. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
9. Disconnect the 4 LH ignition wires from the RH cylinder head 4 lower spark plugs.
the spark plugs.
Remove the 4 lower spark plugs from the RH cylinder head.
11. Rotate the engine clockwise until the No. 1 cylinder camshaft lobe intake valve is closed.
12. Remove the 10 bolts and the RH intake rocker arm shaft assembly.
13. Rotate the engine clockwise until the No. 1 cylinder camshaft lobe exhaust valve is closed.
14. Remove the 10 bolts and the RH exhaust rocker arm shaft assembly.
Installation
NOTICE: If the components are to be reinstalled, they must be installed in the same positions.
Failure to follow this instruction may result in engine damage.
All rocker arm shafts
1. Lubricate the rocker arm shaft-to-valve tip and rocker arm-to-camshaft lobe contact area with clean
LH cylinder head rocker arm shafts
2. Rotate the engine clockwise until the No. 6 cylinder camshaft intake lobe is positioned so that the
intake valve would be fully opened.
3. Position the LH intake rocker arm shaft assembly and install the bolts finger-tight.
4. Tighten the 10 LH intake rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
5. Rotate the engine clockwise until the No. 6 cylinder camshaft exhaust lobe is positioned so that the
exhaust valve would be fully opened.
6. Position the LH exhaust rocker arm shaft assembly and install the bolts finger-tight.
7. Tighten the 10 LH exhaust rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
Install the LH cylinder head lower 4 spark plugs.

9. Connect the 4 LH cylinder head ignition wires to the LH cylinder head lower 4 spark plugs.
z Apply a light coat of dielectric compound to the inside of the ignition wire boots prior to
installation.
10. Install the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
RH cylinder head rocker arm shafts
intake valve would be fully closed.
12. Position the RH intake rocker arm shaft assembly and install the bolts finger-tight.
13. Tighten the 10 RH intake rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
exhaust valve would be fully closed.
15. Position the RH exhaust rocker arm shaft assembly and install the bolts finger-tight.
16. Tighten the 10 RH exhaust rocker arm shaft assembly bolts in the sequence shown, in 3 stages.

Install the RH cylinder head lower 4 spark plugs.

18. Connect the 4 RH cylinder head ignition wires to the RH cylinder head lower 4 spark plugs.
installation.
19. Install the RH valve cover. For additional information, refer to Valve Cover — RH in this section.

Material
Item Specification
XG-3-A

2 6L266 RH timing chain tensioner
3 6256 RH camshaft phaser and sprocket
4 6268 RH timing chain
7 6L266 LH timing chain tensioner
8 6268 LH timing chain
9 6256 LH camshaft phaser and sprocket
Removal
2. Disconnect the 8 ignition wires from the lower 8 spark plugs.
the spark plugs.
Remove the lower 8 spark plugs.
4. Rotate the engine clockwise until the No. 1 intake valve is open.
5. Remove the 10 bolts and the LH intake rocker arm shaft assembly.
6. Rotate the engine clockwise until the No. 1 exhaust valve is open.
7. Remove the 10 bolts and the LH exhaust rocker arm shaft assembly.
8. Rotate the engine clockwise until the No. 1 intake valve is closed.
9. Remove the 10 bolts and the RH intake rocker arm shaft assembly.
10. Rotate the engine clockwise until the No. 1 exhaust valve is closed.
11. Remove the 10 bolts and the RH exhaust rocker arm shaft assembly.
12. Position the crankshaft keyway at the 11 o'clock position.
13. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
14. Remove the bolt and the RH timing chain guide.
15. Remove the RH timing chain.
16. Remove the 2 bolts and the LH timing chain tensioner.
17. Remove the LH timing chain tensioner arm.
18. Remove the bolt and the LH timing chain guide.
19. Remove the LH timing chain.
Installation
NOTICE: Timing chain procedures must be followed exactly or damage to valves and pistons will
result.
1. Using a small pick, carefully push the tensioner rack pawl retainer away from the rack pawl and
compress the tensioner plunger and rack using a vise.
2. Install a small pick into the tensioner to hold the rack pawl and plunger in the seated position for
tensioner installation.
3. Remove the tensioner from the vise.
4. If the blue links are not visible, mark 2 links on each end, and use as timing marks.
5. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel and above the
chain guide pin.
Position the upper end of the LH (inner) timing chain on the LH camshaft phaser and sprocket,
aligning the timing mark on the outer flange of the camshaft phaser and sprocket with the single blue
(marked) link on the chain.
6. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing
mark on the outer flange of the crankshaft sprocket with the single blue (marked) link on the chain
and install the crankshaft sprocket onto the crankshaft and verify the crankshaft keyway is at the 11
o'clock position.
7. Install the LH timing chain tensioner arm.
8. Position the LH timing chain tensioner and install the 2 bolts in 2 stages.
9. Position the LH timing chain guide and install the bolt in 2 stages.
10. Remove the retaining clip from the LH timing chain tensioner.
11. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing
mark on the sprocket with the single blue (marked) chain link.
12. Position the upper end of the RH (outer) timing chain on the RH camshaft phaser and sprocket,
aligning the timing mark on the outer flange of the camshaft phaser and sprocket with the single blue
(marked) link on the chain.
13. Position the RH timing chain tensioner arm on the dowel pin and the RH timing chain tensioner and
install the 2 bolts in 2 stages.
14. Position the RH timing chain guide and install the bolt in 2 stages.
15. Remove the retaining clip from the RH timing chain tensioner.
17. Lubricate the rocker arm shaft-to-valve tip and rocker arm-to-camshaft lobe contact area with clean
intake valve would be fully opened.
19. Position the LH intake rocker arm shaft assembly and install the bolts finger-tight.
20. Tighten the 10 LH intake rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
exhaust valve would be fully opened.
22. Position the LH exhaust rocker arm shaft assembly and install the bolts finger-tight.
23. Tighten the 10 LH exhaust rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
intake valve would be fully closed.
25. Position the RH intake rocker arm shaft assembly and install the bolts finger-tight.
26. Tighten the 10 RH intake rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
exhaust valve would be fully closed.
28. Position the RH exhaust rocker arm shaft assembly and install the bolts finger-tight.
29. Tighten the 10 RH exhaust rocker arm shaft assembly bolts in the sequence shown, in 3 stages.
Install the lower 8 spark plugs.

31. Connect the 8 ignition wires to the lower 8 spark plugs.

installation.

Valve Cover — LH
Material
Item Specification
ZC-31-A
TA-30 A4
Remover
ZC-30
PCV Tube and LH Ignition Wires

1 6K817 Crankcase ventilation tube
2 12286 Ignition wire (4 required)
LH Variable Camshaft Timing (VCT) Electrical Connector and Engine Wiring Harness Retainers
Part
1 — LH Variable Camshaft Timing (VCT) solenoid electrical
2 — Engine wiring harness-to-LH valve cover retainers (part
of 12C508) (2 required)
3 — Engine wiring harness-to-LH valve cover retainers (part
of 12C508) (3 required)
LH Valve Cover and Gasket

Removal
2. Disconnect the quick connect couplings and remove the crankcase ventilation tube. For additional
3. Disconnect the 4 LH ignition wires from the 4 LH ignition coils.
4. Disconnect the 4 LH ignition wire retainers from the valve cover.
5. Disconnect the LH Variable Camshaft Timing (VCT) variable force solenoid electrical connector.
6. Disconnect the 2 wiring harness retainers from the front and the 3 wiring harness retainers from the
top of the LH valve cover.
NOTICE: When removing the valve cover, make sure to avoid damaging the Variable Camshaft
Timing (VCT) variable force solenoid.
NOTE: The fasteners are part of the valve cover and should not be removed.
suitable solvent.
Installation
1. NOTE: If the valve cover is not secured within 5 minutes, the sealant must be removed and the
sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on
the packaging. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure
to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the
cylinder head.
2. NOTICE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft
Timing (VCT) variable force solenoid.
Position the LH valve cover and new gasket on the cylinder head and tighten the 10 fasteners in the
sequence shown.
3. Connect the 3 wiring harness retainers to the top and the 2 wiring harness retainers to the front of the
LH valve cover.
4. Connect the LH VCT solenoid electrical connector.
5. Connect the 4 LH ignition wire retainers to the valve cover.
6. Connect the 4 LH ignition wires to the 4 LH ignition coils.
7. Position the crankcase ventilation tube and connect the quick connect couplings. For additional

Valve Cover — RH
Material
Item Specification
ZC-31-A
TA-30 A4
Remover
ZC-30
RH Ignition Wires, RH Fuel Injector Electrical Connectors and PCV Tube
Part
1 6K817 Crankcase ventilation tube
2 12286 Ignition wire (4 required)
3 — RH ignition coil electrical connectors (part of 12C508)
(4 required)
RH Variable Camshaft Timing (VCT) Electrical Connector, Engine Wiring Harness Retainers and
Engine Oil Level Indicator Tube Bolt
Part
1 — RH Variable Camshaft Timing (VCT) solenoid
electrical connector (part of 12C508)
2 — Engine wiring harness-to-RH valve cover retainers
(part of 12C508) (2 required)
3 — Engine wiring harness-to-RH valve cover retainers
4 W503276 Engine oil level indicator tube bolt
5 6B667 Engine oil level indicator tube
RH Valve Cover and Gasket

Removal
2. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to
Section 310-00 .
3. Disconnect the 4 RH ignition wires from the 4 RH ignition coils.
4. Disconnect the 4 RH ignition wire retainers from the valve cover.
5. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
6. Disconnect the 6 wiring harness retainers from the RH valve cover.
NOTICE: When removing the valve cover, make sure to avoid damaging the Variable Camshaft
Timing (VCT) solenoid.
NOTE: The fasteners are part of the valve cover and should not be removed.
suitable solvent.
Installation
1. NOTE: If the valve cover is not secured within 5 minutes, the sealant must be removed and the
sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on
the packaging. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure
to follow this procedure can cause future oil leakage.
Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the
cylinder head.
2. NOTICE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft
Timing (VCT) solenoid.
Position the RH valve cover and new gasket on the cylinder head and tighten the 10 fasteners in the
sequence shown.
3. Connect the 6 wiring harness retainers to the RH valve cover.
4. Connect the RH VCT solenoid electrical connector.
5. Connect the 4 RH ignition wire retainers to the valve cover.
6. Connect the 4 RH ignition wires to the 4 RH ignition coils.
7. Position the PCV tube and connect the quick connect couplings. For additional information, refer to
Section 310-00 .

Valve Seals
Material
Item Specification
LSP12 (Canada)
Removal
1. Remove the rocker arm shaft assembly from the cylinder head being serviced. For additional
information, refer to Rocker Arm in this section.
2. Remove the lower spark plug for the cylinder being serviced. For additional information, refer to
Section 303-07D .
4. Use compressed air in the cylinder being serviced to hold both valves in position.
z Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
5. NOTICE: If the components are to be reinstalled, they must be installed in the same positions.
Mark the components for installation into their original locations. Failure to follow these
instructions may result in engine damage.
NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will
allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to
removal. If a valve drops into the cylinder, remove the cylinder head. For additional information, refer
to Cylinder Head in this section.
Using a valve spring compressor, compress the valve spring and remove the valve spring retainer
keys.
6. Remove the valve spring retainer, the valve spring and the valve seal.
z Discard the valve seal.
7. Inspect the components. For additional information, refer to Section 303-00 .
Installation
1. NOTE: Lubricate the valve seal and valve stem with clean engine oil prior to installation.
Position a new valve seal onto the valve stem.
2. Using a valve stem oil seal installer, install the new valve seal.
Using a valve spring compressor, install the valve spring, the valve spring retainer and the valve
spring retainer keys.
4. Relieve the air pressure from the cylinder.
5. Install the lower spark plug. For additional information, refer to Section 303-07D .
6. Install the rocker arm shaft assembly onto the cylinder head being serviced. For additional

Valve Springs
Removal
1. Remove the rocker arm shaft assembly from the cylinder head being serviced. For additional
2. Remove the lower spark plug for the cylinder being serviced. For additional information, refer to
Section 303-07D .
4. Use compressed air in the cylinder being serviced to hold both valves in position.
z Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
Mark the components for installation into their original locations. Failure to follow these
instructions may result in engine damage.
NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will
allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to
removal. If a valve drops into the cylinder, remove the cylinder head. For additional information, refer
to Cylinder Head in this section.
Using a valve spring compressor, compress the valve spring and remove the valve spring retainer
keys.
6. Remove the valve spring retainer and the valve spring.
7. Inspect the valve spring. For additional information, refer to Section 303-00 .
Installation
Using a valve spring compressor, install the valve spring, the valve spring retainer and the valve
spring retainer keys.
2. Relieve the air pressure from the cylinder.
3. Install the lower spark plug. For additional information, refer to Section 303-07D .
4. Install the rocker arm shaft assembly onto the cylinder head being serviced. For additional

Rocker Arm Shafts, Valves, Valve Springs, Valve Spring Retainer Keys and Retainers

4 6A517 Valve seal (8 required)
7 W713746 Rocker arm shaft bolt (20 required)
8 6C553 Intake rocker arm shaft assembly
9 6C552 Exhaust rocker arm shaft assembly
Camshaft Phaser and Sprocket, VCT System Oil Filter, Camshaft Bearing Caps and Camshaft

1 W714203 Camshaft bearing cap bolt (10 required)
2 6B284 Camshaft bearing cap (4 required)
3 6B280 Camshaft front bearing cap
4 6A274 Camshaft
5 6C683 Variable Camshaft Timing (VCT) system oil filter
6 W712998 Camshaft phaser and sprocket bolt (3 required)
7 6C524 Camshaft phaser and sprocket

Variable Camshaft Timing (VCT) System Oil Filter
1. Remove the camshaft phaser and sprocket. For additional information, refer to Camshaft Phaser and
Sprocket — LH or Camshaft Phaser and Sprocket — RH in this section.
Installation
1. Install the new VCT system oil filter with the open end facing the front of the engine.
2. Install the camshaft phaser and sprocket. For additional information, refer to Camshaft Phaser and
Sprocket — LH or Camshaft Phaser and Sprocket — RH in this section.
SECTION 303-03: Engine Cooling 2014 F-150 Workshop Manual

Material
Motorcraft® Metal — —
Surface Prep
ZC-31-A
Motorcraft® Premium ESR-M14P7- —
Cooling System Flush A
VC-1
Motorcraft® Silicone — —
Gasket Remover
ZC-30
Motorcraft® Orange WSS- 3.5L Gasoline
Antifreeze/Coolant M97B44-D Turbocharged Direct
Concentrated Injection (GTDI) —
VC-3-B (US); CVC-3- 15.6L (16.5 qt),
B2 (Canada) 3.7L — 15.1L (16.0
qt),
5.0L — 16.1L (17.0
qt),
6.2L — 18.5L (19.5
qt)
Motorcraft® Orange WSS- 3.5L Gasoline
Antifreeze/Coolant M97B44-D2 Turbocharged Direct
Prediluted Injection (GTDI) —
VC-3DIL-B (US); CVC- 15.6L (16.5 qt),
3DIL-B (Canada) 3.7L — 15.1L (16.0
qt),
5.0L — 16.1L (17.0
qt),
6.2L — 18.5L (19.5
qt)
Item Specification
Pressure Tests
Complete cooling system maximum pressure 110 kPa (16 psi)
Pressure relief cap 110 kPa (16 psi)
Radiator (out of vehicle) 138 kPa (20 psi)
Thermostat Opening Temperatures — 3.5L Gasoline Turbocharged Direct Injection (GTDI)
Starts to open 83.8-90.6°C (183-195°F)
Fully open 98.8°C (210°F)
Thermostat Opening Temperatures — 3.7L
Starts to open 83.8-90.6°C (183-195°F)
Fully open 98.8°C (210°F)

Thermostat Opening Temperatures — 5.0L
Starts to open 87.5°C (189.5°F)
Fully open 100°C (212°F)
Thermostat Opening Temperatures — 6.2L (2V)
Starts to open 88-92°C (190.4-197.6°F)
Fully open 104°C (219.2°F)
lb- lb-
Description Nm ft in
A/C fitting nut and bolt 15 — 133
Air dam bolts 20 — 177
Air dam nuts 20 — 177
Battery Junction Box (BJB) bolts 10 — 89
Block heater - 5.0L, 6.2L 40 30 —
Block heater bolt - 3.5L Gasoline Turbocharged Direct Injection (GTDI), 3.7L 6 — 53
Coolant crossover manifold assembly bolts a — — —
Coolant expansion tank module bolts 15 — 133
Coolant inlet connector bolt - 3.5L Gasoline Turbocharged Direct Injection (GTDI), 3.7L, 10 — 89
5.0L
Coolant outlet connection bolts — 6.2L 10 — 89
Coolant pump bolts — 3.5L GTDI , 3.7L a — — —
Coolant pump bolts — 5.0L a — — —
Coolant pump bolts — 6.2L a — — —
Cooling fan motor and shroud bolts 7 — 62
Cooling module bolts 30 22 —
Degas bottle bolts 17 — 150
Front bumper cover bracket bolts 3 — 27
Front wheel moulding nuts 3 — 27
Front bumper cover bracket bolts 3 — 27
Generator positive cable nut 9 — 80
Heater outlet tube bolt 10 — 89
Hood latch bolts 25 18 —
Hood latch release handle bolt 8 — 71
Intake manifold bolt 10 — 89
LH turbocharger-to-Charge Air Cooler (CAC) tube bracket bolt 6 — 53
LH turbocharger-to- CAC tube clamp 5 — 44

Positive battery cable nut — 6.2L 9 — 80
Power steering fluid reservoir bolt 11 — 97
Radiator bolts 15 — 133
Thermostat housing bolts — 3.5L GTDI , 3.7L a — — —
Thermostat housing bolts — 5.0L 10 — 89
Transmission cooler tube bolt — 3.5L GTDI , 3.7L and 5.0L engines 12 — 106
a

Engine Cooling
NOTICE: Vehicle cooling systems are filled with Motorcraft® Orange Antifreeze/Coolant. Always fill
the cooling system with the manufacturer's specified coolant. Chemically flush the cooling system if
a non-specified coolant has been used. Refer to Cooling System Flushing in this section. Failure to
follow these instructions may damage the engine or cooling system.
NOTE: During normal vehicle operation, Motorcraft® Orange Antifreeze/Coolant may change color from
orange to pink or light red. As long as the engine coolant is clear and uncontaminated, this color change
does not indicate the engine coolant has degraded nor does it require the engine coolant to be drained, the
system to be flushed, or the engine coolant to be replaced.
The cooling system consists of the following components:
z Block heater (located in the thermostat housing for 3.5L Gasoline Turbocharged Direct Injection
(GTDI) and 3.7L engines, the LH front of the 5.0L engine cylinder block and the LH rear of the 6.2L
engine cylinder block.)
z Coolant expansion tank (6.2L engine)
z Degas bottle (3.5L GTDI , 3.7L and 5.0L engines)
z Electric cooling fan and shroud assembly
z Radiator
z Pressure relief cap (located on the radiator for the 6.2L engine and on the degas bottle for the 3.5L
GTDI , 3.7L and 5.0L engines)
z Radiator draincock (located in the RH corner of the radiator)
z Upper and lower radiator hoses
z Coolant pump
Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the
engine and cooling components. In order to obtain these protections, the engine coolant must be maintained
at the correct concentration and fluid level in the degas bottle or coolant expansion tank.
When adding engine coolant, use a 48/52 to 50/50 mixture of engine coolant and distilled water, which
equates to a freeze point between -31°C (-30°F) and -37°C (-34°F).
To maintain the integrity of the coolant and the cooling system:
z Add Motorcraft® Orange Antifreeze/Coolant or equivalent.

z Do not add/mix any other engine coolant. Mixing coolants may degrade the coolant's corrosion
protection.
z Do not add alcohol, methanol, brine or any engine coolants mixed with alcohol or methanol
antifreeze. These can cause engine damage from overheating or freezing.
z Do not mix with recycled coolant. Use of such coolants may harm the engine and cooling system
components. Do not mix coolant types.
On 3.5L GTDI and 3.7L engines, a channel cover plate is located behind the front cover. It contains a timing
chain idler and press in place gaskets separating engine coolant and engine oil. A weep hole is provided on
the front left side of the engine behind the generator. If oil or coolant is leaking from the weep hole, then a
gasket has failed and must be replaced. Refer to Section 303-01A for 3.5L GTDI engines or Section 303-
01B for 3.7L engines.
The 3.5L GTDI , 3.7L and 5.0L engines use a cold side thermostat. This means the thermostat controls the
flow of cooled radiator coolant into the warmer engine cooling circuit. The thermostat is located at the lower
radiator hose connection to the engine. During initial warm-up, the engine coolant increases in temperature,
causing the thermostat to open. The cooler coolant from the radiator mixes with the warm engine coolant,
causing the thermostat to close. The thermostat opens and closes several times before the engine coolant is
warm enough to allow the thermostat to remain open. The engine must run much longer than a vehicle with
a hot side thermostat before the thermostat remains fully opened.
The 6.2L engine uses a typical hot side thermostat.
Coolant Flow Diagram, 3.5L Gasoline Turbocharged Direct Injection (GTDI)
NOTE: Black arrows indicate hot, white arrows indicate cold.

1 8260 Upper radiator hose and clamp assembly
2 18472 Heater outlet hose
3 63K682 RH turbocharger
4 8K153 RH engine-to-turbocharger hose
5 8A520 RH turbocharger-to-engine hose
6 8A505 Coolant inlet pipe
8 8C368 Coolant crossover manifold assembly
9 18472 Heater inlet hose
10 18472 Heater inlet restrictor
11 18472 Heater outlet restrictor
12 18476 Heater core
14 8A520 LH turbocharger-to-engine hose
15 6K682 LH turbocharger
16 8K153 LH engine-to-turbocharger hose
17 8A080 Degas bottle
18 8075 Radiator-to-degas bottle hose
19 8276 Thermostat housing-to-degas bottle hose
21 8501 Cylinder block coolant pump hole cover

23 — Thermostat housing (part of 8592)
24 8575 Thermostat (part of 8592)
25 — Coolant inlet connection (part of 8592)
26 8286 Lower radiator hose and clamp assembly
27 6A642 Oil cooler
28 8005 Radiator
Coolant Flow Diagram, 3.7L

4 8501 Coolant pump

10 6A642 Engine oil cooler (if equipped)
11 8005 Radiator
14 8501 Cylinder block coolant pump hole cover
17 18472 Heater outlet jumper
18 18472 Heater inlet jumper
19 18476 Heater core

2 8566 Coolant bypass T-connector
5 18476 Heater core

6 8276 Coolant outlet connection-to-degas bottle hose
10 8592 Coolant outlet connection
11 18696 Heater inlet tube
14 6A642 Engine oil cooler
19 8C350 Degas bottle-to-heater outlet tube hose
20 8005 Radiator

1 8260 Upper radiator hose
4 18696 Heater inlet tube
7 18476 Heater core
9 8575 Thermostat
12 8A080 Coolant expansion tank
13 8N029 Radiator overflow hose
17 6A642 Engine oil cooler
19 8005 Radiator

Engine Cooling
Special Tool(s)
3-Way HD Antifreeze Coolant
Test Kit
Coolant/Battery Refractometer
300-ROB75240 or equivalent
D-Gas Adapter
Radiator Tester
STN12270 or equivalent
UView® Combustion Leak Tester

UVU560000-R or equivalent

appropriate hardware or
Material
Item Specification
Motorcraft® Orange WSS-M97B44-
Antifreeze/Coolant Concentrated D

Antifreeze/Coolant Prediluted D2
VC-3DIL-B (US); CVC-3DIL-B
(Canada)
Engine coolant flows primarily from the engine to the radiator circuit and back to the coolant pump. Coolant
is sent from the coolant pump through the engine block and cylinder heads. A separate circuit from the
engine also feeds the heater core with coolant. The coolant pump is operated by engine rotation through a
pulley which is driven by the accessory drive belt to circulate the coolant. The coolant thermostat is a control
valve actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator
circuit and returns to the coolant pump. When the thermostat is opened, coolant flows through the radiator
circuit to transfer engine-generated heat to the outside air.
The degas bottle (3.5L GTDI, 3.7L and 5.0L engines) removes air from the cooling system. It also allows for
coolant expansion and system pressurization, replenishes coolant to the cooling system and serves as the
location for service fill.
The coolant expansion tank (6.2L engines) holds surplus coolant, allows for coolant expansion and
replenishes coolant to the cooling system. It is equipped with a non-pressurized cap which allows coolant to
be added to the tank to keep it filled to prescribed levels.
The cooling fan draws air through the radiator to help cool the system coolant as it passes through the
radiator.
The thermostat monitor is a function of the PCM and is designed to verify correct thermostat operation. The
monitor executes once per drive cycle and has a monitor run duration of 300-800 seconds. If a malfunction
occurs, DTC P0125 or P0128 is set and the Malfunction Indicator Lamp (MIL) is illuminated.
the coolant pressure relief cap when the engine is operating or the cooling system is hot. The
cooling system is under pressure; steam and hot liquid can come out forcefully when the cap is
loosened slightly. Failure to follow these instructions may result in serious personal injury.
NOTICE: The engine cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Do not mix
coolant types. Mixing coolant types degrades the corrosion protection of Motorcraft® Orange
Antifreeze/Coolant. Failure to follow these instructions may damage the engine or cooling system.
NOTICE: Always fill the cooling system with the manufacturer's specified coolant. Chemically flush
the cooling system if a non-specified coolant has been used. Refer to Cooling System Flushing in
this section. Failure to follow these instructions may damage the engine or cooling system.
NOTE: During normal vehicle operation, Motorcraft Orange Antifreeze/Coolant may change color from
2. Visually check the engine coolant level at the degas bottle when the system is cold.
3. Make sure the pressure relief cap is installed correctly.
4. Record any cooling system DTCs retrieved. Refer to the PCM DTC Chart in this section for DTC
descriptions.
5. NOTE: Take note of any coolant odor or steam coming from cooling system components.
If the system coolant is filled correctly and no DTCs associated with fail-safe cooling are retrieved,
verify the customer's concern by operating the engine to duplicate the condition.
6. NOTE: For the coolant flow diagram, refer to Engine Cooling in the Description and Operation portion
of this section.
Visually inspect for obvious signs of any mechanical or electrical damage.

z Leaks or weeps at: z Inoperative or damaged:
Hoses Electric cooling fan
Tubes Wiring, connectors, relays or
Clamp joints modules
Gaskets Cylinder Head Temperature
O-rings (CHT) sensor
Thermostat housing Vehicle Speed Sensor (VSS)
Radiator
Pressure relief cap
Coolant pump
Heater core (wet floor or coolant odor in
vehicle)
Coolant crossover manifold assembly (if
equipped)
Oil filter adapter (if equipped)
Oil cooler (if equipped)
Coolant expansion tank (if equipped)
Degas bottle (if equipped)
Cylinder block core plugs
Cylinder head core plugs
Block heater (if equipped)
Turbochargers (if equipped)
z Cracked or damaged:
Hoses
Tubes
Hose clamps
Thermostat housing
Radiator
Pressure relief cap
Cooling fan
Coolant pump
Coolant expansion tank (if equipped)
Degas bottle (if equipped)

Oil filter adapter (if equipped)
Oil cooler (if equipped)
Coolant crossover manifold assembly (if
equipped)
Cylinder block core plugs
Cylinder head core plugs
Block heater (if equipped)
Tirbochargers (if equipped)
z Restricted airflow through the A/C condenser/radiator
z Drive belt loose, worn or installed incorrectly
z Broken or weak drive belt tensioner
z Excessive white or light gray exhaust smoke (may
have burnt coolant odor)
z Coolant in engine oil
z Engine oil in coolant
z Coolant in automatic transmission fluid
z Automatic transmission fluid in coolant
7. If the inspection reveals an obvious concern that can be readily identified, repair it as necessary. Test
8. Inspect the coolant condition.

1. Inspect the coolant color.
Discoloration may indicate that incorrect coolant may have been added to the system.
Use of incorrect (green or yellow in color) coolant degrades the corrosion protection of
Motorcraft® Orange Antifreeze/Coolant. Addition of Motorcraft® Specialty Green Engine
Coolant may cause the color to appear to be a murky green-brown color. The addition
of Motorcraft® Gold Antifreeze/Coolant, however, may not change the color or
appearance of the orange colored coolant. Detection of contamination with Motorcraft®
Gold Antifreeze/Coolant is determined by the presence of nitrite. If contamination with
Motorcraft® Gold Antifreeze/Coolant is suspected, test the coolant with the 3-Way HD
Antifreeze Coolant Test Kit. Follow the nitrite testing directions in the kit to determine if
nitrite is present in the system. If nitrite is present, flush the system and refill with the
correct mixture of distilled water and Motorcraft® Orange Antifreeze/Coolant. Refer to
Cooling System Flushing in this section.
A darker orange with the presence of debris could indicate a commercially available
stop leak may have been used and could result in loss of coolant flow to critical parts of
the engine. If sediment is present in the coolant sample, flush the system and refill with
the correct mixture of distilled water and Motorcraft® Orange Antifreeze/Coolant. Refer
to Cooling System Flushing in this section.
A light or reddish brown color indicates that rust may be present in the cooling system.
Flush the system and refill with the correct mixture of distilled water and Motorcraft®
Orange Antifreeze/Coolant. Refer to Cooling System Flushing in this section.
An iridescent sheen on top of the coolant could indicate a trace of oil is entering the
system. For engine diagnosis, refer to Section 303-00 . Flush the cooling system and
refill with the correct mixture of distilled water and Motorcraft® Orange
Antifreeze/Coolant. Refer to Cooling System Flushing in this section.
A milky brown color may indicate that engine oil is entering the cooling system.
Pressure test the cooling system. Refer to the Component Tests in this section. If
engine oil is suspected, the cause of the leak may be internal to the engine. For engine
diagnosis, refer to Section 303-00 . Flush the cooling system and refill with the correct
mixture of distilled water and Motorcraft® Orange Antifreeze/Coolant. Refer to Cooling
2. If the engine coolant appearance is acceptable, test the engine coolant freezing point range
with the Coolant/Battery Refractometer. Maintain the coolant concentration within 48% to 50%,
which equates to a freeze point between -31˚C and -37˚C (-30˚F and -34˚F). If the vehicle is
driven in cold climates less than -37°C (-34°F), it may be necessary to increase the coolant
concentration to get adequate freeze protection. Recommended coolant concentration is 48/52
to 50/50 (freeze protection -31°C [-30°F] to -34°C [-34°F]) engine coolant to distilled water.
Maximum coolant concentration is 60/40 for cold weather areas.
Minimum coolant concentration is 40/60 for warm weather areas.
3. Adjust coolant range and level if necessary:
If coolant is low, add specified coolant mixture only.
If the engine coolant tests too weak, remove some of the engine coolant and add
undiluted engine coolant until the readings are within acceptable levels.
If the engine coolant tests strong, remove some of the engine coolant and add distilled
water until the readings are within acceptable levels.
9. If an obvious cause for an observed or reported concern is found, correct the cause and test the
system for normal operation before proceeding to the next step.

z refer to Section 418-00 The PCM Does Not Respond To The Scan Tool, to diagnose no

418-00 .
(CMDTCs).
15. If the DTCs recovered are related to the concern, go to the PCM DTC Chart. For all other PCM DTCs,
PCM DTC Chart
PCM DTC Chart

P0217 Engine Coolant Over Temperature Condition GO to Pinpoint Test B .

P1285 Cylinder Head Over Temperature Condition GO to Pinpoint Test B .
P1299 Cylinder Head Over Temperature Protection GO to Pinpoint Test B .
Active
P0125 Insufficient Coolant Temperature For Closed GO to Pinpoint Test C .
Loop Fuel Control
P0128 Coolant Thermostat (Coolant Temperature GO to Pinpoint Test C .
Below Thermostat Regulating Temperature)
P0480 Fan 1, 2 or 3 Control Circuit, Respectively REFER to the Powertrain
Control/Emissions Diagnosis (PC/ED)
P0481 manual.
P0482
All Other — REFER to Section 303-14 .
PCM DTCs
Symptom Chart
Symptom Chart
z Loss of coolant z Coolant hoses or tubes z GO to Pinpoint Test A .
z Hose clamps
z Coolant pump O-ring seal
z Thermostat O-ring seal
z Thermostat housing
z Radiator
z Transmission fluid cooler
(in radiator) (may leak
internally or externally)
z Coolant expansion tank
z Degas bottle
z Pressure relief cap
z Coolant pump leaking
from weep hole
z Cylinder block coolant
pump hole cover
z Heater core
z Coolant crossover
manifold assembly
z Engine gaskets (may leak
z Oil filter adapter (may leak
z Oil cooler (may leak
z Cylinder block core plugs
z Cylinder head core plugs
z Block heater (if equipped)
z Turbochargers (if
equipped)
z The engine z Low coolant level z GO to Pinpoint Test B .

overheats z External engine coolant
leak
z Airlock in system
installation
z Restricted airflow through
the A/C
condenser/radiator
z Internal engine coolant
leak
z Coolant
condition/concentration
z Accessory drive
components
z Non-OEM engine
enhancement components
z Electric cooling fan
z Radiator
z Thermostat
z Temperature gauge
z Cylinder Head
Temperature (CHT)
sensor
z Coolant pump
z Coolant flow restriction
z The engine does z Low coolant level z GO to Pinpoint Test C .
not reach normal z Thermostat
operating z Electric cooling fan always
temperature on
z ECT gauge
z CHT sensor
z The block heater z Block heater power cable z CHECK continuity in all 3
does not operate power cable circuits. If any
correctly circuit measures more than
5 ohms, INSTALL a new
power cable.
z Block heater z CHECK the resistance of
the block heater. If the
resistance does not
measure between 12.5 and
17.0 ohms, INSTALL a new
block heater.
z The electric z Wiring z REFER to the Powertrain
cooling fan is z Relays Control/Emissions
inoperative in one z Fuses Diagnosis (PC/ED) manual.
or more speeds z Cooling fan motor
or does not
operate correctly
z The electric z Wiring z REFER to the Powertrain
cooling fan stays z Relays Control/Emissions
on all the time Diagnosis (PC/ED) manual.
z Noisy electric z Foreign material z REMOVE the foreign
cooling fan contamination material from the cooling
z Fan motor fan and shroud. TEST the
system for normal
operation. If still noisy,

INSTALL a new cooling fan
assembly.
z Fan blade detached from z INSTALL a new cooling fan
fan motor assembly.
Pinpoint Tests
Pinpoint Test A: Loss of Coolant
Normal Operation
The engine cooling system is a closed system providing for coolant expansion and contraction as well as
changes in pressure as coolant warms and cools with engine operation. Various gaskets, seals, hoses and
clamps contain coolant within the cooling system and keep other fluids and contaminants from entering the
cooling system.
Coolant loss can be attributed to either external or internal leaks anywhere within the cooling system.
For engine specific information, refer to Engine Cooling in the Description and Operation portion of this
section.

z Coolant hoses or tubes
z Hose clamps
z Thermostat O-ring seal
z Coolant pump gasket or O-ring seal
z Thermostat housing
z Radiator
z Transmission fluid cooler (in radiator)
z Coolant pump leaking from weep hole
z Cylinder block coolant pump hole cover
z Heater core
z Coolant crossover manifold assembly
z Engine gaskets (may leak internally or externally)
z Oil filter adapter (may leak internally or externally)
z Oil cooler (may leak internally or externally)
z Coolant expansion tank
z Degas bottle
z Cylinder block core plugs
z Cylinder head core plugs
z Block heater (if equipped)
z Turbochargers (if equipped)
PINPOINT TEST A: LOSS OF COOLANT

A1 CARRY OUT INSPECTION AND VERIFICATION
z Carry out the inspection and verification procedure Yes
in this section. REPAIR as needed. TEST the system for
z Were any concerns found? normal operation.
No
GO to A2 .
A2 CHECK THE ENGINE COOLANT LEVEL
Yes
NOTE: Allow the engine to cool before checking
GO to A3 .
the engine coolant level.
z Ignition OFF. No
z Visually inspect the engine coolant level at the ADJUST the engine coolant level as
coolant expansion tank. necessary. GO to A3 .
z Is the engine coolant level within
specifications?
A3 PRESSURE TEST THE ENGINE COOLING
SYSTEM
z Pressure test the engine cooling system. For 3.5L Yes
GTDI, 3.7L or 5.0L engines, refer to Component REPAIR or INSTALL new components.
Tests, Cooling System Pressure Test - Degas TEST the system for normal operation.
Bottle Systems in this section. For 6.2L engines,
refer to Component Tests, Cooling System No
Pressure Test - Coolant Expansion Tank Systems GO to A4 .
in this section.
z Does the engine cooling system leak
externally?
A4 CHECK THE ENGINE COOLANT FOR AN
INTERNAL LEAK
z Inspect the engine coolant in the degas bottle or Yes
the coolant expansion tank and the radiator for If engine oil is evident, GO to Section 303-
signs of engine oil or transmission fluid. 00 for engine diagnosis. If transmission
z Is engine oil or transmission fluid evident in fluid is evident, INSTALL a new radiator.
the coolant? REPAIR the transmission as necessary.
Refer to the appropriate section in Group
307 for the procedure. TEST the system for
normal operation.
No
GO to A5 .
A5 CHECK THE ENGINE OIL AND TRANSMISSION
FLUID FOR COOLANT
z Remove the oil level indicators from the engine Yes
and the transmission. If coolant is in the engine oil, GO to Section
z Is coolant evident in the oil or transmission 303-00 . If coolant is in the transmission
fluid? fluid, INSTALL a new radiator. REPAIR the
transmission as necessary. Refer to the
appropriate section in Group 307 for the
procedure.
No
GO to A6 .
A6 CHECK THE COOLING SYSTEM FOR
COMBUSTION GASES
z NOTE: Use UView® Combustion Leak Tester part Yes
number UVU560000-R or equivalent. GO to Section 303-00 for engine diagnosis.
z Using a cooling system combustion gas leak
tester, following the instructions supplied with the
tester, check the coolant for combustion gases. No
z Are combustion gases present? The cooling system is operational.
Pinpoint Test B: The Engine Overheats
Normal Operation
The engine cooling system maintains the engine temperature during operation. Correct coolant flow through
the engine, radiator and remainder of cooling system passages and components is essential to maintaining
a correct engine temperature.
engine also feeds the heater core with coolant. The coolant pump, operated by engine rotation through a
pulley driven by the accessory drive belt, circulates the coolant. The coolant thermostat is a control valve
actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit
and returns to the coolant pump. When the thermostat is opened, coolant flows through the radiator circuit to
transfer engine-generated heat to the outside air.
Engine overheating generally occurs when there is a disruption in the ability to control either coolant flow at
the proper rate, the inability to transfer heat from the engine through the coolant (including low coolant) or an
inability to transfer engine generated heat to the outside air through the radiator.
For engine specific information, refer to Engine Cooling in the Description and Operation portion of this
section.
z DTC P0217 (Engine Coolant Over Temperature Condition) — Indicates an engine overheat condition
was detected by the Cylinder Head Temperature (CHT) sensor.
z DTC P1285 (Cylinder Head Over Temperature Condition) — Indicates an engine overheat condition
was sensed by the CHT sensor.
z DTC P1299 (Cylinder Head Over Temperature Protection Active) — Indicates an engine overheat
condition was detected by the CHT sensor. A failure mode effects management strategy called fail-
safe cooling was activated to cool the engine.

z Low coolant level
z External engine coolant leak
z Airlock in system
z Pressure relief cap installation
z Restricted airflow through the A/C condenser/radiator
z Internal engine coolant leak
z Coolant condition/concentration
z Accessory drive components
z Non-OEM engine enhancement components
z Electric cooling fan

z Temperature gauge
z CHT sensor
z Coolant pump
z Coolant flow restriction
z Radiator
z Thermostat
PINPOINT TEST B: THE ENGINE OVERHEATS

B1 CARRY OUT INSPECTION AND
VERIFICATION
z Carry out the inspection and verification Yes
procedure in this section. REPAIR as needed. TEST the system for
z Were any concerns found? normal operation.
No
GO to B2 .
B2 CHECK FOR DTCs
z Check for DTC P0217, P1285 or P1299. Yes
z Is DTC P0217, P1285 or P1299 present? GO to B3 .
No
Actual engine overheating has not been
verified. CHECK the engine coolant
temperature gauge operation. REFER to
Section 413-01 . If any other PCM DTCs are
retrieved, REFER to Section 303-14 .
B3 CHECK FOR AN AIRFLOW OBSTRUCTION
z Check the radiator or A/C condenser for an Yes
obstruction such as leaves or cardboard. REMOVE the obstruction. TEST the system
z Is an obstruction present? for normal operation.
No
GO to B4 .
B4 CHECK THE ENGINE COOLANT LEVEL
Yes
NOTE: Allow the engine to cool before
checking the coolant level. GO to B5 .
z Ignition OFF. No
z Visually check the engine coolant level in the ADJUST the engine coolant level as
coolant expansion tank. necessary. GO to B5 .
z Is the engine coolant level within
specification?
B5 PRESSURE TEST THE ENGINE COOLING

SYSTEM
z Pressure test the engine cooling system. For Yes
3.5L GTDI, 3.7L or 5.0L engines, refer to REPAIR or INSTALL new components. TEST
Component Tests, Cooling System Pressure the system for normal operation.
Test - Degas Bottle System in this section. For
6.2L engines, refer to Component Tests, No
Cooling System Pressure Test - Coolant For 6.2L engines, GO to B6 . For 3.5L GTDI,
Expansion Tank System in this section. 3.7L or 5.0L engines, GO to B7 .
z Does the engine cooling system leak
externally?
B6 CHECK THE PRESSURE RELIEF CAP
z Carry out the Pressure Relief Cap Pressure Yes
Test. Refer to Component Test, Pressure Relief GO to B7 .
Cap Pressure Test in this section.
z Is the pressure relief cap OK? No
INSTALL a new pressure relief cap. TEST the
B7 CHECK THE ENGINE COOLANT FOR AN
INTERNAL LEAK
z Inspect the engine coolant in the degas bottle Yes
or the coolant expansion tank and the radiator If engine oil is evident, GO to Section 303-00
for signs of engine oil or transmission fluid. for engine diagnosis. If transmission fluid is
z Is engine oil or transmission fluid evident in evident, INSTALL a new radiator. REPAIR the
the coolant? transmission as necessary. Refer to the
procedure. TEST the system for normal
operation.
No
GO to B8 .
B8 CHECK THE ENGINE OIL AND
TRANSMISSION FLUID FOR COOLANT
z Remove the oil level indicators from the engine Yes
and the transmission. If coolant is in the engine oil, GO to Section
z Is coolant evident in the oil or transmission 303-00 . If coolant is in the transmission fluid,
fluid? INSTALL a new radiator. REPAIR the
transmission as necessary. Refer to the
procedure.
No
GO to B9 .
B9 CHECK THE COOLING SYSTEM FOR
COMBUSTION GASES
z NOTE: Use UView® Combustion Leak Tester Yes
part number UVU560000-R or equivalent. GO to Section 303-00 for engine diagnosis.
z Using a cooling system combustion gas leak
tester, following the instructions supplied with No
the tester, check the coolant for combustion GO to B10 .
gases.
z Are combustion gases present?
B10 CHECK COOLANT CONDITION
z Check the coolant for dirt, rust or contamination Yes

and check the coolant concentration. GO to B11 .
z Is the coolant condition OK?
No
FLUSH the engine cooling system. REFER to
Cooling System Flushing in this section. TEST
B11 CHECK THE ELECTRIC COOLING FAN
OPERATION
z Start the engine. Yes
z Place the climate control function selector in GO to B12 .
the MAX A/C position and the blower motor
switch in the HI position. No
z Did the electric cooling fan operate? DIAGNOSE the electric cooling fan operation.
REFER to the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.
B12 CHECK THE COOLANT PUMP OPERATION
z Allow the engine to run for 10 minutes. Place GO to B13 .
the climate control function selector in the MAX
HEAT position. Feel the heater outlet hose. No
z Is the heater outlet hose hot? INSTALL a new coolant pump. TEST the
B13 CHECK THE THERMOSTAT OPERATION
z Allow the engine to run for 10 minutes (6.2L CHECK the engine coolant temperature
engines) or 30 minutes (3.5L GTDI, 3.7L or gauge operation. REFER to Section 413-01 .
5.0L engines). Feel the upper radiator hose.
z Is the upper radiator hose hot? No
GO to B14 .
B14 VISUALLY INSPECT THE THERMOSTAT
z Carry out the Thermostat Visual Inspection in Yes
the Component Tests portion of this section. INSTALL a new thermostat. TEST the system
z Is the thermostat damaged? for normal operation.
No
INSTALL a new thermostat. TEST the system
for normal operation. If the engine still
overheats, INSTALL a new radiator. TEST the
Pinpoint Test C: The Engine Does Not Reach Normal Operating Temperature
Normal Operation
The engine cooling system maintains engine temperature during operation. Correct coolant flow through the
engine, radiator and remainder of cooling system passages and components is essential to maintaining a
correct engine temperature.
engine also feeds the heater core with coolant. The coolant pump, operated by engine rotation through a
pulley driven by the accessory drive belt, circulates the coolant. The coolant thermostat is a control valve
actuated by coolant temperature. When the thermostat is closed, coolant flow bypasses the radiator circuit
and returns to the coolant pump. When the thermostat is opened, coolant flows through the radiator circuit to
transfer engine generated heat to the outside air.
Concerns of engine inability to reach normal operating temperature typically occur when the rate of coolant
flow through some coolant circuits (radiator, heater core) is more than expected given the conditions, or
when the cooling fans operate all of the time. Heat is not allowed to build in the engine because a heat
exchanger is removing too much heat, including the radiator, heater core and oil cooler. In addition,
perceived concerns that the engine does not reach normal operating temperature can be related to a low
coolant level or trapped air which does not allow for hot coolant to be available at the heater core, an
inoperative climate control system, or for concerns perceived or related to an incorrect engine temperature
gauge indication.
z DTC P0125 (Insufficient Coolant Temperature For Closed Loop Fuel Control) — Indicates the
Cylinder Head Temperature (CHT) sensor has not achieved the required temperature level to enter
closed loop operating conditions within a specified amount of time after starting the engine.
z DTC P0128 (Coolant Thermostat [Coolant Temperature Below Thermostat Regulating Temperature])
— Indicates the thermostat monitor has not achieved the required engine operating temperature
within a specified amount of time after starting the engine.

z Low coolant level
z Thermostat
z Temperature gauge
z Electric cooling fan always on
z Cylinder Head Temperature (CHT) sensor
PINPOINT TEST C: THE ENGINE DOES NOT REACH NORMAL OPERATING TEMPERATURE

C1 CARRY OUT
INSPECTION AND
VERIFICATION
z Carry out the Yes
inspection and REPAIR as needed. TEST the system for normal operation.
verification procedure
in this section. No
z Were any concerns GO to C2 .
found?
C2 CHECK FOR DTC
P0125 or P0128
z Check for DTC P0125 Yes
or P0128. GO to C3 .
z Is DTC P0125 or
P0128 present? No
The cooling system is operational. If an inoperative engine coolant
temperature gauge is suspected, CHECK the engine coolant
temperature gauge operation. REFER to Section 413-01 . If an

inoperative climate control system is suspected, CHECK the climate
control system operation. REFER to Section 412-00 . If any other PCM
DTCs are retrieved, REFER to Section 303-14 .
C3 CHECK THE ELECTRIC
COOLING FAN OPERATION
z Allow the engine to Yes
cool. DIAGNOSE the electric cooling fan operation. REFER to the
z Make sure the A/C Powertrain Control/Emissions Diagnosis (PC/ED) manual.
switch is OFF.
z Check the electric GO to C4 .
cooling fan.
z Is the electric cooling
fan on all the time?
C4 CHECK THE COOLANT
LEVEL
z NOTE: Allow the Yes
engine to cool before INSTALL a new thermostat. TEST the system for normal operation.
checking the coolant
level. No
z Visually check the GO to Pinpoint Test A to diagnose a coolant leak.
engine coolant level in
the coolant expansion
tank.
z Is the engine coolant
level within
specification?
Component Tests
Cooling System Pressure Test - Degas Bottle Systems
NOTE: Vehicles equipped with a degas bottle system have the pressure relief cap on the degas bottle and
no radiator cap. The pressure relief cap is tested as part of the cooling system pressure test.
1. Turn the engine off.
2. Check the engine coolant level. Adjust the coolant level as necessary.
3. Attach the D-Gas Adapter to the degas bottle nipple and overflow hose. Install the Radiator Tester to
the quick connect fitting of the D-Gas Adapter.
4. NOTICE: Do not pressurize the cooling system beyond the maximum pressure listed in the
specifications table in this section or cooling system components may be damaged.
NOTE: If the plunger of the pressure tester is pressed too fast, an erroneous pressure reading
results.
Slowly press the plunger of the pressure test pump until the pressure gauge reading stops increasing
and note the highest pressure reading obtained. If the pressure reading exceeds the maximum cap
pressure listed in the specifications table, install a new pressure relief cap.
5. If the system does not hold pressure, remove the pressure relief cap and wash in clean water to
dislodge all of the foreign material from the gasket. Check the sealing surface in the filler neck of the
degas bottle for nicks or cuts. Install the pressure relief cap.
6. Pressurize the engine cooling system as described in Step 4. Observe the gauge reading for
approximately 2 minutes. Pressure should not drop during this time. If the pressure drops, inspect for
leaks and repair as necessary.
7. If no leaks are found and the pressure drops, the pressure relief cap may be leaking. Install a new
pressure relief cap and retest the system.
8. If no leaks are found after a new pressure relief cap is installed, and the pressure drops, the leak may
be internal to the engine. Inspect the coolant for engine oil and the engine oil for coolant. Refer to
Section 303-00 to diagnose the engine.
9. Release the system pressure by loosening the pressure relief cap. Check the coolant level and adjust
as necessary.
Coolant System Pressure Test - Coolant Expansion Tank Systems
NOTE: Vehicles equipped with a coolant expansion tank have the pressure relief cap on the radiator. The
pressure relief cap is tested separately.
1. Turn the engine off.
2. Remove the pressure relief cap. Fill the radiator with coolant if needed.
3. Fit the Radiator Tester to the radiator fill neck.
4. NOTICE: Do not pressurize the cooling system beyond the maximum pressure listed in the
specifications table in this section, or cooling system components can be damaged.
NOTE: If the plunger of the pressure tester is pressed too fast, an erroneous pressure reading
results.
Slowly press the plunger of the pressure test pump to the maximum allowed pressure and hold for 2
minutes. If the pressure drops within this time, inspect for leaks and repair as necessary.
5. If no leaks are found and the pressure drops, the leak may be internal to the radiator transmission
cooler. Inspect the coolant for transmission fluid and the transmission fluid for coolant. Repair as
necessary.
6. If there is no contamination of the coolant or transmission fluid, the leak may be internal to the engine.
Inspect the coolant for engine oil and the engine oil for coolant. Refer to Section 303-00 to diagnose
the engine.
Pressure Relief Cap Pressure Test
1. Inspect the pressure relief cap and seals for damage or deterioration. Install a new pressure relief cap
if necessary.
2. Using the correct adapter, fit the pressure relief cap to the Radiator Tester.
3. NOTE: If the plunger of the pressure tester is pressed to fast, an incorrect pressure reading results.
Slowly press the plunger of the pressure test pump until the pressure gauge stops increasing and
note the highest pressure reading. Release the pressure and repeat the test. Install a new pressure
relief cap if the pressure is not within the pressure listed in the Specifications table in this section.
Thermostat
A new thermostat should be installed only after the following tests and checks have been carried out:
z Pinpoint Test B or C
z Thermostat Visual Inspection
Thermostat Visual Inspection
1. Remove the thermostat.
2. Examine the thermostat for signs of damage including:

z Valve not fully seated (light visible through the valve)
z Foreign material lodged in the main valve
z Bent or broken frame or flange
z Bent or broken spring
z Bent or broken valve or valve stem
z Wax leaking from wax reservoir or a bulge in the reservoir
z Any other damage or distortion
3. NOTE: If no damage is found during the inspection, do not attempt to open the thermostat using hot
water or other heat sources. This method is not an accurate means to test the function of the
thermostat and may damage the thermostat.
If damage is found during the inspection, remove any foreign material or broken pieces and install a
new thermostat.
Radiator Leak Test, Removed From Vehicle
NOTICE: Never leak test an aluminum radiator in the same water that copper/brass radiators are
tested in. Flux and caustic cleaners may be present in the cleaning tank and they will damage
aluminum radiators.
NOTE: Always install plugs in the transmission fluid cooler fittings before leak testing or cleaning any
radiator.
NOTE: Clean the radiator before leak testing to avoid contamination of tank.
Leak test the radiator in clean water with air pressurized to the maximum pressure listed in the
Specifications.

Cooling System Draining, Filling and Bleeding
Special Tool(s)
Air Lift Cooling System Tester
UVU550000 or equivalent
Material
Item Specification
Antifreeze/Coolant Prediluted D2
VC-3DIL-B (US); CVC-3DIL-B
(Canada)
Draining
NOTICE: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is
contaminated it must be recycled or disposed of correctly. Failure to follow these instructions may
result in engine or cooling system damage.
NOTE: Less than 80% of the coolant capacity can be recovered with the engine in the vehicle. Dirty, rusty or
contaminated coolant requires replacement.
NOTE: During normal vehicle operation, Motorcraft Orange Antifreeze/Coolant may change color from
02 .
2. Make sure the engine is cool.
3. Wrap a thick cloth around the pressure relief cap. Slowly turn the cap counterclockwise until the
pressure begins to release.
4. Step back while the pressure releases.
5. When sure all the pressure has been released, use the cloth to turn and remove the cap.
6. Place a suitable container below the radiator draincock. Drain the coolant.
z Tighten the radiator draincock when finished.
Filling and Bleeding with a Vacuum Cooling System Filler - Degas Bottle Systems
NOTICE: The engine cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Always fill
NOTICE: Engine coolant provides boil protection, corrosion protection, freeze protection, and
cooling efficiency to the engine and cooling components. In order to obtain these protections,
maintain the engine coolant at the correct concentration and fluid level in the degas bottle.
z Add Motorcraft® Orange Antifreeze/Coolant or equivalent. Do not mix coolant types.

z Do not add or mix with any other type of engine coolant. Mixing coolants may degrade the
coolant's corrosion protection.
z Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol
z Ford Motor Company does NOT recommend the use of recycled engine coolant in vehicles
originally equipped with Motorcraft® Orange Antifreeze/Coolant since a Ford-approved
recycling process is not yet available.
1. Install the vacuum cooling system filler and follow the manufacturer's instructions to fill and bleed the
cooling system.
When adding or topping of the engine coolant:
1. Measure the coolant concentration in the vehicle using the Coolant/Battery Refractometer 300-
ROB75240 or equivalent.
2. Determine the concentration desired based on the vehicle duty cycle of extreme hot or cold
operating conditions.
3. Add/top off or adjust coolant as follows:
For concentrations measured 48/52 to 50/50 (equates to a freeze point between -31°C
[-30°F] and -34°C [-37°F]), use Motorcraft® Orange Antifreeze/Coolant Prediluted to
maintain a coolant concentration in this same range.
For all other concentrations, use Motorcraft® Orange Antifreeze/Coolant Concentrated
and/or distilled water to get to the desired concentration.
When refilling the engine coolant after a flush procedure, use a mixture of Motorcraft®
Orange Antifreeze/Coolant Concentrated and distilled water to get to the desired
concentration.
4. Recommended coolant concentration is 48/52 to 50/50 engine coolant to distilled water (freeze
protection -31°C [-30°F] to -34°C [-37°F]).
5. For extremely cold climates (less than -37°C [-34°F]):
It may be necessary to increase the coolant concentration above 50%.
NEVER increase the coolant concentration above 60%.
A coolant concentration of 60% provides freeze point protection down to -50°C (-58°F).
Engine coolant concentration above 60% decreases the overheat protection
characteristics of the engine coolant and may damage the engine.
6. For extremely hot climates:
It is still necessary to maintain the coolant concentration above 40%.
NEVER decrease the coolant concentration below 40%.
Engine coolant concentration below 40% decreases the corrosion and freeze protection
7. Vehicles driven year-round in non-extreme climates should use a 48/52 to 50/50 mixture of
engine coolant and distilled water (freeze protection -31°C [-30°F] to -34°C [-37°F]) for
optimum cooling system and engine protection.
Filling and Bleeding without a Vacuum Cooling System Filler - Degas Bottle Systems
NOTICE: The engine cooling system is filled with Motorcraft® Orange Antifreeze/Coolant. Always fill
NOTICE: Engine coolant provides boil protection, corrosion protection, freeze protection and
cooling efficiency to the engine and cooling components. In order to obtain these protections,
maintain the engine coolant at the correct concentration and fluid level in the degas bottle.

z Do not add alcohol, methanol, or brine, or any engine coolants mixed with alcohol or methanol
1. Fill the radiator through the degas bottle until the coolant level is between the COOLANT FILL LEVEL
marks.
concentration.
2. Select the maximum heater temperature and blower motor speed settings. Position the control to
discharge air at A/C vents in instrument panel.
3. Start the engine and allow to idle. While engine is idling, feel for hot air at A/C vents.
4. NOTICE: If the air discharge remains cool and the Engine Coolant Temperature (ECT) gauge
does not move, the engine coolant level is low and must be filled. Stop the engine, allow the
engine to cool and fill cooling system. Failure to follow these instructions may result in
damage to the engine.
Start the engine and allow it to idle until normal operating temperature is reached. Hot air should
discharge from A/C vents. The Engine Coolant Temperature (ECT) gauge should maintain a
stabilized reading in the middle of the NORMAL range. The upper radiator hose should feel hot to the
touch.
5. Shut the engine off and allow the engine to cool.
6. Check the engine coolant level in the degas bottle and fill as necessary.
7. Repeat the previous 4 steps as necessary.
Filling and Bleeding with a Vacuum Cooling System Filler - Coolant Expansion Tank System
NOTICE: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion
protection to the engine and cooling components. In order to obtain these protections, the engine
coolant must be maintained at the correct concentration and fluid level. Failure to follow these
instructions may damage the engine or cooling system.

z Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol
1. Connect the vacuum cooling system filler and the appropriate rubber adapter to the radiator.
2. Clamp the radiator-to-coolant expansion tank hose near the radiator.
3. Follow the vacuum cooling system filler manufacturer's instructions to fill and bleed the cooling
system.
concentration.
Filling and Bleeding without a Vacuum Cooling System Filler - Coolant Expansion Tank Systems
NOTICE: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion
protection to the engine and cooling components. In order to obtain these protections, the engine
coolant must be maintained at the correct concentration and fluid level. Failure to follow these
instructions may damage the engine or cooling system.

z Do not add alcohol, methanol or brine, or any engine coolants mixed with alcohol or methanol
Vehicles equipped with a 6.2L engine
1. NOTE: For coolant flow diagrams, refer to Engine Cooling in Description and Operation in this
section.
Release the clamp and disconnect the heater inlet hose from the heater inlet tube.
2. Fill the radiator through the radiator fill neck until engine coolant flows from the heater inlet tube.
concentration.
3. Connect the heater inlet hose to the heater inlet tube and position the clamp.
All vehicles
4. Fill the radiator through the radiator fill neck until the coolant level is at the bottom of the filler neck.
concentration.
5. Install the radiator cap.
6. Fill the coolant expansion tank until the coolant reaches the COLD FILL mark.
7. Select the maximum heater temperature and blower motor speed settings. Position the control to
discharge air at A/C vents in instrument panel.
8. NOTICE: If the air discharge remains cool and the engine coolant temperature gauge does not
move, the engine coolant level is low in the engine and must be filled. Stop the engine, allow it
to cool and fill the cooling system. Failure to follow this instruction may result in damage to
the engine.
Run the engine at idle until it reaches normal operating temperature.
9. Turn the engine off and allow it to cool.
10. Add the correct coolant mixture to the coolant expansion tank until the coolant level is at the COLD
FILL mark.
11. Start the engine and allow it to idle until it reaches normal operating temperature. While the engine is
idling, feel for hot air from the A/C vents.
z Hot air should discharge from the A/C vents. The engine coolant temperature gauge should
maintain a stabilized reading in the middle of the NORMAL range and the upper radiator hose
should feel hot to the touch.
12. Check the engine coolant level in the coolant expansion tank and fill it as necessary.
13. Repeat the previous 5 steps as necessary.

Cooling System Flushing
Material
Item Specification
Motorcraft® Premium Cooling ESR-M14P7-
System Flush A
VC-1
1.
unscrew the coolant pressure relief cap when the engine is operating or the cooling system is
hot. The cooling system is under pressure; steam and hot liquid can come out forcefully when
the cap is loosened slightly. Failure to follow these instructions may result in serious personal
injury.
Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling
and Bleeding in this section.
2. Remove the thermostat. For additional information, refer to Thermostat — 3.5L GTDI , Thermostat —
3.7L , Thermostat — 5.0L or Thermostat — 6.2L in this section.
3. Install the coolant inlet connection (3.5L GTDI, 3.7L or 5.0L engines) or the coolant outlet connection
(6.2L engines) without the thermostat.
4. NOTE: Refer to the cooling system flusher manufacturer's operating instructions for specific vehicle
hook-up.
Use a cooling system flusher to flush the engine and radiator.

z Use Motorcraft® Premium Cooling System Flush and follow the directions on the packaging.
5. Install the thermostat. For additional information, refer to Thermostat — 3.5L GTDI , Thermostat —
3.7L , Thermostat — 5.0L or Thermostat — 6.2L in this section.
6. Fill and bleed the cooling system. For additional information, refer to Cooling System Draining, Filling

Block Heater
3.5L Gasoline Turbocharged Direct Injection (GTDI) and 3.7L Engines

1 — Block heater electrical connector (part of 6B018)
2 W503277 Block heater bolt - 6 Nm (53 lb-in)
3 6A051 Block heater
5.0L Engine

2 6A051 Block heater - 40 Nm (30 lb-ft).
6.2L Engine

2 6A051 Block heater - 40 Nm (30 lb-ft).
5.0L and 6.2L engines
1. Drain the engine cooling system. For additional information, refer to Cooling System Draining, Filling
3.5L Gasoline Turbocharged Direct Injection (GTDI) and 3.7L engines
2. Remove the air cleaner outlet pipe. For additional information, refer to Section 303-12 .
All engines
3. NOTICE: To install, route the block heater power cable away from hot or rotating components,
or the cable can be damaged.
Disconnect the block heater electrical connector.
3.5L GTDI and 3.7L engines
4. Remove the bolt and the block heater.

5. Remove the block heater.

All engines

Coolant Crossover Manifold Assembly — 3.5L GTDI
Part
1 W527362 Heater hose clamp
2 18472 Heater hose
3 W714988 Intake manifold bolt
4 W503279 Coolant crossover manifold assembly bolt (3
required)
5 8C368 Coolant crossover manifold assembly
6 9439 Coolant crossover manifold assembly gasket (2
required)
Removal
1. Drain the cooling system. For additional information, refer to Cooling System Draining, Filling and
2. Release the clamp and disconnect the heater hose from the coolant crossover manifold assembly.
3. Remove the LH rear intake manifold bolt.
4. Remove the 3 bolts and the coolant crossover manifold assembly.
Installation
1. Install new gaskets, position the coolant crossover manifold assembly and install the bolts finger tight.
2. Tighten the bolts in 2 stages.

3. Install the LH rear intake manifold bolt.

4. Connect the heater hose and position the clamp.

Coolant Expansion Tank — 6.2L
Material
Item Specification
Part
1 8N029 Coolant overflow hose
2 8A080 Coolant expansion tank/lower Air Cleaner (ACL)
housing assembly
3 W701835 Coolant expansion tank bolts (2 required)
1. NOTICE: Allow the engine to cool before removing the coolant expansion tank. The radiator
draws coolant from the coolant expansion tank as the engine cools. If the coolant expansion
tank is removed before the engine cools, the radiator will draw air into the system, resulting in
possible engine damage.
NOTE: During normal vehicle operation, Motorcraft® Specialty Orange Engine Coolant may change
color from orange to pink or light red. As long as the engine coolant is clear and uncontaminated, this
color change does not indicate the engine coolant has degraded nor does it require the engine
coolant to be drained, the system to be flushed, or the engine coolant to be replaced.
Using a suitable suction device, siphon the coolant from the coolant expansion tank.
2. Remove the Air Cleaner (ACL) element. For additional information, refer to Section 303-12 .
3. Disconnect the coolant overflow hose from the radiator.
4. Remove the 2 bolts and the coolant expansion tank/lower ACL housing assembly.

z Fill the coolant expansion tank with a 50/50 mixture of coolant and distilled water.

Coolant Inlet Pipe — 3.5L GTDI
Material
Item Specification
NOTE: Intake manifold removed for clarity.

1 8A505 Coolant inlet pipe
2 8527 Coolant inlet pipe O-ring seal
1. Remove the thermostat housing. For additional information, refer to Thermostat Housing — 3.5L
GTDI in this section.
2. Remove the cooling fan motor and shroud. For additional information, refer to Cooling Fan Motor and
Shroud .

z Install a new O-ring seal and lubricate it with clean engine coolant.

Coolant Pump — 3.5L GTDI, 3.7L
Material
Item Specification
Part
1 W503291 Coolant pump pulley bolt - 25 Nm (18 lb-ft) (4
required)
3 W503278 Coolant pump bolt (7 required)
4 8501 Coolant pump
5 8507 Coolant pump gasket (part of 8501)
6 8565 Coolant pump O-ring seal (part of 8501)
Removal
3. Remove the accessory drive belt. For additional information, refer to Section 303-05 .
4. NOTICE: Cover the A/C compressor belt to prevent coolant contamination of the belt.
Completely cover the A/C compressor belt with waterproof plastic.
5. Remove the thermostat housing. For additional information, refer to Thermostat Housing — 3.5L
GTDI or Thermostat Housing — 3.7L in this section.

z Remove and discard the gasket and the O-ring seal in the coolant pump.
Installation
1. Install a new O-ring seal in the coolant pump and lubricate it with clean engine coolant.
2. Position a new gasket, press the coolant pump over the channel cover plate snout protruding from the
engine front cover and install the 7 bolts finger tight.
3. Tighten the coolant pump bolts in the sequence shown in 2 stages.

4. Position the coolant pump pulley and install the 4 bolts finger tight.
5. Install the thermostat housing. For additional information, refer to Thermostat Housing — 3.5L GTDI
or Thermostat Housing — 3.7L in this section.
6. Remove the plastic from the A/C compressor belt.
7. Install the accessory drive belt. For additional information, refer to Section 303-05 .

9. Install the air cleaner outlet pipe. For additional information, refer to Section 303-12 .

Coolant Pump — 5.0L
Material
Item Specification
ZC-31-A

2 — Degas bottle-to-engine hose clamp (part of 8C350)
3 8C350 Degas bottle-to-engine hose
6 W503277 Heater outlet tube bolt - 10 Nm (89 lb-in)
8 8565 Heater outlet tube O-ring seal

Removal
All vehicles
Vehicles with an A/C compressor belt tensionser
5. NOTICE: Remove the A/C compressor belt to prevent coolant contamination of the belt.
Remove the A/C compressor belt.
Vehicles without an A/C compressor belt tensioner
All vehicles
7. Remove the thermostat housing. For additional information, refer to Thermostat Housing — 5.0L in
this section.
8. Remove the bolts and the coolant pump pulley.
9. Disconnect the heater outlet hose from the heater outlet tube.
10. Release the clamp and disconnect the degas bottle-to-engine hose from the heater outlet tube.
12. If a new coolant pump is being installed, remove the bolt and the heater outlet tube.
Installation
All vehicles
1. If a new coolant pump is being installed, install a new O-ring seal on the heater outlet tube and
lubricate it with clean engine coolant.
2. Install the heater outlet tube and the bolt.
3. Inspect the sealing surfaces and clean with metal surface prep. Follow the directions on the
packaging.
4. NOTICE: Align the bolt holes with the bosses prior to insertion of the coolant pump and insert
the pump straight into the coolant pump cavity. Do not rotate the coolant pump once installed
in the coolant pump cavity or the O-ring seal can be damaged, causing the coolant pump to
leak.
NOTE: Install a new O-ring seal and lubricate it with clean engine coolant.
Install the coolant pump and the bolts

z Tighten the coolant pump bolts in 2 stages.
5. Connect the degas bottle-to-engine hose to the heater outlet tube and position the clamp.
6. Connect the heater outlet hose to the heater outlet tube.
7. Position the coolant pump pulley and install the bolts finger tight.
8. Install the thermostat housing. For additional information, refer to Thermostat Housing — 5.0L in this
section.
Vehicles with an A/C compressor belt tensioner
z Rinse off any coolant from the accessory drive pulleys using clear water prior to belt
installation.
All vehicles
installation.
12. Tighten the coolant pump pulley bolts in a criss-cross pattern.

13. Install the air cleaner outlet tube. For additional information, refer to Section 303-12 .

Coolant Pump — 5.0L
Material
Item Specification
ZC-31-A

2 — Degas bottle-to-engine hose clamp (part of 8C350)
3 8C350 Degas bottle-to-engine hose
6 W503277 Heater outlet tube bolt - 10 Nm (89 lb-in)
8 8565 Heater outlet tube O-ring seal

Removal
All vehicles
Vehicles with an A/C compressor belt tensionser
5. NOTICE: Remove the A/C compressor belt to prevent coolant contamination of the belt.
Remove the A/C compressor belt.
All vehicles
7. Remove the thermostat housing. For additional information, refer to Thermostat Housing — 5.0L in
this section.
8. Remove the bolts and the coolant pump pulley.
9. Disconnect the heater outlet hose from the heater outlet tube.
10. Release the clamp and disconnect the degas bottle-to-engine hose from the heater outlet tube.
12. If a new coolant pump is being installed, remove the bolt and the heater outlet tube.
Installation
All vehicles
1. If a new coolant pump is being installed, install a new O-ring seal on the heater outlet tube and
lubricate it with clean engine coolant.
2. Install the heater outlet tube and the bolt.
3. Inspect the sealing surfaces and clean with metal surface prep. Follow the directions on the
packaging.
4. NOTICE: Align the bolt holes with the bosses prior to insertion of the coolant pump and insert
the pump straight into the coolant pump cavity. Do not rotate the coolant pump once installed
in the coolant pump cavity or the O-ring seal can be damaged, causing the coolant pump to
leak.
NOTE: Install a new O-ring seal and lubricate it with clean engine coolant.
Install the coolant pump and the bolts

z Tighten the coolant pump bolts in 2 stages.
5. Connect the degas bottle-to-engine hose to the heater outlet tube and position the clamp.
6. Connect the heater outlet hose to the heater outlet tube.
7. Position the coolant pump pulley and install the bolts finger tight.
8. Install the thermostat housing. For additional information, refer to Thermostat Housing — 5.0L in this
section.
Vehicles with an A/C compressor belt tensioner
installation.
All vehicles
installation.
12. Tighten the coolant pump pulley bolts in a criss-cross pattern.

13. Install the air cleaner outlet tube. For additional information, refer to Section 303-12 .

Cooling Fan Motor and Shroud
Wiring Harness and Power Steering Fluid Reservoir - 6.2L Engine
Part
1 — Generator battery positive cable retainer (part of
14305)
2 W711851 Battery Junction Box (BJB) bracket bolt (4 required)
3 14A65 BJB bracket
5 W710897 Power steering fluid reservoir stud bolt (6.2L engine
only)
6 3E764 Power steering fluid reservoir (6.2L engine only)
7 — Power steering fluid cooler hose retainer (part of
3A713) (6.2L engine only)
3.5L Gasoline Turbocharged Direct Injection (GTDI), 3.7L and 5.0L Engines

1 — Battery positive cable retainer (part of 14305)
2 W711851 Battery Junction Box (BJB) bracket bolt (4 required)
3 14A65 BJB bracket

Wiring Harness and Radiator Hose Retainers

2 8W287 Upper radiator hose retainer (6.2L only)
3 — Wiring harness retainer (part of 12A581) (3 required)
Part
1 — Cooling fan wiring harness retainer (part of 12A581)
(3 required)
2 — Cooling fan electrical connector (part of 12A581) (2
required)
3 W503924 Cooling fan motor and shroud bolt (2 required)
4 8600 Cooling fan motor and shroud
All engines
1. Disconnect the battery negative cable. For additional information, refer to Section 414-01 .
2. Remove the Air Cleaner (ACL) outlet tube. For additional information, refer to Section 303-12 .
6.2L engines
5. Remove the 2 bolts and position the coolant expansion tank aside.
6. Detach the power steering fluid cooler hose retainer from the cooling fan motor and shroud.
7. Detach the wiring harness retainer from the power steering fluid reservoir stud bolt.
8. Remove the nut, detach the generator battery positive cable from the positive battery terminal, detach
the 3 wiring harness retainers from the cooling fan shroud and position the wiring harness aside.
9. Detach the upper radiator hose retainer from the cooling fan motor and shroud.
3.5L Gasoline Turbocharged Direct Injection (GTDI), 3.7L and 5.0L engines
10. Detach the wiring harness retainer from the stud bolt on the LH side of the cooling fan shroud.
11. Disconnect the positive battery cable. For additional information, refer to Section 414-01 .
12. Detach the battery cable retainer from the cooling fan shroud.
All engines
13. NOTE: Push the 2 LH wiring harness retainer tabs outward to release.
Detach the LH wiring harness retainer and the 3 RH wiring harness pushpins.
14. Disconnect the 2 cooling fan electrical connectors.
15. Detach the 3 cooling fan wiring harness retainers.
16. Remove the 4 Battery Junction Box (BJB) bracket bolts.

3.5L GTDI , 3.7L and 5.0L Engines
17. Position the wiring harness aside.
6.2L engines
18. Remove the power steering fluid reservoir stud bolt and position the power steering fluid reservoir and
the wiring harness aside.
All engines
19. Remove the 2 bolts and the cooling fan motor and shroud.

Cooling Module
Special Tool(s)
Disconnect Tool, Transmission
Cooler Line
307-569
Hood Latch, Transmission Cooler Tubes, Power Steering Cooler Tubes (6.2L) and Cooling Module
Bolts
Part
1 16B975 Hood latch assembly cable retainer
2 W711848 Hood latch assembly bolts (2 required)

3 6100 Hood latch assembly
4 7J801 Transmission fluid cooler tube secondary latch (2
required) (6.2L shown, 3.5L Gasoline Turbocharged
Direct Injection (GTDI), 3.7L and 5.0L similar)
5 7H420 Transmission fluid cooler tube (2 required) (6.2L shown,
3.5L GTDI , 3.7L and 5.0L similar)
6 — Power steering fluid cooler hose clamp (2 required)
(6.2L only)
7 3A713 Power steering gear-to-fluid cooler return hose (6.2L
only)
8 W701835 Cooling module upper bolt (2 required)
9 W701835 Cooling module front bolt (4 required)
Wiring Harness and Power Steering Fluid Reservoir - 6.2L
Part
1 — Generator battery positive cable retainer (part of
14305)
2 — Battery Junction Box (BJB) (part of 12A581)
4 W710897 Power steering fluid reservoir stud bolt (6.2L only)
5 3E764 Power steering fluid reservoir (6.2L only)
6 — Power steering fluid cooler hose retainer (part of
3A713) (6.2L only)
Wiring Harness - 3.5L Gasoline Turbocharged Direct Injection (GTDI), 3.7L and 5.0L

1 — Battery positive cable retainer (part of 14305)
2 — Battery Junction Box (BJB) (part of 12A581)
Wiring Harness and Radiator Hose Retainers

2 8W287 Upper radiator hose retainer (6.2L only)
3 — Wiring harness retainer (part of 12A581) (3 required)
Cooling Fan Wiring
Part
1 — Cooling fan electrical connector (part of 12A581) (2
required)
2 — Cooling fan wiring harness retainer (part of 12A581)
(3 required)
A/C Fittings

1 W500110 Condenser inlet fitting bolt
2 W520413 Condenser outlet fitting nut
3 19E558 Condenser inlet jumper line fitting
4 — Condenser outlet fitting (part of 19A834)
5 19B596 O-ring seal and gasket seal kit (2 required)
Radiator Hoses - 3.5L Gasoline Turbocharged Direct Injection (GTDI), 3.7L and 5.0L

1 15161 Radiator-to-degas bottle hose clamp
2 8W005 Radiator-to-degas bottle hose
3 15161 Upper radiator hose clamp
5 8D037 Lower radiator hose spring clip
6 8286 Lower radiator hose
7 8D038 Lower radiator hose O-ring seal
Radiator Hoses - 6.2L

2 8B274 Upper radiator hose
3 8B273 Lower radiator hose
4 8B365 Lower radiator hose spring clip
Removal
All engines
02 .
3. Evacuate the A/C system. For additional information, refer to Section 412-00 .
4. Disconnect the battery ground. For additional information, refer to Section 414-01 .
5. Remove the headlights. For additional information, refer to Section 417-01 .
6. Detach the LH hood latch cable retainer.
7. Detach the 2 RH hood latch cable retainers.
8. Remove the bolts and position the hood latch aside.
9. Remove the bolt, detach the hood latch release handle and the cable from the front bumper cover,
and position the hood latch release handle aside.
If equipped, remove the 4 LH and 4 RH front wheel moulding pushpins.
If equipped, remove the 2 LH and 2 RH front wheel moulding nuts and detach the front wheel
mouldings far enough to remove the front bumper cover.
Remove the 3 LH and 3 RH bumper cover-to-fender bolts.
13. Remove the 6 bumper cover bracket bolts and remove the bumper cover and the brackets as an
assembly.
14. Disconnect the horn electrical connector and detach the wiring harness and ambient temperature
sensor retainers. Position the wiring harness aside.
15. Detach the wiring harness retainer from the RH side of the radiator grille support.
Disconnect the RH and LH front impact severity sensor electrical connectors and 2 wiring harness
retainers. Position the wiring harnesses aside.
17. Release the clamp and disconnect the upper radiator hose from the radiator.
6.2L engines
20. Detach the upper radiator hose retainer from the cooling fan motor and shroud.
21. Remove the nut, detach the generator battery positive cable, detach the 3 wiring harness retainers
from the cooling fan shroud and position the wiring harness aside.
3.5L GTDI , 3.7L and 5.0L engines
23. Detach the wiring harness retainer from the stud bolt on the LH side of the cooling fan shroud.
24. Disconnect the positive battery cable. For additional information, refer to Section 414-01 .
25. Detach the battery cable retainer from the cooling fan shroud.
6.2L engines
26. Detach the power steering fluid cooler hose retainer and position the hose aside.
27. Syphon the power steering fluid from the power steering reservoir, release the clamp and disconnect
the power steering fluid cooler return hose on top of the radiator.
28. Detach the wiring harness retainer from the power steering fluid reservoir stud bolt.
29. Remove the power steering fluid reservoir stud bolt and position aside the reservoir.
All engines
30. If equipped, cut the block heater tie strap.
31. Remove the bolt and nut, and disconnect the A/C tube fittings from the A/C condenser.
z Discard the O-ring seals and gaskets.
32. Disconnect the 2 cooling fan electrical connectors and detach the 3 cooling fan wiring harness
retainers.
33. Release the 4 Battery Junction Box (BJB) retaining tabs and detach the BJB from the bracket.
34. NOTE: Push the 2 LH wiring harness retainer tabs outward to release.
Detach the LH wiring harness retainer and the 3 RH wiring harness pushpins and position the BJB ,
the wiring harness.
35. Release the clamp and disconnect the radiator-to-degas bottle hose from the radiator.
36. NOTE: The quick connect coupling illustrated is to show the spring clip release location only. The
quick connect coupling on the hose may differ.
Pull the lower radiator hose spring clip up until the end of the clip is in the detent on the quick connect
coupling and disconnect the lower radiator hose from the radiator.
6.2L engines
37. Remove the spring clip and disconnect the lower radiator hose from the radiator.
38. Disconnect the radiator overflow hose from the radiator.
39. Remove the 3 front air deflector-to-bumper pushpins.
All engines
40. Remove the 2 RH air deflector-to-frame rail pushpins.
3.5L GTDI engines
41. Turn the 4 quarter-turn retainers, detach the 8 pushpins and remove the lower air deflector.
42. Remove the 2 air dam bolts and the air dam.
43. Remove the 3 front air deflector-to-bumper pushpins.
All engines
44. Remove the 2 transmission cooler tube latch assemblies.
45. NOTE: 6.2L shown, 3.5L GTDI , 3.7L and 5.0L similar.
Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes.
46. For vehicles without an auxiliary transmission fluid cooler, remove the transmission cooler tube
bracket bolt and detach the transmission cooler tube retainer from the crossmember.
47. For vehicles with an auxiliary transmission fluid cooler, remove the transmission cooler tube bracket
bolt and detach the 2 transmission cooler tube retainers from the crossmember.
6.2L engines
48. Disconnect the power steering cooler-to-power steering fluid reservoir hose from the power steering
fluid reservoir.
All engines
49. Remove the 6 cooling module bolts.
50. Remove the cooling module.
Installation
All engines
1. Position the cooling module into the vehicle.
2. Install the 6 cooling module bolts.

6.2L engines
3. Connect the power steering cooler-to-power steering fluid reservoir hose at the power steering
reservoir.
4. For vehicles with an auxiliary transmission fluid cooler, attach the 2 transmission cooler tube retainers
and install the transmission cooler tube bracket bolt.
5. For vehicles without an auxiliary transmission fluid cooler, attach the transmission cooler tube retainer
and install the transmission cooler tube bracket bolt.
All vehicles
6. Connect the transmission cooler tubes.
7. Install the transmission cooler tube latch assemblies.
8. Install the 3 air deflector-to-front bumper pushpins.
9. Position the air dam and install the 2 bolts.

3.5L GTDI engines
10. Position the lower air deflector, attach the 8 pushpins and turn the 4 quarter-turn retainers.
6.2L engines
11. Install the 3 front air deflector-to-bumper pushpins.
All engines
12. Install the 2 RH air deflector-to-frame rail pushpins.
13. Push the spring clip in place and connect the lower radiator hose quick connect coupling to the
radiator, making sure the coupling is secure.
14. Connect the radiator-to-degas bottle hose to the radiator and position the clamp.
6.2L engines
15. Connect the radiator overflow hose to the radiator.
16. Connect the lower radiator hose to the radiator and install the spring clip.
All engines
17. Position the BJB and wiring harness into place, connect the BJB retaining tabs, and attach the LH
wiring harness retainer and the 3 RH wiring harness pushpins.
18. Attach the 3 cooling fan wiring harness retainers and connect the 2 cooling fan electrical connectors.
19. Install new O-ring seals and gaskets on the A/C condenser fittings.
20. Connect the A/C fittings to the A/C condenser and install the bolt and the nut.
21. If equipped, install a new block heater tie strap.
22. Attach the wiring harness retainer to the stud bolt on the LH side of the cooling fan shroud.
23. Connect the battery positive cable. For additional information, refer to Section 414-01 .
24. Attach the battery cable retainer to the cooling fan shroud.
25. Install the upper radiator air deflector and install the 4 pushpins.
6.2L engines
26. Position the power steering fluid reservoir and install the stud bolt.
27. Attach the wiring harness retainer to the power steering fluid reservoir stud bolt.
28. Connect the power steering fluid cooler return hose on top of the radiator.
29. Connect the power steering fluid cooler hose retainer.
30. Position the wiring harness, attach the 3 wiring harness retainers to the cooling fan shroud, attach the
generator battery positive cable and install the nut.
31. Attach the upper radiator hose retainer to the cooling fan motor and shroud.
All engines
32. Connect the MAF sensor electrical connector.
33. Install the ACL outlet tube. For additional information, refer to Section 303-12 .
34. Connect the upper radiator hose to the radiator and install the clamp.
Position the wiring harness into place and connect the RH and LH front impact severity sensor
electrical connectors and wiring harness pushpin retainers.
36. Attach the wiring harness retainer to the RH side of the radiator grille support.
37. Position the wiring harness into place and connect the horn and ambient temperature sensor
electrical connectors and attach the pushpin retainer.
38. Position the front bumper cover and the brackets as an assembly and install the 6 bumper cover
bracket bolts.
Install the 3 LH and 3 RH bumper cover-to-fender bolts.

If equipped, attach the front wheel mouldings and install the 2 LH and 2 RH nuts.
If equipped, install the 4 LH and 4 RH front wheel moulding pushpins.
42. Position and attach the hood latch release handle and cable onto the front bumper cover and install
the bolt.
43. Position the hood latch into place and install the 2 bolts.
44. Attach the 2 RH hood latch cable pushpin retainers.
45. Attach the LH hood latch cable pushpin retainers.
46. Install the headlights. For additional information, refer to Section 417-01 .
48. Fill the cooling system. For additional information, refer to Cooling System Draining, Filling and
49. Recharge the A/C system. For additional information, refer to Section 412-00 .
50. If equipped, fill the power steering system. For additional information, refer to Section 211-00B .
51. Check the transmission fluid and fill as necessary. For additional information, refer to Section 307-01 .

Degas Bottle — 3.5L GTDI, 3.7L, 5.0L
Material
Item Specification
Part
1 — Radiator-to-degas bottle hose clamp (part of 8075)
3 8101 Pressure relief cap
4 W707108 Degas bottle/lower air cleaner tray bolts - 17 Nm (150
lb-in) (2 required)
5 — Thermostat housing-to-degas bottle hose clamp (part
of 8276)
7 18472 Heater outlet hose (3.5L Gasoline Turbocharged Direct
Injection (GTDI) and 3.7L engines)
7 8C350 Degas bottle-to-heater outlet tube hose (5.0L engines)
8 8A080 Degas bottle/lower air cleaner tray assembly
1.
injury.
NOTE: During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may change
Release the pressure in the cooling system by slowly turning the pressure relief cap one half turn
counterclockwise. When the pressure is released, remove the pressure relief cap.
2. Using hose pinch pliers, clamp the heater outlet hose near the degas bottle.
3. Using a suitable suction device, siphon the coolant from the degas bottle.
4. Release the clamp and disconnect the radiator-to-degas bottle from the radiator.
5. Release the clamp and disconnect the thermostat housing-to-degas bottle hose from the degas
bottle.
6. Remove the spring clip and disconnect the heater outlet hose (3.5L GTDI or 3.7L engines) or the
degas bottle-to-heater outlet tube hose (5.0L engines) from the degas bottle.
7. Remove the 2 bolts and the degas bottle/lower air cleaner tray assembly.
9. Fill the degas bottle with a 50/50 mixture of coolant and distilled water.

Radiator Hose
3.5L GTDI and 3.7L Engines

1 — Upper radiator hose clamp (2 required) (part of 8260)
3 — Oil cooler hose clamp (2 required) (part of 8286)
4 — Lower radiator hose clamp (part of 8286)
5.0L Engine

3 — Oil cooler hose clamp (2 required) (part of 8286)
6.2L Engine

2 8W287 Upper radiator hose retainer (part of 8286)
For 3.5L GTDI, 3.7L and 5.0L engines, completely cover the accessory drive belts with waterproof
plastic.
For radiator hose quick connect couplings, pull the radiator hose spring clip up until the end of the clip
is in the detent on the quick connect coupling and disconnect the radiator hose.
z To install, push the spring clip in place and connect the radiator hose quick connect coupling,
making sure the coupling is secure.

Radiator
Special Tool(s)
Cooler Line
307-569
Material
Item Specification
MERCON® V Automatic MERCON® V
Transmission Fluid
XT-5-QM (or XT-5-QMC) (US); CXT-
5-LM12 (Canada)
A/C Condenser Fittings
1 W500110 Condenser inlet fitting bolt

2 W520413 Condenser outlet fitting nut
3 19E558 Condenser inlet jumper line fitting
4 — Condenser outlet fitting (part of 19A834)
5 19B596 O-ring seal and gasket seal kit (2 required)
Radiator Hoses - 3.5L Gasoline Turbocharged Direct Injection (GTDI), 3.7L and 5.0L

1 15161 Radiator-to-degas bottle hose clamp
2 8W005 Radiator-to-degas bottle hose
3 15161 Upper radiator hose clamp
5 8D037 Lower radiator hose spring clip
7 8D038 Lower radiator hose O-ring seal
Radiator Hoses 6.2L

2 8D037 Lower radiator hose spring clip (part of 8286)
Radiator
NOTE: 6.2L shown, 3.5L GTDI GTDI , 3.7L and 5.0L similar.

1 W503924 Radiator bolt (2 required)
2 7F113 Transmission fluid cooler-to-radiator upper hose
3 7B028 Transmission fluid cooler-to-radiator lower hose
4 8005 Radiator
5 8B204 Radiator insulator (2 required)
Removal
All engines
1. Recover the A/C system. For additional information, refer to Section 412-00 .
2. Drain the cooling system.
3. Remove the cooling fan motor and shroud. For additional information, refer to Cooling Fan Motor and
Shroud in this section.
5. Release the clamp and disconnect the radiator-to-degas bottle hose from the radiator.
Pull the lower radiator hose spring clip up until the end of the clip is in the detent on the quick connect
coupling and disconnect the lower radiator hose from the radiator.
8. NOTE: 6.2L shown, 3.5L GTDI , 3.7L and 5.0L similar.
Remove the 2 bolts and position the coolant expansion tank (6.2L) or the degas bottle (3.5L GTDI ,
3.7L and 5.0L) aside.
6.2L engines
10. Disconnect the overflow hose from the radiator.
11. Remove the spring clip and disconnect the lower radiator hose from the radiator.
12. Release the clamp and disconnect the power steering cooler hose from the power steering cooler.
All engines
13. Disconnect the 3 RH and 2 LH air deflector-to-condenser pushpin retainers.
3.5L GTDI engines
14. Turn the 4 quarter-turn retainers, detach the 8 pushpins and remove the lower air deflector.
3.7L, 5.0L and 6.2L engines
15. Remove the 4 lower radiator air deflector-to-A/C condenser pushpins.
All engines
16. Remove the bolt and the nut and disconnect the A/C condenser fittings.
z Discard the gasket seals and the O-ring seals.
17. Remove the transmission cooler tube secondary latches.
18. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes.
19. Detach the wiring harness retainer.
20. NOTE: Hoses with an auxiliary transmission fluid cooler shown, hoses without an auxiliary
transmission fluid cooler similar.
Disconnect the 2 transmission fluid cooler hoses from the radiator.
21. If equipped, detach the auxiliary transmission fluid cooler from the A/C condenser and position aside.
6.2L engine
22. Using a suction device, syphon the power steering fluid from the power steering fluid reservoir.
23. Release the clamp and disconnect the power steering fluid cooler hose from the power steering fluid
cooler.
All engines
24. Remove the radiator/condenser core as an assembly.
25. Release the lock tabs and separate the radiator from the condenser core.
Installation
All engines
1. Position the condenser core into the radiator locking tabs.
2. Position the radiator/condenser core assembly into the vehicle and onto the radiator insulators.
6.2L engine
3. Connect the power steering cooler hose to the power steering cooler and position the clamp.
All engines
4. Install the 2 radiator bolts.

5. If equipped, attach the auxiliary transmission fluid cooler to the A/C condenser.
All engines
6. Connect the transmission fluid cooler hoses to the radiator.
7. Connect the wiring harness retainer.
8. Connect the transmission fluid cooler tubes.
9. Install the transmission cooler tube secondary latches.
10. Using new gasket seals and O-ring seals, connect the A/C condenser fittings and install the bolt and
nut.
3.5L GTDI engines
11. Position the lower air deflector, attach the 8 pushpins and turn the 4 quarter-turn retainers.
12. Install the 4 lower radiator air deflector-to-condenser pushpins.
All vehicles
13. Connect the 3 RH and 2 LH air deflector-to-condenser pushpin retainers.
14. Install the degas bottle and the 2 bolts.

15. Connect the MAF sensor electrical connector.
16. Push the spring clip in place and connect the lower radiator hose quick connect coupling to the
radiator, making sure the coupling is secure.
17. Connect the radiator-to-degas bottle hose to the radiator and position the clamp.
18. Connect the upper radiator hose to the radiator and position the clamp.
6.2L engines
19. Install lower radiator hose and the spring clip.
20. Connect the radiator overflow hose.
21. Connect the upper radiator hose and position the clamp.
All engines
22. Install the cooling fan motor and shroud. For additional information, refer to Cooling Fan Motor and
Shroud in this section.
6.2L engine
23. Fill the power steering fluid reservoir with MERCON® V.
All engines
24. Fill the cooling system. For additional information, refer to Cooling System Draining, Filling and
25. Recharge the A/C system. For additional information, refer to Section 412-00 .
26. Check the transmission fluid and fill as necessary. For additional information, refer to Section 307-01 .

Thermostat — 3.5L GTDI
Material
Item Specification
Part
3 W500014 Coolant inlet connector bolt - 10 Nm (89 lb-in) (2
required) (part of 8592)
4 — Coolant inlet connector (part of 8592)
5 8255 Thermostat O-ring seal (part of 8592)
4. If installing a new coolant connector, release the clamp and disconnect the lower radiator hose.
5. Remove the bolts and detach the coolant inlet connector.

6. Remove the thermostat and the O-ring seal.


z Install a new O-ring seal and lubricate it with clean engine coolant.

Thermostat — 5.0L
Material
Item Specification
Part
2 15161 Lower radiator hose clamp
3 W500014 Coolant inlet connection bolt (2 required) (part of
8A586)
4 8K528 Coolant inlet connection (part of 8592)
5 8255 Thermostat O-ring seal (part of 8592)
3. NOTICE: Remove the accessory drive belt to prevent coolant contamination of the belt.
Remove the accessory drive belt. For additional information, refer to Section 303-05 .
z To install, rinse off any coolant from the accessory drive pulleys using clear water.
4. NOTICE: Cover the A/C compressor drive belt to prevent coolant contamination of the belt.
Completely cover the A/C compressor drive belt with waterproof plastic.
5. If installing a new coolant inlet connection, release the clamp and disconnect the lower radiator hose.
6. Remove the bolts and the coolant inlet connection.

7. Remove the thermostat and the O-ring seal.


z Use a new O-ring seal and lubricate it with clean engine coolant.

Thermostat — 6.2L
Material
Item Specification
ZC-31-A
Remover
ZC-30

1 W503278 Coolant outlet connection bolt (2 required)
3 N806807 O-ring seal
4 8575 Thermostat
2. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12 .
3. If a new coolant outlet connection is being installed, release the clamp and disconnect the upper
radiator hose.
4. Remove the 2 bolts, the thermostat housing and the thermostat. Discard the O-ring seal.
z Inspect the mating surfaces. Clean the sealing surfaces with metal surface prep and silicone
gasket remover. Follow the directions on the packaging.
z If necessary, install a new thermostat with the spring facing down.
z NOTE: Make sure the thermostat housing is seated evenly by hand tightening the 2 coolant
outlet connection bolts prior to final tightening.
To install, tighten to 10 Nm (89 lb-in).

Thermostat Housing — 3.5L GTDI
Material
Item Specification
Part
1 — Thermostat housing-to-degas bottle hose clamp (part
of 8276)
3 — Upper radiator hose clamp (part of 8260)
5 — Heater outlet hose clamp (part of 18472)
9 W714841 Thermostat housing bolts
11 8527 Coolant inlet tube O-ring seal
12 8590 Thermostat housing inlet gasket (part of 8592)
Removal
2. Remove the Air Cleaner (ACL) outlet pipe, the ACL outlet pipe-to-LH turbocharger pipe and the LH
turbocharger-to-Charge Air Cooler (CAC) pipe. For additional information, refer to Section 303-12 .
4. NOTICE: Install the oil fill cap to prevent debris from falling into the engine.
Remove the oil fill cap and the engine appearance cover.
z Install the oil fill cap.
5. If equipped, disconnect the block heater electrical connector.
6. Remove the bolt and the LH turbocharger-to CAC tube bracket.
7. Release the clamp and disconnect the degas bottle-to-thermostat housing hose from the thermostat
housing.
8. Release the clamp and disconnect the lower radiator hose from the thermostat housing.
9. Release the clamp and disconnect the heater outlet hose from the thermostat housing.
10. Release the clamp and disconnect the upper radiator hose from the thermostat housing.
11. Remove the 4 thermostat housing bolts.
12. NOTICE: Do not allow the coolant inlet pipe to come out of the coolant crossover manifold
assembly or the coolant inlet pipe O-ring seal may be damaged.
NOTE: Use the ear on the top of the coolant inlet pipe to prevent the coolant pipe from coming out of
the coolant crossover manifold assembly.
Remove the thermostat housing.
13. Remove and discard the gasket and the O-ring seal.
Installation
1. Install a new gasket and a new O-ring seal.

z Lubricate the O-ring seal with clean engine coolant.
2. Position the thermostat housing, install the 4 bolts and tighten the 4 bolts in the sequence shown in 2
stages.
3. Connect the upper radiator hose to the thermostat housing and position the clamp.
4. Connect the heater outlet hose to the thermostat housing and position the clamp.
5. Connect the lower radiator hose to the thermostat housing and position the clamp.
6. Connect the degas bottle-to-thermostat housing hose to the thermostat housing and position the
clamp.
7. Install the LH turbocharger-to- CAC tube bracket and the bolt.

8. If equipped, connect the block heater electrical connection.
9. Remove the oil fill cap and install the engine appearance cover.
z Install the oil fill cap.
10. Remove the waterproof plastic from the accessory drive belts.
11. Install the LH turbocharger-to-Charge Air Cooler (CAC) pipe, the ACL outlet pipe-to-LH turbocharger
pipe and the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .
12. Fill and bleed the engine cooling system. For additional information, refer to Cooling System Draining,
Filling and Bleeding in this section.

Thermostat Housing — 5.0L
Part
1 8B365 Upper radiator hose spring clip (part of 8260)
3 8590 Upper radiator hose O-ring seal (part of 8260)
4 8B365 Upper radiator hose T-connector spring clip (part of
8566)
5 8590 Upper radiator hose T-connector O-ring seal (part of
8566)
6 8566 Upper radiator hose T-connector
7 W713197 Thermostat housing bolts - 10 Nm (89 lb-in) (2
required)
9 8590 Thermostat housing gasket (part of 8592)
2. NOTICE: Remove the accessory drive belt to prevent coolant contamination of the belt.
Remove the accessory drive belt. For additional information, refer to Section 303-05 .
z To install, rinse off any coolant from the accessory drive pulleys using clear water.
3. NOTICE: Cover the A/C compressor drive belt to prevent coolant contamination of the belt.
4. Release the clamp and disconnect the lower radiator hose from the coolant inlet connection.
Pull the upper radiator hose spring clip up until the end of the clip is in the detent on the quick connect
coupling and disconnect the upper radiator hose from the upper radiator hose T-connector.
z To install, push the spring clip in place and connect the upper radiator hose quick connect
coupling, making sure the coupling is secure.
6. Remove the thermostat housing bolts.

Pull the upper radiator hose T-connector spring clip up until the end of the clip is in the detent on the
quick connect coupling and remove the thermostat housing from the upper radiator hose T-connector.
z Remove and discard the thermostat housing gasket.
z To install, align the tab on the thermostat housing with the slot in the upper radiator hose T-
connector.
z To install, push the spring clip in place and connect the thermostat housing to the upper
radiator hose T-connector quick connect coupling, making sure the coupling is secure.

z Use a new thermostat housing gasket.
SECTION 303-04A: Fuel Charging and Controls — 3.5L GTDI 2014 F-150 Workshop Manual
Material
Capacity
Motorcraft® SAE 5W-30 Premium WSS-M2C946- —
Synthetic Blend Motor Oil (US); A, 5W30;
Thread Sealant with PTFE WSK-M2G350- —
TA-24 A2
Charge Air Cooler (CAC) outlet tube-to-Throttle Body (TB) clamp 5 — 44
Fuel injection pump bolts a — — —
Fuel injection pump mounting plate bolt 10 — 89
Fuel Pump Control Module (FPCM) bolts 9 — 80
Fuel rail bolts a — — —
High pressure fuel tube bracket bolt a — — —
High pressure fuel tube flare nut a — — —

High pressure fuel tube bracket nut 8 — 71
TB bolts 10 — 89
Fuel Charging and Controls
3.5L Gasoline Turbocharged Direct Injection (GTDI)
The fuel charging and controls system consists of the:
z fuel injectors.
z fuel injection pump.
z Fuel Pump Control Module (FPCM).
z fuel rails.
z Throttle Body (TB).
The fuel charging and controls system is:
z a Gasoline Turbocharged Direct Injection (GTDI) system.

z Pulse Width Modulated (PWM).
Fuel is metered directly into the combustion chamber. Fuel injectors pulse to follow engine firing order, in
accordance with engine demand.
Fuel Injectors
NOTICE: Handle the fuel injectors and fuel rail with extreme care to prevent damage to the fuel inlet
of the fuel rail, fuel injector sealing areas, and sensitive fuel-metering orifices.
The fuel injectors:
z are electronically operated by the PCM.

z atomize the fuel as the fuel is delivered.
z each have an internal solenoid that opens a needle valve, which injects fuel directly into the
combustion chamber.
z are deposit resistant.
Fuel Injection Pump
The fuel injection pump is a single piston and a delivery-on-demand design. The pump is driven from an
eccentric on the LH intake camshaft. It can raise fuel pressure from 448 kPa (65 psi) to anywhere between
1,516 and 14,823 kPa (220 and 2,150 psi). The fuel is then supplied to the fuel injectors for distribution into
the cylinders.
Fuel Pump Control Module (FPCM)
The FPCM is electronically operated by the PCM and controls the voltage to the FP depending on engine
load.
Fuel Rails
NOTICE: Handle the fuel injectors and fuel rail with extreme care to prevent damage to the fuel inlet
of the fuel rail, fuel injector sealing areas, and sensitive fuel-metering orifices.
The fuel rails:
z receive and store high pressure fuel from the fuel injection pump.
z deliver fuel to the fuel injectors.
Throttle Body (TB)
The TB :
z controls air supply to the intake manifold by electronically positioning the throttle plate.
z is not adjustable.
Fuel Injection Pump Roller Tappet Inspection
1. Inspect the fuel injection pump tappet for flat spots or scoring. If any damage is found, inspect the fuel
injection pump and the fuel injection pump tappet drive lobe. Install new components as necessary.
Fuel Rail
Special Tool(s)
310-205

310-206

310-207

303-1567
Slide Hammer
307-005 (T59L-100-B) or
equivalent
Material
Item Specification
LSP12 (Canada)
Removal
the event of fuel spillage. Spilled fuel may be ignited by hot vehicle components or other ignition
sources. Failure to follow these instructions may result in serious personal injury.
personal injury.
NOTE: A clean working environment is essential to prevent dirt or foreign material contamination.
2. Remove the intake manifold. For additional information, refer to Section 303-01A .
3. Remove the thermostat housing. For additional information, refer to Section 303-03 .

5. Remove the 3 bolts and position aside the coolant crossover assembly.
6. Remove the high-pressure fuel tube bracket bolt.
7. Loosen the 2 flare nuts, remove and discard the high-pressure fuel tube.
8. NOTICE: It is very important to note the routing of the fuel charge wire harnesses on the fuel
rails and index-mark the location of the tie straps prior to removal or damage may occur to the
wire harnesses during installation.
NOTE: Use compressed air and remove any dirt or foreign material from the cylinder head, block and
general surrounding area of the fuel rail and injectors.
the fuel injectors.
NOTE: When removing the fuel rails, the fuel injectors may remain in the cylinder heads and require
the use of a Fuel Injector Remover tool to extract. Wiggling the injector by hand to break it loose may
allow the injector to be removed by hand.
the fuel injectors.
13.
14.
15. Using the Slide Hammer and the Fuel Injector Remover, remove any of the fuel injectors that
remained in the cylinder head.
z Special Tool(s): Slide Hammer 307-005 (T59L-100-B) or equivalent.
z Special Tool(s): Remover, Fuel Injector 310-206.
block and the general surrounding area of the fuel rails and injectors.
NOTE: Do not use a brush to clean the tip of the fuel injector.
Using the Fuel Injector Brush, clean the fuel injector bore in the cylinder head. Special Tool(s): 310-
205.
Installation
1. NOTICE: Do not attempt to cut the lower Teflon® seal without first pulling it away from the fuel
injector or damage to the injector may occur.
NOTICE: Use care when removing the lower Teflon® seals, not to scratch, nick or gouge the
fuel injectors.
1. Pull the lower Teflon® seal away from the injector.

1. Special Tool(s): 310-207.

2. NOTICE: Once the Teflon® seal is installed on the Teflon® Seal Guide 310-207 (part of
the Fuel Injector Seal Installer), it should immediately be installed onto the fuel injector
to avoid excessive expansion of the Teflon® seal.
NOTE: Make sure that new lower fuel injector Teflon® seals are installed.
Special Tool(s): 310-207.

3. Using the Pusher Tool 310-207 (part of the Fuel Injector Seal Installer), slide the Teflon® seals
off of the Teflon® Seal Guide and into the groove on the fuel injectors. Special Tool(s): 310-
207.
3. NOTICE: Install the fuel injectors into the cylinder head within 15 minutes of sizing the seals
due to Teflon® seal expansion.
1. NOTE: Make sure the Teflon® seal is fully seated in the groove on the fuel injector before
sizing the Teflon® seal.
Some Teflon® seal massaging with your fingers before the Teflon® seal sizer tool is installed
will aid in installing the Teflon® seal sizer tool.
2. Position the Teflon® seal sizer tool 303-1567 with the larger opening towards the Teflon® seal.
Push while turning the Teflon® seal sizer tool 180 degrees. Special Tool(s): 303-1567.
3. Once the Teflon® seal sizer tool 303-1567 is installed, check and make sure the Teflon® seal
is in the sizing portion of the Teflon® seal sizer tool. After one minute, turn the Teflon® seal
sizer tool back 180 degrees and remove.
of ordinary O-ring seals may cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE: Make sure that new upper fuel injector O-ring seals, upper fuel injector O-ring seal support
rings and fuel injector retainer clips are installed.
Material: Motorcraft® SAE 5W-30 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-30
Super Premium Motor Oil (Canada) XO-5W30-QSP (US); CXO-5W30-LSP12 (Canada); or
equivalent.
NOTE: The anti-rotation finger of the fuel injector clip must slip into the groove of the fuel rail cup.
6. NOTICE: It is very important to note the routing of the fuel charge wiring harnesses on the fuel
wire harnesses during installation. The illustration details the correct fuel charge wire harness
routing and tie strap positioning for installation.
Install the fuel charge wire harnesses and tie straps to the index-marked locations on the fuel rails.
Start by attaching the first tie strap farthest down the wire harness and continue to the connector end
of the harness, leaving ample slack between the fuel injectors.
NOTICE: Do not lubricate the new lower Teflon® fuel injector seals.
NOTE: Make sure that 6 new fuel rail bolts are installed.
NOTE: Tighten the bolts in a method that draws the fuel rail evenly to the head, preventing a rocking
motion.
Tighten the 6 fuel rail bolts in the following 3 stages.

z Stage 1: Push down on the fuel rail face above the injectors.
z Stage 1: Tighten to 10 Nm (89 lb-in) in the sequence shown.
z Stage 2: Tighten an additional 45 degrees in the sequence shown.
motion.

z Stage 3: Hand tighten the high-pressure fuel tube-to-fuel injection pump flare nut.
10. Loosely install the new high-pressure fuel tube bracket nut and bolt.
11. Tighten the 3 high-pressure fuel tube flare nuts in 9 stages:
z Stage 7: Tighten the high-pressure fuel tube-to-fuel injection pump flare nut to 15 Nm (133 lb-
in).
12. Tighten the high-pressure fuel tube bracket bolt in 2 stages.

13. Tighten the high-pressure fuel tube bracket nut.

14. NOTE: Use care when installing the fuel injection pump noise insulator. Spreading the openings will
aid in installing the fuel injection pump noise insulator and reduce the risk of damage.
Install the fuel injection pump noise insulator shield.
15. Using new gaskets, position back the coolant crossover manifold assembly and install the 3 bolts.
16. NOTE: Lubricate the O-ring seals with clean engine coolant.
17. Install the thermostat housing. For additional information, refer to Section 303-03 .
18. Install the intake manifold. For additional information, refer to Section 303-01A .
Fuel Rail
Special Tool(s)
310-205

310-206

310-207

303-1567
Slide Hammer
307-005 (T59L-100-B) or
equivalent
Material
Item Specification
LSP12 (Canada)
Removal
personal injury.

the fuel injectors.
the fuel injectors.
13.
14.
205.
Installation
fuel injectors.



207.
equivalent.
motion.

motion.

in).


Fuel Pump Control Module
Part
1 — Fuel Pump Control Module (FPCM) electrical
connector (part of 14404)
2 W706027 FPCM bolt (2 required)
3 9345 FPCM
1. Disconnect theFuel Pump Control Module (FPCM) electrical connector.
2. Remove the 2 bolts and the FPCM .

Fuel Rail and Fuel Injector — Exploded View
3.5L Gasoline Turbocharged Direct Injection (GTDI) Fuel Rails and High Pressure Fuel Tube
Part
1 — RH fuel charge wire harness electrical connector (part
of 12A581)
2 — Fuel Rail Pressure (FRP) sensor electrical connector
(part of 12A581)
3 — LH fuel charge wire harness electrical connector (part
of 12A581)
4 9D280 RH fuel rail
5 9D280 LH fuel rail
6 — High pressure fuel tube-to-fuel injection pump flare nut
(part of 9J323)
7 — High pressure fuel tube-to-fuel rail flare nut (part of
9J323)
8 9350 Fuel injection pump
9 W503282 High pressure fuel tube bracket bolt
10 W520100 High pressure fuel tube bracket nut

11 9K540 Fuel injection pump noise insulator shield
3.5L GTDI LH Fuel Rail and Fuel Injectors
Part
1 — Fuel injector electrical connector (part of 12B637) (3
required)
2 12B637 LH fuel charge wire harness
3 9D280 LH fuel rail
5 13A506 LH fuel charge wire harness retainer (3 required)
6 — LH fuel charge wire harness electrical connector (part
of 12B637)
7 — Fuel injector clip (part of 9229) (3 required)
8 — Upper fuel injector O-ring seal (part of 9229)(3
required)
9 — Upper fuel injector O-ring seal support ring (part of
9229)(3 required)
11 — Lower fuel injector Teflon® seal (part of 9229) (3
required)
3.5L GTDI RH Fuel Rail and Fuel Injectors
Part
1 — Lower fuel injector Teflon® seal (part of 9229) (3
required)
3 — Upper fuel injector O-ring seal support ring (part of
9229)(3 required)
4 — Upper fuel injector O-ring seal (part of 9229) (3
required)
5 — Fuel injector clip (part of 9229) (3 required)
6 9F972 FRP sensor
7 — RH fuel charge wire harness electrical connector (part
of 12B637)
8 13A506 RH fuel charge wire harness retainer (2 required)
9 12B637 RH fuel charge wire harness
10 — Fuel injector electrical connector (part of 12B637) (3
required)
12 9D280 RH fuel rail
Fuel Rail
Special Tool(s)
310-205

310-206

310-207

303-1567
Slide Hammer
307-005 (T59L-100-B) or
equivalent
Material
Item Specification
LSP12 (Canada)
Removal
personal injury.

the fuel injectors.
the fuel injectors.
13.
14.
205.
Installation
fuel injectors.



207.
equivalent.
motion.

motion.

in).


Throttle Body
Part
1 9E936 Throttle Body (TB) gasket
2 9E926 TB
3 — TB electrical connector (part of 12A581)
4 — TB wiring harness retainer (part of 12A581)
6 — Charge Air Cooler (CAC) outlet pipe-to- TB clamp
(part of 6F073)
7 6F073 CAC outlet pipe
3. Loosen the clamp and disconnect the Charge Air Cooler (CAC) outlet pipe-to- TB .
4. Remove the 4 bolts and the TB .
z Discard the TB gasket.

5. NOTE: Install a new TB gasket.
SECTION 303-04B: Fuel Charging and Controls — 3.7L 2014 F-150 Workshop Manual
Material
Capacity
LSP12 (Canada)
Fuel Pump Control Module (FPCM) bolts 9 80
Fuel rail bolts 10 89
Intake manifold vacuum tube bolt 10 89
Throttle Body (TB) bolts 10 89
Sequential Multi-Port Fuel Injection (SFI)
z electronic Throttle Body (TB).

z fuel injectors.
z fuel rail.
z Fuel Pump Control Module (FPCM).
z a Sequential Multi-Port Fuel Injection (SFI) system.

z Mass Air Flow (MAF) controlled.
Fuel is metered into each intake port in a sequential firing order. Fuel injectors pulse to follow engine firing
order, in accordance with engine demand, on a tuned intake manifold.
The basic fuel requirement of the engine is determined from the data supplied to the PCM by the MAF
sensor, which measures the amount of air being drawn into the engine.
Throttle Body (TB)
The TB :
z controls air supply to the intake manifold by electronically positioning the throttle plates.
Fuel Rail
The fuel rail:
z receives fuel from the fuel supply tube.

z delivers fuel to the fuel injectors.
Fuel Injectors
The fuel injectors:

z each have an internal solenoid which opens a needle valve to inject fuel into the intake manifold.
z are deposit-resistant.
Fuel Pump Control Module (FPCM)
The FPCM :
z is electronically operated by the PCM.

z controls voltage (10 or 12 volts) to the FPCM depending on load.
Fuel Injectors
1. The fuel injectors are serviced with the fuel rail. For additional information, refer to Fuel Rail and Fuel
Injector — Exploded View and Fuel Rail in this section.
Part
1 — Fuel Pump Control Module (FPCM) electrical
connector (part of 14405)
2 W705549 FPCM bolt (2 required)
3 9D370 FPCM
1. Disconnect the Fuel Pump Control Module (FPCM) electrical connector.
2. Remove the 2 bolts and the FPCM .

Part
1 6P013 LH fuel rail noise insulator shield

2 6P013 RH fuel rail noise insulator shield
3 — Fuel tube-to-fuel rail quick connect coupling (part of
9J280)
4 — Fuel injector electrical connector (part of 14A411) (6
required)
6 9F792 Fuel rail
7 9C995 Fuel injector clip (6 required)
9 9229 Upper fuel injector O-ring seal (6 required)
10 9229 Lower fuel injector O-ring seal (6 required)
removal.
Fuel Rail
Material
Item Specification
LSP12 (Canada)
Removal
personal injury.
3. Remove the upper intake manifold. For additional information, refer to Section 303-01B .
4. Disconnect the fuel tube-to-fuel rail quick connect coupling. For additional information, refer to
Section 310-00 .
5. Remove the LH and RH fuel rail noise insulator shields.
7. Remove the 4 fuel rail bolts.
8. Remove the fuel rail and injectors as an assembly.
9. Remove the 6 fuel injector clips and the 6 fuel injectors.

z Remove and discard the 12 fuel injector O-ring seals.
Installation
1. NOTICE: Use O-ring seals that are made of special fuel-resistant material. The use of ordinary
O-rings may cause the fuel system to leak. Do not reuse the O-ring seals.
NOTE: The upper and lower fuel injector O-ring seals are similar in appearance, but are not
interchangeable.
Install the new O-ring seals onto the fuel injectors and lubricate them with clean engine oil.
2. Install the 6 fuel injectors and the 6 fuel injector clips into the fuel rail.
3. Install the fuel rail and fuel injectors as an assembly.
4. Install the 4 fuel rail bolts.

6. Install the LH and RH fuel rail noise insulator shields.
7. Connect the fuel tube-to-fuel rail quick connect coupling. For additional information, refer to Section
310-00 .
8. Install the upper intake manifold. For additional information, refer to Section 303-01B .
Throttle Body
Part
1 — Electronic throttle control electrical connector (part of
14A411)
2 — Electronic throttle control electrical connector wiring
harness pin-type retainer (part of 14A411)
3 W713443 Throttle Body (TB) bolt (4 required)
4 9F991 TB
5 9E936 TB gasket
1. Remove the engine Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12 .
2. Remove the bolt for the intake manifold vacuum tube.

z Detach the intake manifold vacuum tube pin-type retainer from the Throttle Body (TB).
3. Disconnect the electronic throttle control electrical connector.

z Detach the electronic throttle control electrical connector wiring harness pin-type retainer.
4. Remove the 4 bolts and the TB .

z Discard the TB gasket.
5. NOTE: Install a new TB gasket.
SECTION 303-04C: Fuel Charging and Controls — 5.0L (4V) 2014 F-150 Workshop Manual
Material
Capacity
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Fuel pump control module nuts 8 71
Fuel rail bolts a — —
Throttle Body (TB) bolts a — —
a Refer to the procedure.
z electronic Throttle Body (TB).

z fuel injectors.
z fuel rail.
z fuel pump control module.

Throttle Body (TB)
The TB :
Fuel Rail
The fuel rail:

Fuel Injectors
The fuel injectors:

z each have an internal solenoid which opens a needle valve to inject fuel into the intake manifold.
z are deposit-resistant.
The fuel pump control module:
z controls the voltage to the Fuel Pump (FP) based on the duty cycle request from the PCM.
Fuel Injectors
Part
1 14A464 Fuel Pump (FP) control module electrical connector
(part of 14404)
2 W705549 FP control module bolt (2 required)
3 9D412 FP control module
1. Disconnect the Fuel Pump (FP) control module electrical connector.
2. Remove the 2 bolts and the FP control module.

Fuel Rail Insulators, Fuel Rail and Fuel Injectors
Part
1 — Evaporative Emission (EVAP) tube retaining clips
(part of 9J280)
2 9J280 Fuel supply tube
3 9F792 Fuel rail
5 6P013 Fuel rail insulators
6 — Fuel injector electrical connector (part of 12A581) (8
required)
7 9C995 Fuel injector clip (8 required)
9 9229 Lower fuel injector O-ring seal (8 required)
10 9229 Upper fuel injector O-ring seal (8 required)
removal.
Fuel Rail
Material
Item Specification
equivalent
Removal
personal injury.
1. Release the fuel system pressure. For additional information refer to Section 310-00 .
3. Disconnect the 2 Evaporative Emission (EVAP) tube retaining clips from the fuel rail.
4. Remove the LH and RH fuel rail insulators.
6. Disconnect the fuel supply tube. For additional information, refer to the quick connect procedure in
Section 310-00 .
7. Remove the 4 fuel rail bolts.
8. Remove the fuel rail and fuel injectors as an assembly from the intake manifold.
9. Remove the retaining clips and fuel injectors from the fuel rail.
10. NOTICE: Do not reuse the O-ring seals. Failure to follow this direction may cause the fuel
system to leak.
Remove and discard the fuel injector O-ring seals.
Installation
1. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-
ring seals may cause the fuel system to leak.
Install new O-ring seals on the fuel injectors.
2. NOTE: The fuel injector clip can be reused if it is not damaged during removal. If the clip is reused,
the 2 sides of the clip should be squeezed back into shape by placing it between index finger and
thumb.
NOTE: Lubricate the upper and lower fuel injector O-ring seals with clean engine oil prior to
installation.
Install the fuel injectors and retaining clips onto the fuel rail.
3. Install the fuel rail and fuel injectors as an assembly onto the intake manifold.
4. Install the 4 bolts and tighten in the sequence shown in 3 stages.

5. Connect the fuel supply tube. For additional information, refer to the quick connect procedure in
Section 310-00 .
7. Install the LH and RH fuel rail insulators.
8. Connect the 2 EVAP tube retaining clips to the fuel rail.
Throttle Body
Part
1 9E936 Throttle Body (TB) gasket
2 9E926 TB
3 — Electronic throttle control electrical connector (part of
12A581)
Removal
2. Disconnect the Electronic Throttle Control (ETC) electrical connector.
3. Remove the 4 bolts and the Throttle Body (TB)

Installation
1. Using a new gasket, position the TB and install the 4 bolts loosely.
2. While holding the TB in the most upward position tighten the 4 bolts in 2 stages.

3. Connect the ETC electrical connector.
SECTION 303-04D: Fuel Charging and Controls — 6.2L (2V) 2014 F-150 Workshop Manual
Material
Capacity
Oil CXO-5W20-LSP12 (Canada);
or equivalent
Air Cleaner (ACL) outlet pipe-to-Throttle Body (TB) adapter bolts 10 89
Fuel Pump (FP) control module bolts 9 80
Fuel rail bolts a — —
TB adapter-to- TB clamp 5 44
TB bolts a — —
The fuel charging and controls system consists of the following:
z Throttle Body (TB)

z Fuel injectors
z Fuel rail

Throttle Body (TB)
The TB :
Refer to Throttle Body in this section.
Fuel Injectors
The fuel injectors:

z each have an internal solenoid that opens a needle valve, which injects fuel into the intake port in the
cylinder head.
z are deposit resistant.
For removal and installation, refer to Fuel Rail and Fuel Injector — Exploded View and Fuel Rail in this
section.
Fuel Rail
NOTICE: The fuel injectors and the fuel rail must be handled with extreme care to prevent damage to
sealing areas and sensitive fuel-metering orifices.
The fuel rail:

For removal and installation, refer to Fuel Rail and Fuel Injector — Exploded View and Fuel Rail in this
section.
Fuel Injector
Part
1 14A464 Fuel Pump (FP) control module electrical connector
(part of 14404)
2 W705549 FP control module bolt (2 required)
3 9D412 FP control module
1. Disconnect the Fuel Pump (FP) control module electrical connector.
2. Remove the 2 bolts and the FP control module.

Air Cleaner (ACL) Outlet Pipe-to-Throttle Body (TB) Adapter
Part
2 9C490 Brake booster vacuum hose
3 — Heater coolant hose position retainer

4 — Throttle Body (TB) adapter-to- TB clamp (part of
9F805)
5 W505426 Air Cleaner (ACL) outlet pipe-to- TB adapter bolt (2
required)
6 9A589 ACL outlet pipe-to- TB adapter
Fuel Rail and Fuel Injectors
Part
1 — Fuel supply tube quick connect coupling

2 12286 LH ignition wire (4 required)
3 12029 LH ignition coil electrical connector (part of 12B637)
(4 required)
4 12029 RH ignition coil electrical connector (part of 12B637)
(4 required)
5 12286 RH ignition wire (4 required)
6 14A464 Fuel injector electrical connector (part of 12B637) (8
required)
8 9F792 Fuel rail
9 9C995 Fuel injector-to-fuel rail locking clip (8 required)
10 9U509 Fuel injector-to-fuel rail O-ring (8 required)
12 9U509 Fuel injector-to-intake manifold O-ring (8 required)
Fuel Rail
Material
Item Specification
equivalent
Removal
NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It
is therefore essential that absolute cleanliness is observed when working with these components.
Always install blanking plugs to any open orifices or tubes.
NOTICE: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove
any foreign material from the connector retaining clip area before separating from the tube.
3. Disconnect the heater coolant hose retainer from the ACL outlet pipe-to-Throttle Body (TB) adapter.
4. Disconnect the crankcase ventilation tube quick connect fitting from the ACL outlet pipe-to- TB
adapter. For additional information, refer to Section 310-00 .
5. Disconnect the brake booster vacuum hose from the ACL outlet pipe-to- TB adapter.
6. Loosen the clamp and disconnect the TB adapter from the TB .
7. Remove the 2 bolts and the ACL outlet pipe-to- TB adapter.
8. Disconnect the fuel tube quick connect coupling. For additional information, refer to Section 310-00 .
9. Disconnect the 8 ignition coil electrical connectors.
10. Disconnect the 8 ignition wires from the 8 ignition coils.
12. Remove the 4 fuel rail bolts and the fuel rail and injectors as an assembly.
13. Remove the fuel injector-to-fuel rail locks and separate the 8 fuel injectors from the fuel rail.
z Discard the upper and lower fuel injector O-ring seals.
Installation
1. NOTICE: Use O-ring seals that are made of special fuel-resistant material. Use of ordinary O-
rings can cause the fuel system to leak.
NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation.
Install 16 new O-ring seals on each of the fuel injectors.
2. Assemble the 8 fuel injectors onto the fuel rail and install the 8 fuel injector retaining clips.
3. Install the fuel rail and fuel injectors as an assembly onto the intake manifold.
4. Install the 4 fuel rail bolts in 2 stages.

6. Connect the 8 ignition wires to the 8 ignition coils.
7. Connect the 8 ignition coil electrical connectors.
8. Connect the fuel tube quick connect coupling. For additional information, refer to Section 310-00 .
9. Position the ACL outlet pipe-to- TB adapter and install the 2 bolts.
10. Tighten the TB adapter-to- TB clamp.

11. Connect the brake booster vacuum hose from the ACL outlet pipe-to- TB adapter.
12. Connect the crankcase ventilation tube quick connect fitting to the ACL outlet pipe-to- TB adapter. For
13. Connect the heater coolant hose retainer to the ACL outlet pipe-to- TB adapter.
Throttle Body
Air Cleaner (ACL) Outlet Pipe-to-Throttle Body (TB) Adapter
Part
3 — Heater coolant hose position retainer

4 — Throttle Body (TB) adapter-to- TB clamp (part of
9F805)
5 W505426 Air Cleaner (ACL) outlet pipe-to- TB adapter bolt (2
required)
6 9A589 ACL outlet pipe-to- TB adapter
Throttle Body (TB)
Part
1 — Electronic Throttle Control (ETC) electrical connector
(part of 12B637)
2 N709168 Throttle Body (TB) bolt (4 required)
3 9F991 TB
4 9E936 TB O-ring seal
Removal
2. Disconnect the heater coolant hose retainer from the ACL outlet pipe-to-Throttle Body (TB) adapter.
3. Disconnect the crankcase ventilation tube quick connect fitting from ACL outlet pipe-to- TB adapter.
4. Disconnect the brake booster vacuum hose from the ACL outlet pipe-to- TB adapter.
5. Remove the 2 bolts and the ACL outlet pipe-to- TB adapter.
6. Loosen the clamp and disconnect the TB adapter from the TB .
7. Disconnect the Electronic Throttle Control (ETC) electrical connector.
8. Remove the 4 bolts and the TB assembly.

z Discard the TB O-ring seal.
Installation
1. Using a new O-ring seal, position the TB and tighten the 4 bolts in 2 stages.
2. Connect the ETC electrical connector.
3. Position the TB adapter onto the TB and install the 2 bolts.

4. Tighten the TB adapter-to- TB clamp.

5. Connect the crankcase ventilation tube quick connect coupling to the ACL outlet pipe-to- TB adapter.
6. Connect the brake booster vacuum hose to the ACL outlet pipe-to- TB adapter.
7. Connect the crankcase ventilation tube quick connect fitting to the ACL outlet pipe-to- TB adapter. For
8. Connect the heater coolant hose retainer to the ACL outlet pipe-to- TB adapter.
SECTION 303-04E: Fuel Charging and Controls — Turbocharger 2014 F-150 Workshop Manual
Material
Capacity
LSP12 (Canada)
Charge Air Cooler (CAC) tube clamp 5 — 44
Exhaust system heat shield bolts 20 — 177
Transmission crossmember bolts 90 66 —
Transmission insulator and retainer bolts 90 66 —
Transmission insulator and retainer nuts 103 75 —
Turbocharger bracket bolts 28 21 —
Turbocharger bracket-to-cylinder block bolts 10 — 89
Turbocharger exhaust flange stud bolts 40 30 —
Turbocharger heat shield bolts 6 — 53
Turbocharger intake tube clamp 5 — 44
Turbocharger mounting bolts 32 24 —
Turbocharger oil return tube bolt a — — —
Turbocharger oil supply tube bolt a — — —
Turbocharger oil tube assembly bolts a — — —
a
file:///C:/TSO/tsocache/VDTOM2_10764/SE2~us~en~file=SE234E01.HTM~gen~ref.H...
file:///C:/TSO/tsocache/VDTOM2_10764/SE2~us~en~file=SE234E01.HTM~gen~ref.H... 2014-03-01
Turbocharger
NOTICE: When removing the turbocharger air intake system components, cover the open ports to
prevent debris from entering the system. The turbocharger compressor blades are susceptible to
damage from even small particles. Inspect and clean all components if necessary, prior to
installation or reassembly.
The turbocharger assembly consists of LH and RH turbochargers.
The turbocharger is an exhaust-driven centrifugal air compressor used to increase power output by
supplying compressed air to the engine. The internal components are oil, coolant and air cooled. Engine oil
and coolant are circulated through the center housing which acts as a heat barrier between the hot turbine
and the cold compressor. Bearings are sleeve type and lubricated by engine oil. Oil is circulated to the
turbocharger center housing and returned to the sump through an oil drain in the center housing.
Expanding exhaust gases drive the turbine shaft assembly to speeds ranging from 10,000 to 185,000 rpm.
Filtered air entering the compressor side of the turbocharger is compressed and delivered through a Charge
Air Cooler (CAC). The very hot compressed air is cooled, then continues on to fill the intake manifold at a
higher pressure than atmospheric pressure. Because more air is forced into the intake manifold, the results
are increased power, fuel efficiency and the ability to maintain power at higher altitudes.
The EcoBoost™ twin turbochargers are used in a parallel arrangement with one turbocharger connected to
each cylinder bank. This configuration improves engine responsiveness due to the reduced inertia of 2 small
turbochargers. This also leads to an improved turbocharger package and better utilization of heat energy
from the compact exhaust manifolds. The compact design of the system allows the catalysts to be located
very close to the turbocharger outlet for improved emissions.
Turbocharger
The turbocharger is an exhaust-driven centrifugal air compressor used to increase power output by
supplying compressed air to the engine. The internal components are oil, coolant and air cooled. Engine oil
and coolant are circulated through the center housing which acts as a heat barrier between the hot turbine
and the cold compressor. Bearings are sleeve type and lubricated by engine oil. Oil is circulated to the
turbocharger center housing and returned to the sump through an oil drain in the center housing.
Expanding exhaust gases drive the turbine shaft assembly to speeds ranging from 10,000 to 185,000 rpm.
Filtered air entering the compressor side of the turbocharger is compressed and delivered through a Charge
Air Cooler (CAC). The very hot compressed air is cooled, then continues on to fill the intake manifold at a
higher pressure than atmospheric pressure. Because more air is forced into the intake manifold, the results
are increased power, fuel efficiency and the ability to maintain power at higher altitudes.
NOTE: This section provides mechanical diagnosis of the turbocharger assembly. If there is a Malfunction
Indicator Lamp (MIL) illuminated, or DTCs are present, these should be diagnosed prior to performing
turbocharger mechanical diagnosis. Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual.
2. Inspect the entire turbocharger system for obvious signs of damage or other mechanical concerns,
using the following chart.

Mechanical
z Oil inlet pipe and connection
z Oil outlet pipe and connection
z Compressor housing inlet circuit and piping
z Compressor housing outlet circuit and piping
z Turbine housing inlet circuit and piping
z Turbine housing outlet circuit and piping
z Turbocharger actuator tubing or linkage
z Wastegate actuator rod
3. If the concern(s) remains after the inspection, GO to Symptom Chart .
4. If a driveability condition still exists, refer to the Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
Symptom Chart
Symptom Chart
z Loss of z Clogged Air Cleaner z INSTALL a new ACL
power/performance (ACL) element element. REFER to
Section 303-12 . TEST the
system for normal
operation.
z Loose connections or z TIGHTEN the hose
damage to air intake clamps. INSPECT for
hoses and tubes damage and REPAIR as
necessary.
z Malfunctioning fuel z REFER to the Powertrain
system Control/Emissions
Diagnosis (PC/ED)
manual.
z Poor fuel quality z DRAIN and FILL with fresh
fuel.
z Engine wear (piston z REPAIR as required.
rings, valve guides)
z Turbocharger turbine or z INSPECT the
compressor wheel turbocharger. REFER to
damage the Check for Free
Rotation — Off Vehicle in
this section.
z Damaged exhaust or z INSPECT for leaks. Leaks
exhaust leaks at can usually be detected
turbocharger housing or audibly or visually, by a
exhaust manifolds discoloration caused by
escaping hot exhaust
gases. REPAIR as
required.
z Malfunctioning z REFER to the Powertrain
turbocharger bypass Control/Emissions
valve Diagnosis (PC/ED)
manual.
z Obstructed wastegate z INSPECT the suspect
actuator linkage turbocharger wastegate
linkage for obstruction.
REPAIR as necessary.
z Damaged wastegate z INSPECT the suspect
actuator linkage turbocharger wastegate
linkage for damage.
INSTALL a new
turbocharger.
z Wastegate actuator z TEST the wastegate
operation actuator operation. REFER
to the Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
z PCM — DTCs z REFER to the Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
z Excessive oil z Incorrect type or grade z DRAIN and FILL with
consumption of oil specified oil.
z Oil in exhaust manifolds z REPAIR as required.
z Clogged ACL element z INSTALL a new ACL
element. REFER to
Section 303-12 . TEST the
system for normal
operation.
z Blocked or restricted z INSPECT the turbocharger
turbocharger oil drain oil drain pipes. REPAIR as
pipes necessary.
z Damaged or collapsed z TIGHTEN hose clamps.
air intake hoses and INSPECT for damage and
tubes REPAIR as necessary.
z Damaged exhaust or z INSPECT for leaks. Leaks
exhaust leaks at can usually be detected
turbocharger housing or audibly or visually, by a
exhaust manifolds discoloration caused by
gases. REPAIR as
required.
z Turbocharger oil seals z REFER to Turbocharger
leaking Internal Oil Leak Test in
this section.
z Damaged crankcase z Visually INSPECT the
ventilation system crankcase ventilation
system.
z Excessive noise z Turbocharger z REPAIR or INSTALL a
compressor air intake new pipe as required.
pipe leaking
z Loose connections or z TIGHTEN hose clamps.
damage to air intake INSPECT for damage and
hoses and tubes REPAIR as necessary.
z Air leaks at turbine z INSPECT for leaks. Leaks
housing, blown joints or can usually be detected
damaged exhaust audibly or visually, by a
discoloration caused by
gases. REPAIR as
required.
z Carbon build up in the z INSPECT the
turbine housing causing turbocharger. REFER to
contact with turbine the Check for Free
wheel Rotation — Off Vehicle in
this section.
z Turbocharger z REPAIR as required.
imbalance due to
foreign object/damage
z Turbine bearing failure z INSPECT the
turbocharger. REFER to
the Check for Free
Rotation — Off Vehicle in
this section.
z Change to the z INSPECT the turbocharger
wastegate nut location paint mark location. If the
paint marks are not
aligned, INSTALL a new
turbocharger.
z Inoperative z REFER to the Powertrain
turbocharger bypass Control/Emissions
valve Diagnosis (PC/ED)
manual.
z Engine emits z Clogged ACL element z INSTALL a new ACL
excessive smoke element. REFER to
(black/blue/white) Section 303-12 . TEST the
system for normal
operation.
z Incorrect type or grade z DRAIN and FILL with
of oil specified oil.
z Blocked or restricted z INSPECT the turbocharger
turbocharger oil drain oil drain pipes. REPAIR as
pipes necessary.
z Damaged/restricted or z REPAIR or INSTALL a
leaking turbocharger new pipe as required.
compressor air intake
pipe
z Engine wear (piston z REPAIR as required.
rings, valve guides)
z Plugged crankcase z Visually INSPECT the
ventilation system crankcase ventilation
system.
z Turbocharger oil seals z REFER to Turbocharger
leaking Internal Oil Leak Test in
this section.
Component Tests
Turbocharger Internal Oil Leak Test
NOTE: Some engine oil may be present in the turbocharger compressor inlet and in the air inlet components
due to the crankcase breather system.
Check the turbocharger compressor inlet for evidence of oil. If excessive oil is present, this indicates that the
failure could be in the engine or turbocharger. Refer to Section 303-00 or the following turbocharger check. If
excessive oil is found in the turbocharger compressor outlet, check the Charge Air Cooler (CAC) for oil
contamination. If contamination is present, flush the CAC . Refer to Section 303-12 .
Check the turbocharger turbine outlet for evidence of oil. If excess oil is present in the outlet, remove the
turbocharger from the engine and examine the oil supply and return passages in the turbocharger and
engine block for restriction. If no restriction is found, install a new turbocharger.
Check for Free Rotation — Off Vehicle
NOTE: Pre-oil the turbocharger before carrying out this check.
NOTE: Turbine and compressor wheels must spin freely when turned by hand. No housing contact is
permitted.
Inspect the turbocharger compressor and turbine blades for damage. If the compressor or turbine wheel
blades are damaged, replace the turbocharger.
Press and rotate the turbocharger shaft, then repeat from the opposite side. If either the compressor or the
turbine wheel blades contact the housing, the bearings are worn or damaged and a new turbocharger must
be installed.
Turbocharger — LH
Material
Item Specification
Motorcraft® High Temperature —
Nickel Anti-Seize Lubricant
XL-2
LSP12 (Canada)
Removal
NOTICE: Whenever turbocharger air intake system components are removed, always cover open
ports to protect from debris. It is important that no foreign material enter the system. The
turbocharger compressor blades are susceptible to damage from even small particles. All
components should be inspected and cleaned, if necessary, prior to installation or reassembly.
2. Drain the engine cooling system. Refer to Section 303-03 .
3. Remove the Air Cleaner (ACL) outlet pipe, LH ACL pipe-to-turbocharger pipe, LH turbocharger
bypass hose and the LH turbocharger-to-Charge Air Cooler (CAC) pipe. Refer to Intake Air System
12 .
4. Remove the LH catalytic converter. Carry out the exhaust Y-pipe - dual catalytic converter procedure.
5. If equipped, remove the 2 exhaust system heat shield bolts and the exhaust system heat shield.
6. NOTE: Position a drain pan prior to disconnecting the turbocharger coolant supply tube.
Using a commercially available quick disconnect tool, disconnect the turbocharger coolant supply
tube at the turbocharger.
z Position the coolant supply tube aside.
7. Disconnect the wastegate hose.
8. Remove the bolt for the LH turbocharger coolant and oil tubes.
9. Remove the 2 bolts at the LH turbocharger oil return tube.

z Remove and discard the turbocharger oil return tube assembly gasket.
10. Remove the 3 turbocharger mounting bolts and the turbocharger.

11. Remove the bolt and the turbocharger oil return tube assembly.
z Remove and discard the turbocharger oil return tube O-ring seal.
12. NOTE: If it is necessary to remove the turbocharger coolant tube, use a commercially available quick
disconnect tool to disconnect the turbocharger coolant tube at the turbocharger.
If necessary, remove the turbocharger coolant tube.
13. If necessary, remove the 2 turbocharger exhaust flange stud bolts and the turbocharger exhaust
flange.
z Discard the 2 turbocharger exhaust flange stud bolts and the turbocharger exhaust flange
gasket.
Installation
1. NOTE: Apply high temperature nickel anti-seize lubricant to the turbocharger exhaust flange stud bolt
threads prior to installation of the turbocharger exhaust flange.
If removed, using a new turbocharger exhaust flange gasket, install the turbocharger exhaust flange
and the 2 new turbocharger exhaust flange stud bolts.
2. If removed, install the turbocharger coolant tube.
NOTE: Apply clean engine oil to the turbocharger oil return tube O-ring seal.
NOTE: Make sure the turbocharger oil supply tube is positioned in the cylinder block during the
installation of the turbocharger oil return tube assembly.
Using a new turbocharger oil return tube O-ring seal, install the turbocharger oil return tube assembly.
4. Using a new turbocharger exhaust manifold gasket, install the LH turbocharger and the 3
turbocharger mounting bolts.
z Tighten finger tight.
5. Tighten the 3 turbocharger mounting bolts.

6. Using a new turbocharger oil return tube gasket, install the 2 turbocharger center housing bolts at the
turbocharger. Tighten in the following stages:
7. Install the turbocharger oil return tube bolt at the cylinder block. Tighten in the following stages:
8. Install the bolt for the LH turbocharger coolant and oil tubes. Tighten in the following stages:
9. Connect the wastegate hose.
10. Connect the turbocharger coolant supply tube to the turbocharger.
11. If equipped, install the exhaust system heat shield and the 2 exhaust system heat shield bolts.
12. Install the LH catalytic converter. Carry out the exhaust Y-pipe - dual catalytic converter procedure.
13. Install the ACL outlet pipe, LH ACL pipe to-turbocharger pipe, LH turbocharger bypass hose and the
LH turbocharger-to- CAC pipe. Refer to Intake Air System Components — Exploded View, 3.5L GTDI
in Section 303-12 .
14. Fill the engine cooling system. Refer to Section 303-03 .
Turbocharger — RH
Material
Item Specification
Motorcraft® High Temperature —
Nickel Anti-Seize Lubricant
XL-2
LSP12 (Canada)
Removal
turbocharger compressor blades are susceptible to damage from even small particles. All
All vehicles
2. Drain the engine cooling system. Refer to Section 303-03 .
3. Remove the Air Cleaner (ACL) outlet pipe, RH ACL pipe to-turbocharger pipe, RH turbocharger
bypass hose and the RH turbocharger-to-Charge Air Cooler (CAC) pipe. Refer to Intake Air System
12 .
4. Remove the Air Conditioning (A/C) compressor belt. Refer to Section 303-05 .
5. Remove the 3 A/C compressor bolts and position the A/C compressor aside.
6. Remove the exhaust Y-pipe - dual catalytic converter. Refer to Section 309-00 .
Rear Wheel Drive (RWD) vehicles
NOTE: The exhaust Y-pipe - dual catalytic converter procedure requires the removal of the transmission
insulator and retainer and the transmission crossmember. The transmission insulator and retainer and the
transmission crossmember must be installed to continue the procedure.
7. Install the transmission insulator and retainer and the 3 transmission insulator and retainer bolts.
8. Install the transmission crossmember and the 4 transmission crossmember nuts and bolts (2 each
side).
9. Lower the transmission onto the transmission crossmember and install the 2 transmission insulator
and retainer nuts.
Four-Wheel Drive (4WD)
NOTE: The exhaust Y-pipe - dual catalytic converter procedure requires the removal of the transmission
insulator and retainer and the transmission crossmember. The transmission insulator and retainer and the
transmission crossmember must be installed to continue the procedure.
10. Loosely install the transmission insulator and retainer and the 4 transmission insulator and retainer
bolts.
11. Position the transmission crossmember and loosely install the 2 transmission insulator and retainer
nuts.
12. Install the 4 transmission crossmember bolts and nuts.

z Tighten the transmission insulator and retainer bolts to 90 Nm (66 lb-ft).
z Tighten the transmission crossmember bolts and nuts to 90 Nm (66 lb-ft).
z Tighten the transmission insulator and retainer nuts to 103 Nm (75 lb-ft).
All vehicles
13. Remove the starter. Refer to Section 303-06 .
14. NOTE: Position a drain pan prior to disconnecting the turbocharger coolant supply tube.
Using a commercially available quick disconnect tool, remove the turbocharger coolant supply tube.
15. Disconnect the wastegate hose.
16. Remove the bolt for the RH turbocharger coolant and oil tubes.
17. Remove the 2 bolts for the turbocharger oil return tube assembly.
z Remove and discard the turbocharger oil return tube gasket.
18. Remove the 3 turbocharger mounting bolts and the turbocharger.

19. Remove the bolt and the RH turbocharger oil return tube.
z Remove and discard the turbocharger oil return tube O-ring seal.
20. If necessary, using a commercially available quick disconnect tool, remove the turbocharger coolant
tube.
21. If necessary, remove the 2 turbocharger exhaust flange stud bolts and the turbocharger exhaust
flange.
z Discard the 2 turbocharger exhaust flange stud bolts and the turbocharger exhaust flange
gasket.
Installation
All vehicles
1. NOTE: Apply high temperature nickel anti-seize lubricant to the turbocharger exhaust flange stud bolt
threads prior to installation of the turbocharger exhaust flange.
If removed, using a new turbocharger exhaust flange gasket, install the turbocharger exhaust flange
and the 2 new turbocharger exhaust flange stud bolts.
2. If removed, install the turbocharger coolant tube.
NOTE: Apply clean engine oil to the turbocharger oil return tube O-ring seal.
NOTE: Make sure the turbocharger oil supply tube is positioned in the cylinder block during the
installation of the turbocharger oil return tube assembly.
Using a new turbocharger oil return tube O-ring seal, install the turbocharger oil return tube assembly.
4. Using a new turbocharger exhaust manifold gasket, install the RH turbocharger and the 3
turbocharger mounting bolts.
z Tighten finger tight.
5. Tighten the 3 turbocharger mounting bolts.

6. Using a new turbocharger oil return tube gasket, install the 2 turbocharger center housing bolts at the
turbocharger. Tighten in the following stages:
7. Install the turbocharger oil return tube bolt at the cylinder block. Tighten in the following stages:
8. Install the bolt for the RH turbocharger coolant and oil tubes. Tighten in the following stages:
9. Connect the wastegate hose.
10. Install the turbocharger coolant supply tube.
11. Install the starter. Refer to Section 303-06 .
4WD vehicles
12. Remove the 2 transmission insulator and retainer nuts.
13. NOTE: Right side shown, left side similar. Transmission crossmember removed for clarity.
Remove the 4 transmission insulator and retainer bolts.
14. Support the transfer case.
15. Remove the 4 transmission crossmember nuts and bolts.
16. Remove the transmission insulator and retainer.
RWD
18. Position a suitable high-lift transmission jack under the transmission.
19. Remove the 4 transmission crossmember nuts and bolts (2 each side) and remove the transmission
crossmember.
20. Remove the 3 transmission insulator and retainer bolts and remove the transmission insulator and
retainer.
All vehicles
21. Install the exhaust Y-pipe - dual catalytic converter. Refer to Section 309-00 .
22. Position the A/C compressor and install the 3 A/C compressor bolts.
23. Install the A/C compressor belt. Refer to Section 303-05 .
24. Install the ACL outlet pipe, RH ACL pipe to-turbocharger pipe, RH turbocharger bypass hose and the
RH turbocharger-to- CAC pipe. Refer to Intake Air System Components — Exploded View, 3.5L GTDI
in Section 303-12 .
25. Fill the engine cooling system. Refer to Section 303-03 .
SECTION 303-05: Accessory Drive 2014 F-150 Workshop Manual

Item Specification
A/C compressor drive belt — 3.5L and 3.7L 4 ribs
A/C compressor drive belt — 5.0L 6 ribs
Accessory drive belt 6 ribs
A/C compressor drive belt tensioner bolt — 5.0L (4V) late build vehicles only 25 18 —
A/C compressor drive belt idler pully bolt — 5.0L (4V) late build vehicles only 25 18 —
Accessory drive belt tensioner bolts — 3.5L and 3.7L 25 18 —
Accessory drive belt tensioner bolt — 5.0L (4V) 47 35 —
Accessory drive belt tensioner bolts — 6.2L (2V) 25 18 —
Accessory drive belt idler pulley bolt — 6.2L (2V) 25 18 —

Accessory Drive
The accessory drive system:
z has a serpentine drive belt with 6 ribs.

z has a A/C compressor drive belt (3.5L, 3.7L and 5.0L only).
z has an automatic drive belt tensioner and idler pulley for the A/C compressor drive belt (5.0L).
z has an automatic drive belt tensioner for the accessory drive belt.
z has 2 or more idler pulleys (6.2L only).
The accessory drive system provides power to operate components which power other systems. These
could include components such as the generator, power steering pump and A/C compressor. Each of these
components is equipped with a pulley which is driven by the accessory drive belt. The accessory drive belt is
driven by the engine crankshaft pulley. One or more idler pulleys may be provided to facilitate belt routing
and alignment. The automatic belt tensioner maintains correct belt tension and compensates for component
wear and changes in system load. System load changes can be caused by the A/C compressor clutch
engaging or disengaging, or demand changes on other systems powered by the accessory drive belt. To
maintain correct operation of this system, it is critical that the correct length drive belt be installed. The
pulleys must also be correctly aligned and kept clean.
Accessory Drive Belt Routing
Front End Accessory Drive (FEAD) — 3.5L and 3.7L

2 6B209 Accessory drive belt tensioner pulley
4 10A352 Generator pulley
A/C Compressor Drive Belt — 3.5L and 3.7L

1 19D784 A/C compressor pulley
2 6C301 Accessory drive belt
Front End Accessory Drive (FEAD) — 5.0L (4V)

3 6B209 Accessory drive belt tensioner pulley
5 10300 Generator pulley
A/C Compressor Drive Belt — 5.0L (4V)

1 19A216 A/C compressor drive belt idler pulley
2 6C301 A/C compressor drive belt
4 6A228 A/C compressor drive belt tensioner pulley
Front End Accessory Drive (FEAD) — 6.2L (2V)

1 8678 Belt idler pulley
2 10344 Generator pulley
3 8620 Drive belt
4 8678 Belt idler pulley
5 3A733 Power steering pump pulley

8 6B209 Drive belt tensioner

Accessory Drive
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys have any
fluids or belt dressing applied to them as damage to the belt material and tensioner damping
mechanism may occur.
1. Verify the customer concern by operating the system.

Mechanical
z Drive belt cracking/chunking/wear
z Belt/pulley contamination
z Incorrect accessory drive belt
z Incorrectly routed accessory drive belt
z Pulley misalignment or excessive pulley runout
z Loose or mislocated hardware
z Loose accessory drive belt
z Damaged pulleys
z Tensioner arm misalignment
Belt Tensioner With Belt Length Indicator — 3.5L and 3.7L
Item Description
1 Belt length indicator
2 Acceptable belt installation and wear range
3 Belt replacement range
4 Belt tension relief point
Belt Tensioner With Belt Length Indicator — 5.0L
Item Description
Belt Tensioner With Belt Length Indicator — 6.2L
NOTE: 6.2L (2V) accessory drive belt tensioner shown, other accessory drive belt tensioners similar.
NOTE: Belt tensioner is shown in the free-state position against the arm travel stops.
Item Description
3. Check that the belt length indicator, if equipped, on the belt tensioner is in the acceptable belt
installation and wear range. If the indicator is in the belt replacement range, either an incorrect belt is
installed or the belt is worn beyond the service limit. Install a new belt as necessary.
4. Eliminate all other non-belt related noises that could cause belt misdiagnosis, such as A/C
compressor engagement chirp, A/C slugging noise, power steering cavitations at low temperatures,
Variable Camshaft Timing (VCT) tick or generator whine.
5. If a concern is found, correct the condition before proceeding to the next step.
V-Ribbed Serpentine Drive Belt With Cracks Across Ribs
6. Check the belt for cracks. Up to 15 cracks in a rib over a distance of 100 mm (4.0 in) can be
considered acceptable. If cracks exceed this standard, install a new belt.
V-Ribbed Serpentine Belt With Piling
NOTE: Piling is an excessive buildup in the V-grooves of the belt.
7. The condition of the V-ribbed drive belt should be compared against the illustration and appropriate
action taken.
1. Small scattered deposits of rubber material. This is not a concern, therefore, installation of a
new belt is not required.
2. Longer deposit areas building up to 50% of the rib height. This is not considered a durability
concern, but it can result in excessive noise. If noise is apparent, install a new belt.
3. Heavy deposits building up along the grooves resulting in a possible noise and belt stability
concern. If heavy deposits are apparent, install a new belt.
V-Ribbed Serpentine Belt With Chunks of Rib Missing
8. There should be no chunks missing from the belt ribs. If the belt shows any evidence of this, install a
new accessory drive belt.
9. If the concern is not visually evident, verify the symptom and GO to Symptom Chart .
Symptom Chart
Symptom Chart
z Accessory drive belt z Accessory drive z INSPECT the accessory drive
cracking (over 15 belt belt. REFER to Inspection and
cracks in a rib over Verification in this section.
a distance of 100 INSTALL a new accessory drive
mm [4.0 in]) belt as necessary.
z Accessory drive belt z Accessory drive z INSPECT the accessory drive
chunking belt belt. REFER to Inspection and
Verification in this section.
INSTALL a new accessory drive
belt as necessary.
z Damaged pulley z INSPECT the accessory drive
grooves belt pulley grooves for damage.
INSTALL a new pulley or
component as necessary.
z Accessory drive belt z Defective/worn or z REFER to Component Tests,
noise, squeal, incorrect accessory Drive Belt — Noise/Flutter in this
chirping or flutter drive belt section. REPAIR or INSTALL
z Misaligned pulley new parts as necessary.
(s)
z Pulley runout
z Damaged or worn
accessory drive
component or idler
of accessory drive
belt or pulleys
z Damaged or worn z REFER to Component Tests,
accessory drive Belt Tensioner — Mechanical
belt tensioner and Belt Tensioner — Dynamics
in this section. INSTALL a new
accessory drive belt tensioner
as necessary.
z Accessory drive z CHECK the accessory drive
component failure components. INSTALL new
z Accessory drive z INSPECT the accessory drive
belt idler pulley belt idler pulley for freedom of
bearing failure rotation and damage. INSTALL
a new accessory drive belt idler
pulley as necessary.
z Premature z Defective or z REFER to Component Tests,
accessory drive belt incorrect accessory Drive Belt — Noise/Flutter and
wear drive belt Drive Belt — Incorrect
z Misaligned pulley Installation in this section.

(s) REPAIR or INSTALL new parts
z Pulley runout as necessary.
z Damaged
accessories
z Incorrectly installed
drive belt
Component Tests
Drive Belt — Noise/Flutter
NOTICE: Under no circumstances should the accessory drive belt, tensioner or pulleys have any
fluids or belt dressing applied to them as damage to the belt material and tensioner damping
mechanism may occur.
Drive belt chirp occurs due to pulley misalignment or excessive pulley runout. It can be the result of a
damaged or incorrectly aligned grooved pulley.
To correct, determine the area where the noise comes from. Check each of the pulleys in that area with a
straightedge to the crankshaft pulley. Look for accessory pulleys out of position in the fore/aft direction or at
an angle to the straightedge.
Drive belt squeal may be an intermittent or constant noise that occurs when the drive belt slips on an
accessory pulley under certain conditions.
A short intermittent squeal may occur during engine start up and shut down or during very rapid engine
acceleration and decelerations, such as:
z Wide Open Throttle (WOT) 1-2 and 2-3 shifts or 2-3 and 3-4 back-out shifts on automatic
transmissions.
z WOT 1-2 and 2-3 shifts and any combination of rapid downshifting on manual transmissions.
These special short-term transient events are expected, and are due to the higher system inertias required
to meet the electrical and cooling demands on today's vehicle systems. Constant or reoccurring drive belt
squeal can occur:
z if the A/C discharge pressure goes above specifications:

the A/C system is overcharged.
the A/C condenser core airflow is blocked.
the A/C anti-slugging strategy executes after a long hot heat soak.
z if the A/C off equalized pressure (the common discharged and suction pressure that occurs after
several minutes) exceeds specifications.
z if any of the accessories or idler pulley(s) are damaged or have a worn or damaged bearing. All
accessories should be rotatable by hand in the unloaded condition. If not, inspect the accessory.
z if there is evidence of fluid contamination on the accessory drive belt. When the drive belt has been
exposed to fluid contamination during vehicle operation, such as leaks from the power steering
system, A/C system or cooling system, clean all pulleys with soap and water, rinse with clean water
and install a new accessory drive belt. If the drive belt has been exposed to fluids in a localized area
during routine vehicle service, such as replacement of hoses or fluids, the drive belt and pulleys
should be washed with soap and water immediately (prior to starting the engine), and rinsed with
clean water.
z if the accessory drive belt is too long. A drive belt that is too long will allow the accessory drive belt
tensioner arm to go all the way to the arm travel stop under certain load conditions, which will release
tension to the drive belt. If the accessory drive belt tensioner indicator is outside the normal
installation wear range window, install a new accessory drive belt.
z NOTE: The accessory drive belt tensioner arm should rotate freely without binding.
Install a new accessory drive belt tensioner if the drive belt tensioner is worn or damaged.
Drive Belt — Incorrect Installation
NOTICE: Incorrect accessory drive belt installation will cause excessive drive belt wear and may
cause the drive belt to come off the pulleys.
Non-standard accessory drive belts can track differently or incorrectly. If an accessory drive belt tracks
incorrectly, install a new accessory drive belt to avoid performance failure or loss of the drive belt.
Incorrect Installation
Correct Installation
With the engine running, check accessory drive belt tracking on all pulleys. If the edge of the accessory drive
belt rides beyond the edge of the pulleys, noise and premature wear will occur. Make sure the accessory
drive belt rides correctly on the pulley. If an accessory drive belt tracking condition exists, proceed with the
following:
z Visually check the accessory drive belt tensioner for damage and wear, especially the mounting pad
surface and arm alignment. If the accessory drive belt tensioner is not installed correctly, the
mounting surface pad will be out of position. If the tensioner arm is worn, the arm will be out of
alignment. Either of these conditions will result in chirp and squeal noises.
z With the engine running, visually observe the grooves in the pulleys (not the pulley flanges or the
pulley forward faces) for excessive wobble. Install new components as necessary.
z Check all accessories, mounting brackets and the accessory drive belt tensioner for any interference
that would prevent the component from mounting correctly. Correct any interference condition and
recheck the accessory drive belt tracking.
z Tighten all accessories, mounting brackets and accessory drive belt tensioner retaining hardware to
specification. Recheck the accessory drive belt tracking.
Belt Tensioner — Mechanical
The only mechanical check that needs to be made is a check for tensioner stick, grab or bind.
1. With the engine off, check routing of the accessory drive belt. Refer to the illustrations under
Accessory Drive in the Description and Operation portion of this section.
2. NOTE: The accessory drive belt tensioner spring is very strong and requires substantial force to
release.
Using a suitable, commercially available serpentine belt tensioner release tool, release the tension on
the belt and detach the accessory drive belt from the tensioner. Carry out the following tests:
z Using the release tool, move the tensioner from its relaxed position, through its full stroke and
back to the relaxed position to make sure there is no stick, grab or bind, and to make sure that
there is tension on the tensioner spring.
z Rotate the tensioner pulley by hand and check for a binding, contaminated or seized condition.
z Inspect the area surrounding the accessory drive belt tensioner for oil leaks or contamination
and repair any leaks.
3. If the accessory drive belt tensioner does not meet the criteria in the previous step, install a new
tensioner. If the accessory drive belt tensioner meets the criteria in the previous step, proceed to
testing the tensioner dynamically.
4. If the tensioner is saturated with oil and grease internally, install a new tensioner.
Belt Tensioner — Dynamics
The accessory drive belt tensioner can be checked dynamically as follows:
1. With the engine running, observe the accessory drive belt tensioner movement. The accessory drive
tensioner should move (respond) when the A/C clutch cycles (if equipped), or when the engine is
accelerated rapidly. If the accessory drive belt tensioner movement is excessive without A/C clutch
cycling or engine acceleration, check belt rideout. Excessive belt rideout (uneven depth of grooves in
the belt) can cause excessive accessory drive belt tensioner movement. Check rideout condition by
installing a new belt. If excessive accessory drive belt tensioner movement still exists, install a new
accessory drive belt tensioner.

Air Conditioning (A/C) Compressor Belt — 3.5L GTDI, 3.7L, 5.0L
Special Tool(s)
Remover, Stretchy Belt
303-1419
Removal
NOTICE: Under no circumstances should the A/C compressor belt, accessory drive belt, tensioner or
pulleys be lubricated as potential damage to the belt material and tensioner damping mechanism will
occur. Do not apply any fluids or belt dressing to the A/C compressor belt, accessory drive belt or
pulleys.
All Engines
02 .
2. Remove the accessory drive belt. For additional information, refer to Front End Accessory Drive
(FEAD) — Exploded View in this section.
3.5L and 3.7L Engines
3. Position the Stretchy Belt Remover on the A/C compressor belt as shown.
4. NOTE: Feed the Stretchy Belt Remover on to the A/C compressor pulley approximately 180 degrees.
Turn the crankshaft clockwise and feed the Stretchy Belt Remover evenly between the A/C
compressor pulley and the A/C compressor belt as shown.
5. Remove the A/C compressor belt.

z Fold the Stretchy Belt Remover around the inside of the A/C compressor belt as shown.
z In one quick motion, firmly pull the Stretchy Belt Remover from below the vehicle and remove
the A/C compressor belt.
5.0L (4V) Early Build Vehicles
6. Cut the A/C compressor belt and discard the belt.
5.0L (4V) Late Build Vehicles
7. Rotate the drive belt tensioner clockwise and detach the A/C compressor drive belt from the idler
pulley and remove the A/C compressor drive belt.
Installation
3.5L GTDI, 3.7L, 5.0L (4V) Early Build Vehicles
1. NOTE: 5.0L (4V) engine shown, 3.5L and 3.7L engines similar.
Position the A/C compressor belt in 2 stages.

z Stage 1: Slide the A/C compressor belt between the crankshaft pulley and the accessory drive
belt tensioner.
z Stage 2: Position the A/C compressor belt behind the crankshaft pulley with the accessory
drive belt ribs facing towards the front of the vehicle.
z NOTE: Make sure the A/C compressor belt is correctly seated on the A/C compressor pulley.
Stage 3: Position the A/C compressor belt onto the A/C compressor pulley with the lower
portion of the accessory drive belt ribs facing towards the front of the vehicle and above the oil
pan as shown.
NOTE: After installation, make sure the A/C compressor belt is correctly seated on the crankshaft and
A/C compressor pulleys.
Position the A/C compressor belt onto the top of the crankshaft pulley and feed a tie strap with a
minimum width of 3 mm (0.12 in) through the crankshaft pulley spokes, up and over the A/C
compressor belt and tighten the tie strap.
3. NOTICE: The A/C compressor belt must be above the oil pan flange or damage to the A/C
compressor belt and engine can occur.
NOTE: 5.0L (4V) engine shown, 3.5L and 3.7L engines similar.
With the A/C compressor belt positioned above the oil pan flange, rotate the crankshaft by hand
clockwise until the tie strap is at the 6 o'clock position.
NOTE: After installation, make sure the A/C compressor belt is correctly seated on the crankshaft and
A/C compressor pulleys.
Remove the tie strap and rotate the crankshaft clockwise 1 full rotation to verify the A/C compressor
belt has correctly seated onto the crankshaft and A/C compressor pulleys.
5.0L (4V) Late Build Vehicles
5. Position the A/C drive belt and rotate the drive belt tensioner clockwise and attach the A/C
compressor drive belt to the idler pulley.
All Engines
6. Install the accessory drive belt. For additional information, refer to Front End Accessory Drive (FEAD)
— Exploded View in this section.

Front End Accessory Drive (FEAD) — Exploded View
3.5L and 3.7L
NOTE: 3.7L shown 3.5L similar.

5.0L (4V)
Part
1 8620 Accessory drive belt - 47 Nm (35 lb-ft)
2 W709638 Accessory drive belt tensioner bolt
5 Part of A/C compressor drive belt tensioner bolt - 34 Nm (25
6A228 lb-ft)
6 6A228 A/C drive compressor belt tensioner
7 W707288 A/C compressor drive belt idler pulley bolt - 25 Nm
(18 lb-ft)
8 19A216 A/C compressor drive belt Idler pulley
6.2L (2V)

2 N808920 Accessory drive belt tensioner bolt (3 required)
4 N808102 Accessory drive belt idler pulley bolt
5 19A216 Accessory drive belt idler pulley
6 N808102 Accessory drive belt idler pulley bolt
7 19A216 Accessory drive belt idler pulley
removal.
SECTION 303-06: Starting System 2014 F-150 Workshop Manual

Item Specification
Normal engine cranking speed 140-220 rpm
Starter motor maximum load 800 amps a
Starter motor maximum voltage drop (engine at normal operating temperature) 0.5 volt
Starter motor minimum stall torque (at 5 volts) 14.7 Nm (10.8 lb-ft)
Starter motor no load current draw 60-84 amps
Starter motor normal load current draw 130-220 amps b
a
Initial "in-rush" current draw.
b Continuously running current draw.
lb- lb-
Starter motor mounting bolts — 3.5L Gasoline Turbocharged Direct Injection (GTDI) and 48 35 —
3.7L
Starter motor mounting bolts — 5.0L (4V) and 6.2L (2V) 25 18 —
Starter motor mounting stud bolts — 5.0L (4V) and 6.2L (2V) 25 18 —
Starter motor ground cable nut — 5.0L (4V) and 6.2L (2V) 25 18 —
Starter solenoid B+ terminal nut 12 — 106
Starter solenoid S-terminal nut 5 — 44

Starting System
The starting system consists of the following:
z Fuse(s)
z Battery
z Battery cables
z Ignition switch
z Starter motor
z Run/start relay (located in the Battery Junction Box (BJB))
z Starter relay (located in the Battery Junction Box (BJB))
z PCM (located on the RH side of cowl)
z Body Control Module (BCM)
z Transmission Range (TR) sensor (located inside the transmission)
z Integrated Keyhead Transmitter (IKT)
z Tire Pressure Monitor Module (TPM) ( TPM is standard equipment, also used for optional remote start
feature)
z External antenna (if equipped with remote start)
z Hood switch (hood switch is standard equipment, also used for optional remote start feature)

Starting System
Special Tool(s)
Flex Probe Kit


NOTE: This vehicle is equipped with Passive Anti-Theft System (PATS) that disables the engine from
cranking and starting if an unprogrammed PATS key is used or an invalid PCM ID is received. PATS is
controlled by the Body Control Module (BCM). If there is a PATS concern that causes the engine to
disabled, the Instrument Panel Cluster (IPC) displays "STARTING SYSTEM FAULT" in the message center.
Refer to Section 419-01B to diagnose a PATS concern.
The starter system controls the cranking of the engine. The starter motor is enabled by the starter relay
when the relay is activated by the PCM. The starting system is electronically controlled by the PCM. The
PCM requires the following inputs:
z Ignition switch request to start the engine

z Run/start relay voltage
z PATS enable status from the BCM
z Correct transmission PARK or NEUTRAL input from the Transmission Range (TR) sensor
Under normal operation when the ignition is turned to the START position, the BCM generates a key
verification message. It sends this message to the PATS transceiver. The transceiver reads the key and
sends a key verification message back to the BCM . If the message received does not match the key verified
in the BCM memory, the engine is disabled and does not crank and start. Once the BCM determines the
correct programmed key is in the ignition, the BCM sends the PCM a valid PATS message. When the PCM
receives the message, it generates a response and sends it back to the BCM . If the response from the PCM
does not match the response in the BCM memory, PATS is not enabled and the engine does not crank. If
both the key verification and PCM ID pass, PATS is enabled. The PCM recognizes the correct electronically
coded passive key and provides voltage and ground to the starter relay coil. The starter relay coil is
energized causing the relay contacts to close providing voltage to the starter solenoid, allowing the starter
motor to crank and start the engine. The PCM disengages the starter once an engine rpm threshold is
reached, a set crank time is exceeded or the ignition is turned OFF. The BCM also enables the Run/start
relay which sends voltage to the PCM. If the PCM does not receive this voltage the engine will not crank.
The TR sensor prevents operation of the starter motor unless the transmission is in NEUTRAL or PARK.
Remote Start
The factory remote start system (if equipped) does not operate if the ignition is in the RUN/START position
or the hood is not closed.
The remote start system can be enabled or disabled by the customer. When enabled, the customer can set
the engine run time for 5, 10 or 15 minutes. For information on setting the engine run time, refer to the
Owner's Literature or Section 413-01 .
The remote start system enables the engine to be started from up to 100 m (328 ft) away, by pressing a
sequence of buttons on the Integrated Keyhead Transmitter (IKT). The remote start system is activated by
pressing the lock button on the IKT , to make sure the doors are locked, followed by 2 presses of the remote
start button. The 3 button presses must occur within 3 seconds. The system acknowledges the start request
by flashing the exterior lights twice. Once started, the engine runs for 10 minutes (default run time is 10
minutes; the time can be programmed by the customer to 5, 10 or 15 minutes) and the parking lights remain
illuminated until the cycle is complete. The remote start duration can also be extended by initiating remote
start while the first timer is still running or by initiating a completely independent start cycle when the first has
completed. No more than 2 remote start sequences can occur within a one hour period, unless the ignition is
set to the RUN/START position between the remote start requests. During the remote start cycle the power
windows are inhibited and the radio will not turn on automatically but may be switched on manually from
inside the vehicle. If the remote start system fails to start the horn chirps twice.
To transition from remote start mode to drive mode, use a programmed IKT to switch the ignition to the RUN
position. If a programmed IKT is not used, the engine shuts off.
To deactivate the remote start system, press the remote start button once. When deactivating the remote
start system the parking lights turn off to give a visual indication that the engine and climate control features
have turned off. It may be necessary to be closer to the vehicle to deactivate the remote start feature than it
was to initiate it due to ground deflections and added noise from the engine running.
The remote start system conditions the cabin temperature during remote start based on the outside
temperature. For information on cabin temperature conditioning during remote start, refer to Section 412-00 .
starter motor battery terminal lead. If a tool is shorted at the starter motor battery terminal, the tool
can quickly heat enough to cause a skin burn. Failure to follow this instruction may result in serious
personal injury.
NOTE: Make sure the anti-theft system is functioning correctly before carrying out a logical starting system
diagnosis. Address anti-theft system concerns before continuing. Refer to Section 419-01B .
1. Verify the customer concern by operating the starting system.
2. Check the battery condition and state of charge. Section 414-01 .
3. Remove the accessory drive belt. Refer to Section 303-05 . Verify the crankshaft and each of the
components driven by the accessory drive belt rotate and are not seized or damaged.
4. If any aftermarket accessories have been added to the vehicle, make sure they are properly wired.
5. Inspect to determine if any of the following mechanical or electrical concerns apply.

z Starter motor z Battery
z Starter motor bolts z Battery cables
z Battery Junction Box (BJB) Starter relay
z Battery Junction Box (BJB) Run/start relay
z Battery Junction Box (BJB) fuse 13 (30A)
z Body Control Module (BCM) fuse 28 (15A)
z Loose or corroded connections
6. If an obvious cause for an observed or reported concern is found, correct the cause before
proceeding to the next step.
8. NOTE: The LED prove out confirms power and ground from the DLC are provided to the VCM .


z refer to Section 418-00 to diagnose no communication with the scan tool.

418-00 .
11. Carry out the self-test diagnostics for the BCM , PCM and Tire Pressure Monitor Module (TPM) ( TPM
is standard equipment, also used for optional remote start feature).
12. If the DTCs retrieved are related to the concern, go to DTC Charts.
DTC Charts
PCM DTC Chart

P0512 Starter Request Circuit — Circuit CARRY OUT the Ignition Switch Component Test. Refer to
has Power With the Ignition in the Wiring Diagrams Cell 149 for component testing. If
OFF Position necessary, INSTALL a new ignition switch. If the ignition
switch passed the component test, REPAIR circuit CDC35
(BU/WH) for a short to voltage.
P0705 Transmission Range Sensor A REFER to Section 307-01 to diagnose the Transmission
Circuit (PRNDL Input): No Sub Range (TR) sensor concern.
Type Information
P0706 Transmission Range Sensor "A" REFER to Section 307-01 to diagnose the TR sensor
Circuit Range/Performance: No concern.
Sub Type Information
Circuit Low: No Sub Type concern.
Information
Circuit High: No Sub Type concern.
Information
Circuit Intermittent: No Sub Type concern.
Information
P161A Incorrect Response From REFER to Section 419-01B .
Immobilizer Control Module
P1702 Transmission Range Sensor REFER to Section 307-01 to diagnose the TR sensor
Circuit Intermittent: No Sub Type concern.
Information
P1705 Transmission Range Circuit Not REFER to Section 307-01 to diagnose the TR sensor
Indicating Park/Neutral During Self concern.
Test: No Sub Type Information
P1921 Transmission Range Signal: No REFER to Section 307-01 to diagnose the TR sensor
Sub Type Information concern.
P2532 Ignition Switch Run Position Circuit GO to Pinpoint Test G .
High
P2535 Ignition Switch Run/Start Position GO to Pinpoint Test G .
Circuit High
PCM
DTCs

B1305:01 Hood Switch: General REFER to Section 419-01A .
Electrical Failure
C113A:11 Wake up Control: Circuit GO to Pinpoint Test C .
Short to Ground
C113A:15 Wake up Control: Circuit GO to Pinpoint Test C .
Short to Battery or Open
U1000:00 Solid State Driver The Body Control Module (BCM) has temporarily disabled an output
Protection Activated - because an excessive current draw exists (such as a short to
Driver Disabled: No Sub ground). The BCM cannot enable the output until the cause of the
Type Information short is corrected. ADDRESS all other DTCs first. After the cause of
the concern is corrected, CLEAR the DTCs. REPEAT the self-test.
DTCs
Tire Pressure Monitor (TPM) Module DTC Chart

B1D55:01 Antenna #2: General Electrical Failure GO to Pinpoint Test D .
All other DTCs — REFER to Section 204-04 .
Symptom Chart
Symptom Chart
z The engine does z Battery z GO to Pinpoint Test A .
not crank z Battery cables
z Fuses
z Starter motor
z PCM
z Starter relay
z Run/start relay
z Ignition switch
z Transmission
Range (TR)
sensor
z Passive Anti-
Theft System
(PATS)
z Body Control
Module (BCM)
z Wiring, terminals
or connectors
z Unusual starter z Starter motor z GO to Pinpoint Test B .
noise z Starter motor
mounting
z Starter motor
engagement
z Flexplate ring
gear
z The engine z Battery z CARRY OUT the Starter Motor —
cranks slowly z Battery cables Feed Circuit and Starter Motor —
z Starter motor Ground Circuit Tests. REFER to
z Wiring, terminals Component Tests in this section.
or connectors
z The engine z Fuses z Powertrain Control/Emissions
cranks but does z PCM Diagnosis (PC/ED) manual
not start. z Fuel pump
z Fuel pump relay
z The starter spins z Damaged z REFER to Starter Motor Drive Gear
but the engine flexplate and Flywheel Ring Gear Inspection in
does not crank z Starter motor this section to continue diagnosis.
z The starter does z Starter motor z REFER to Starter Motor Drive Gear
not disengage and Flywheel Ring Gear Inspection in
from the this section to continue diagnosis.
flexplate
z Wiring, terminal z REMOVE the starter relay, if the
or connectors engine stops cranking INSTALL a new
z Starter relay relay. If the engine continues to crank,
REPAIR circuit CDC25 (BN/GN) for a
short to voltage.
z The remote start z Wiring, terminals z GO to Pinpoint Test D .
system operates or connectors
with reduced z External
range antenna
z Tire Pressure
Monitor Module
(TPM)
z The remote start z Wiring, terminals z GO to Pinpoint Test E .
is inoperative or connectors
z Remote start
feature not
enabled
z Integrated
Keyhead
Transmitter
(IKT)
z Hood switch
z PCM
z One-Touch z OTIS not z Using a scan tool, ENABLE OTIS .
Integrated Start enabled
(OTIS) is
inoperative
Pinpoint Tests
Pinpoint Test A: The Engine Does Not Crank
Normal Operation
When the ignition switch is turned to the START position, the Body Control Module (BCM) and PCM receive
a request to start the engine. When the PCM receives the correct coded key ID messages from the BCM ,
voltage from the Run/start relay, and the correct input from the Transmission Range (TR) sensor that the
gear selector is in PARK or NEUTRAL, voltage and ground is supplied to the starter relay coil. When the
starter relay is energized the relay contacts close. Voltage is then supplied from Battery Junction Box (BJB)
fuse 13 (30A) to the starter relay contacts which supplies voltage to the starter solenoid. The starter solenoid
is grounded at the starter motor. Energizing the starter solenoid engages the starter drive into the ring gear
and closes the starter solenoid contacts allowing voltage directly from the battery to the starter motor to
crank the engine. The PCM disengages the starter once an RPM threshold is reached, a set crank time is
exceeded or the ignition switch is turned to the OFF position.

z Battery
z Battery cables
z Fuses
z Ignition switch
z PCM
z Starter motor
z Starter relay
z TR sensor
z Passive Anti-Theft System (PATS)
z BCM
PINPOINT TEST A: THE ENGINE DOES NOT CRANK

A1 PERFORM INSPECTION AND VERIFICATION
NOTE: Make sure battery voltage is greater than 12.2 volts Yes
prior to and during this pinpoint test. Correct the cause as necessary.
NOTE: If it is necessary to leave the battery charger
connected during testing, do not leave it on its highest No
setting. The highest and boost settings can occasionally GO to A2 .
exceed 16 volts, resulting in false test results and setting
DTCs.
z Perform the Inspection and Verification procedure in this
section.
z Was an obvious cause for an observed or reported
concern found?
A2 CHECK FOR ANY MESSAGES IN THE MESSAGE CENTER
z Ignition ON. Yes
z Check the message center with the ignition key in the RUN REFER to Section 419-01B .
position.
z Is STARTING SYSTEM FAULT displayed in the message No
center? GO to A3 .
A3 VERIFY BCM AND PCM PASS THE NETWORK TEST
z Ignition ON. Yes

z Using a diagnostic scan tool, perform the Network Test. GO to A4 .
z Did the BCM and PCM pass the Network Test?
No
A4 RETRIEVE BCM AND PCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: BCM REFER to the DTC Charts in
— Self-Test. this section.
z Enter the following diagnostic mode on the scan tool: PCM
— Self-Test. No
z Were DTCs retrieved during the self-test? GO to A5 .
A5 CHECK THE PCM TRANSMISSION RANGE TR SENSOR
PID
DataLogger — PCM. GO to A6 .
z While observing the TR PID, place the gear selector in PARK
and then NEUTRAL. No
z Does the PID match the selector lever position? REFER to Section 307-01 , to
diagnose the TR sensor
concern.
A6 CHECK THE BCM IGN_SW_STATE PID
DataLogger — BCM. GO to A7 .
z While holding the key in the START position, monitor the
BCM IGN_SW_STATE PID. No
z Does the PID change from OFF to START? DIAGNOSE No power in Start.
A7 CHECK THE STARTER MOTOR RELAY
z Swap the starter relay with a known good relay and attempt Yes
to crank the engine. INSTALL a new starter relay.
z Does the engine crank?
No
GO to A8 .
A8 CHECK THE VOLTAGE TO THE STARTER RELAY
z Ignition OFF. Yes
z Disconnect: Starter Relay. GO to A9 .
z Measure the voltage between starter relay socket 3, circuit
SBB13 (GY/RD) and ground. No
VERIFY BJB fuse 13 (30A) is
OK. If OK, REPAIR circuit
SBB13 (GY/RD) for an open. If
not OK, REFER to the Wiring
possible causes of the circuit
short. TEST the system for
normal operation.

A9 CHECK THE STARTER MOTOR
z With the transmission in PARK, connect one end of a fused Yes
jumper wire to starter relay socket 3, circuit SBB13 (GY/RD) GO to A15 .
and momentarily connect the other end of the fused jumper
wire to starter relay socket 5, circuit CDC25 (BN/GN). No
GO to A10 .
z Did the starter motor engage and the engine crank?

A10 CHECK THE BATTERY GROUND CABLE
z Measure the voltage between the positive battery post and Yes
the battery ground cable connection at the engine. GO to A11 .
No
INSTALL new battery cables.
operation.

A11 CHECK THE STARTER MOTOR GROUND
z Measure the voltage between the positive battery post and Yes
the starter motor case. GO to A12 .
No
CLEAN the starter motor
mounting flange and make sure
the starter motor is correctly
mounted. TEST the system for
normal operation.

A12 CHECK THE VOLTAGE TO THE STARTER MOTOR
z Measure the voltage between the starter solenoid C197A-1, Yes
circuit SDC02 (RD) and ground. GO to A13 .
No
INSTALL new battery cables.
operation.

A13 CHECK THE STARTER MOTOR
z Connect one end of a fused jumper wire to starter solenoid Yes
C197A-1, circuit SDC02 (RD) and momentarily connect the GO to A14 .
other end of the fused jumper wire to starter solenoid C197B-
1, circuit CDC25 (BN/GN). No
INSTALL a new starter motor.
REFER to Starter Motor — 3.5L
GTDI, 3.7L or Starter Motor —
5.0L (4V), 6.2L (2V) in this
section. TEST the system for
normal operation.
z Did the starter engage and the engine crank?

A14 CHECK FOR START INPUT AT THE STARTER
z Connect: Starter Relay. Yes
z Disconnect: Starter Solenoid C197B. CLEAN the starter solenoid "S"
z Measure the voltage between the starter solenoid C197B-1, terminal and C197B. CHECK the
circuit CDC25 (BN/GN) and ground, while holding the key in wiring and the starter motor for a
the START position. loose or intermittent connection.
operation.
No
REPAIR circuit CDC25 (BN/GN)
for an open. TEST the system

A15 CHECK THE PCM START CIRCUITS FOR A SHORT TO
GROUND
z Disconnect: PCM C175B (5.0L and 6.2L), C1381B (3.7L) or Yes
C1551B (3.5L). GO to A16 .
z Measure the resistance between the PCM C175B (5.0L and
6.2L) or C1381B (3.7L), harness side and ground, using the No
following chart: REPAIR the affected circuit.
PCM Connector-Pin Circuit operation.
C175B-7 (5.0L and 6.2L) or C1381B-7 CDC12 (YE)

(3.7L)
C175B-37 (5.0L and 6.2L) or C1381B-37 CDC54
(3.7L) (WH/GN)
z Measure the resistance between the PCM C1551B (3.5L),

harness side and ground, using the following chart:
PCM Connector-Pin Circuit

C1551B-43 (3.5L) CDC12 (YE)
C1551B-62 (3.5L) CDC54 (WH/GN)

A16 CHECK THE PCM START CIRCUITS FOR AN OPEN
z Measure the resistance between the PCM C175B (5.0L and Yes
6.2L) or C1381B (3.7L), harness side and the starter relay INSTALL a new PCM. REFER to
using the following chart: Section 303-14 . TEST the
Starter Relay
PCM Connector-Pin Circuit Socket No
REPAIR the affected circuit.
C175B-7 (5.0L and 6.2L) or CDC12 (YE) 2 TEST the system for normal
C1381B-7 (3.7L) operation.
C175B-37 (5.0L and 6.2L) or CDC54 1
C1381B-37 (3.7L) (WH/GN)
z Measure the resistance between the PCM C1551B (3.5L),

harness side and the starter relay using the following chart:
PCM Connector- Starter Relay

Pin Circuit Socket
C1551B-43 (3.5L) CDC12 (YE) 2
C1551B-62 (3.5L) CDC54 1
(WH/GN)
Pinpoint Test B: Unusual Starter Noise
Normal Operation
Correct starter operation relies on correct mounting of the starter to the engine, alignment of the starter ring
gear to the flexplate and correct functioning of the starter assembly (internal gears, bearings).

z Starter motor
z Starter motor mounting
z Starter motor engagement
z Flexplate ring gear
PINPOINT TEST B: UNUSUAL STARTER NOISE

B1 CHECK THE STARTER MOUNTING
z Inspect the starter motor mounting bolts for Yes
looseness. GO to B2 .
z Is the starter motor mounted correctly?
No
INSTALL the starter motor correctly.
REFER to Starter Motor — 3.5L GTDI,
3.7L or Starter Motor — 5.0L (4V), 6.2L
(2V) in this section. TEST the system for
normal operation.
B2 CHECK FOR STARTER NOISE
z Ignition OFF. Yes
z Connect a remote starter switch between the REFER to Starter Motor Drive Gear and
starter solenoid C197A-1 and C197B-1. Flywheel Ring Gear Inspection in this
section to continue diagnosis.
No
REFER to Section 303-00 , Symptom
Chart — Engine NVH to continue
diagnosis.
z Engage the starter and verify the noise is due to

starter operation.
z Is the noise due to the starter engagement?
Pinpoint Test C: DTC C113A:11 or C113A:15
Refer to Wiring Diagrams Cell 112 , Passive Anti-Theft System for schematic and connector information.
Normal Operation
The wake up control circuit is used to wake up the PCM prior to engine cranking. The PCM needs to wake
up prior to a crank request so that it has time to go through its own initialization. The wake up control circuit
also powers the Passive Anti-Theft System (PATS) transceiver. The wake up control circuit is controlled by
the Body Control Module (BCM) and receives voltage from fuse 18 (10A). The BCM uses a Field-Effect
Transistor (FET) to control the wake up control circuit. A DTC sets and the wake up control circuit is disabled
via the FET if a fault is detected. Once the condition that caused the DTC to set is repaired, the BCM must
pass a self-test in order for the DTC to clear and the system to resume normal operation.
The BCM activates the wake up control circuit when:
z the driver door is opened.

z a remote start request is received (if equipped with factory remote start).
z the brake pedal is pressed.
z a key is inserted into the ignition.
z the ignition is in the RUN or START position.
z DTC C113A:11 (Wake up Control: Circuit Short To Ground) — sets when the BCM detects a short to
ground on the wake up control circuit.
z DTC C113A:15 (Wake up Control: Circuit Short To Battery or Open) — sets when the BCM detects a
short to voltage or an open on the wake up control circuit.

z PATS transceiver
z PCM
z BCM
PINPOINT TEST C: DTC C113A:11 OR C113A:15

C1 RETRIEVE THE BCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: GO to C2 .
BCM — Self-Test.
z Is DTC C113A:15 on demand during the self-test? No
GO to C5 .
C2 CHECK THE WAKE UP CONTROL CIRCUIT FOR A
SHORT TO VOLTAGE
z Ignition OFF. Yes
z Disconnect: BCM C2280F. REPAIR the circuit. CLEAR the
z Disconnect: PATS Transceiver C252. DTCs. REPEAT the self-test. TEST
z Disconnect: PCM C175B (5.0L and 6.2L), C1381B the system for normal operation.
(3.7L) or C1551B (3.5L).

z Ignition ON. No
z Measure the voltage between the PCM C1551B-28 GO to C3 .
(3.5L), circuit CE436 (VT/OG), harness side and ground.
z Measure the voltage between the PCM C175B-35 (5.0L

and 6.2L) or C1381B-35 (3.7L), circuit CE436 (VT/OG),
harness side and ground.

C3 CHECK THE WAKE UP CONTROL CIRCUIT FOR AN
OPEN
z Ignition OFF. Yes
z Measure the resistance between the PCM C1551B-28 GO to C4 .
(3.5L), circuit CE436 (VT/OG), harness side and BCM
C2280F-5, circuit CE436 (VT/OG), harness side. No
REPAIR circuit CE436 (VT/OG) for
an open. CLEAR the DTCs. REPEAT
normal operation.
z Measure the resistance between the PCM C175B-35

(5.0L and 6.2L) or C1381B-35 (3.7L), circuit CE436
(VT/OG), harness side and BCM C2280F-5, circuit
CE436 (VT/OG), harness side.

C4 CHECK THE BCM AND PCM FOR CORRECT
OPERATION
z Connect: BCM C2280F. Yes
z Ignition ON. INSTALL a new PCM. REFER to
z Measure the voltage between PCM C1551B-28 (3.5L), Section 303-14 . CLEAR the DTCs.
circuit CE436 (VT/OG), harness side and ground. REPEAT the self-test. TEST the
No
VERIFY BCM fuse 18 (10A) is OK. If
OK, INSTALL a new BCM . REFER
to Section 419-10 . If not OK, REFER
to the Wiring Diagrams manual to
identify the possible causes of the
circuit short. CLEAR the DTCs.
REPEAT the self-test. TEST the
z Measure the voltage between the PCM C175B-35 (5.0L

and 6.2L) or C1381B-35 ( 3.7L), circuit CE436 (VT/OG),

C5 CHECK THE WAKE UP CONTROL CIRCUIT DTC FOR
A FAULT STATUS CHANGE (SHORT TO GROUND
INDICATED)
Clear BCM Continuous DTCs. GO to C6 .
z Ignition OFF.
z Disconnect: PATS Transceiver C252. No
z Connect: PCM C175B (5.0L and 6.2L), C1381B (3.7L) GO to C7 .
or C1551B (3.5L).
z Ignition ON.
BCM — Self-Test.
z Was DTC C113A:11 retrieved on demand during self-
test?
C6 CHECK THE WAKE UP CONTROL CIRCUIT FOR A
SHORT TO GROUND
z Ignition OFF. Yes
z Disconnect: BCM C2280F. INSTALL a new BCM . REFER to
z Measure the resistance between the PCM C1551B-28 Section 419-10 . CLEAR the DTCs.
(3.5L), circuit CE436 (VT/OG), harness side and ground. REPEAT the self-test. TEST the
No
REPAIR the circuit. CLEAR the
DTCs. REPEAT the self-test. TEST
z Measure the resistance between the PCM C175B-35

(VT/OG), harness side and ground.

C7 CHECK THE PCM FOR CORRECT OPERATION
Clear BCM Continuous DTCs. INSTALL a new PCM. REFER to
z Ignition OFF. Section 303-14 . CLEAR the DTCs.
z Connect: PCM C175B (5.0L and 6.2L), C1381B (3.7L) REPEAT the self-test. TEST the
or C1551B (3.5L). system for normal operation.
z Ignition ON.
BCM — Self-Test. INSTALL a new PATS transceiver.
z Was DTC C113A:11 retrieved on-demand during REFER to Section 419-01B . CLEAR
self-test? the DTCs. REPEAT the self-test.
operation.
Pinpoint Test D: DTC B1D55:01
Normal Operation
An external antenna connected to the Tire Pressure Monitor Module (TPM) receives a signal from the
Integrated Keyhead Transmitter (IKT) to enable activation of the remote start function from a distance of up
to 100 meters (328 feet). If the external antenna fails, the remote start operates with a reduction in the range
of operation.
z DTC B1D55:01 (Antenna #2: General Electrical Failure) — this DTC is set if the vehicle is equipped
with remote start but the system feedback circuit does not detect an external antenna.

z External antenna
z External antenna lead
z TPM
PINPOINT TEST D: DTC B1D55:01

D1 CHECK THE EXTERNAL ANTENNA
CONNECTION
z Check the connections at the external antenna Yes
and TPM . REPAIR as necessary. CLEAR the DTCs.
z Are the connections loose or REPEAT the self-test. TEST the system for
disconnected? normal operation.
No
GO to D2 .
D2 CHECK THE EXTERNAL ANTENNA
z INSTALL a new external antenna. Yes
z ATTEMPT to start the vehicle using the IKT System is operating correctly at this time.
from a distance of 100 meters (328 feet) from CLEAR the DTCs. REPEAT the self-test.
the vehicle. TEST the system for normal operation.
z Does the vehicle start from this distance?
No
GO to D3 .
D3 CHECK THE EXTERNAL ANTENNA CABLE
z INSTALL a new external antenna cable. Yes
CLEAR the DTCs. REPEAT the self-test. TEST System is operating correctly at this time.
the system for normal operation. CLEAR the DTCs. REPEAT the self-test.
z ATTEMPT to start the vehicle using the IKT TEST the system for normal operation.
from a distance of 100 meters (328 feet) from
the vehicle No
z Does the vehicle start from this distance? INSTALL a new TPM . REFER to Section 204-
04 . CLEAR the DTCs. REPEAT the self-test.
Pinpoint test E: The Remote Start Is Inoperative
Normal Operation
The factory equipped remote start system enables the engine to be started from up to 100 meters (328 feet)
away by pressing the Integrated Keyhead Transmitter (IKT) lock button followed by 2 presses of the remote
start button. The 3 button presses must occur within 3 seconds. The IKT signal is received through an
external antenna attached to the Tire Pressure Monitor Module (TPM) module and communicated over the
Medium Speed Controller Area Network (MS-CAN) to initiate the vehicle start.

z Remote start feature disabled
z IKT
z Hood switch
z PCM
PINPOINT TEST E: THE REMOTE START IS INOPERATIVE

E1 CHECK THE OPERATION OF THE IKT
z Press all buttons on the IKT and check for the correct Yes
operation. GO to E2 .
z Is the remote start the only function that is
inoperative? No
DIAGNOSE and REPAIR the Remote
Keyless Entry (RKE) system.
E2 CHECK THE VEHICLE STARTING
z Attempt to start the vehicle. Yes
z Did the vehicle start? GO to E3 .
No
This is not a remote start issue. GO to
Symptom Chart to diagnose the no
crank condition.
E3 CHECK FOR ILLUMINATED ENGINE WARNING
LAMPS
z With the engine running check the instrument cluster Yes
for illuminated warning lamps. CARRY OUT a self test of the PCM.
z Are any engine warning lamps illuminated? DIAGNOSE and REPAIR any present
DTCs. REFER to Section 303-14 or
Powertrain Control/Emissions
No
GO to E4 .
E4 RETRIEVE BCM AND TPM DTCs
BCM — Self-Test. For BCM DTCs C113A:11 or
z Enter the following diagnostic mode on the scan tool: C113A:15, GO to Pinpoint Test C .
TPM — Self-Test.
z Are any DTCs present? For BCM DTC B1305:01, REFER to
Section 419-01A .
For TPM DTCs U0140:87 or

U0422:68, REFER to Section 204-04 .
For all other DTCs, REFER to Section

419-10 .
No
GO to E5 .
E5 CONFIRM THE REMOTE START FUNCTION IS
ENABLED
z Ignition ON. Yes
z Check the message center and confirm the remote GO to E6 .
start function is enabled. Refer to the Owner's
Literature or Section 413-01 . No
z Is the remote start function enabled? ENABLE the remote start function.
E6 CHECK THE BCM LAST RECEIVED RKE
TRANSMITTER BUTTON PRESS (LST_RKE_xMTR)
TRANSMITTER PID
DataLogger — BCM . GO to E7 .
z Press the remote start button on the IKT and note the
PID status. No
z Does the selected PID indicate the remote start INSTALL and PROGRAM a new IKT .
button was the last button pressed? REFER to Section 419-01B . TEST
E7 CHECK THE PCM WAKE UP CIRCUIT
z Ignition OFF. Yes
z Disconnect: PCM C175B (5.0L and 6.2L), C1381B GO to E8 .
(3.7L) or C1551B (3.5L).
z Ignition ON. No
z Measure the voltage between the PCM C1551B-28 VERIFY BCM fuse 18 (10A) is OK. If
(3.5L), circuit CE436 (VT/OG), harness side and OK, REPAIR circuit CE436 (VT/OG)
ground. for an open. If not OK, REFER to the
Wiring Diagrams manual to identify the
operation.
z Measure the voltage between the PCM C175B-35

(VT/OG), harness side and ground.

E8 CHECK THE REMOTE START PRECONDITIONS FOR
CORRECT OPERATION
NOTE: The Body Control Module (BCM) acknowledges Yes

INSTALL a new PCM. REFER to
the remote start request and that all preconditions have
Section 303-14 . TEST the system for
been met by providing 2 short flashes of the turn
normal operation.
indicators and a system complete chirp.
z Make sure that the following preconditions for remote No
start have been met: CARRY OUT the required
Hood is closed with no DTC present. precondition as necessary. TEST the
Ignition must be off system for normal operation.
Vehicle must be in PARK.
Remote start feature is configured ON.
Number of remote start events does not exceed
allowed time (2 events in a 1 hour duration).
Attempt to carry out a remote start.
z Is the remote start system still inoperative?
Pinpoint Test G: DTC P2532 And P2535
Normal Operation
When the ignition key is turned to the RUN or START position, the ignition switch supplies voltage to the
PCM logic through the ignition circuit inputs to the BCM . The PCM then provides a ground to the
START/RUN relay control circuit to activate the RUN/START relay. When the relay contacts close voltage is
supplied to the PCM through Battery Junction Box (BJB) fuse 52 (10A) on the RUN/START bus and circuit.
z DTC P2532 (Ignition Switch Run Position Circuit High) –– sets when the PCM detects a voltage from
the ACC/RUN bus when the ignition key is not in the START or RUN position.
z DTC P2535 (Ignition Switch Run/Start Position Circuit High) –– sets when the PCM detects a voltage
from the RUN/START bus when the ignition key is not in the START or RUN position.

z Starter relay
z BJB
z BCM
z PCM
PINPOINT TEST G: DTC P2532 AND P2535

G1 CHECK THE PCM FOR DTCS
z Ignition ON. Yes
z Check the PCM for DTCs. For DTC P2532 ,GO to G2 .
z Are any DTCs present?
For DTC P2535 ,GO to G3 .
For all other PCM DTCs, REFER to

Section 303-14 .
No
time. CLEAR the DTCs. REPEAT the self-
operation.
G2 CHECK THE RUN START CIRCUIT FOR A SHORT
TO VOLTAGE
z Ignition OFF. Yes
z Disconnect: PCM . REPAIR the circuit. CLEAR the DTCs.
z Ignition ON. REPEAT the self-test. TEST the system
z NOTE: Voltage is present ONLY when the ignition for normal operation.
switch is in the START or RUN position.
z For 3.5L equipped vehicles , measure the No
voltage between the PCM C1551B-48, circuit CHECK for causes of the intermittent fault.
CBB53 (GY/BN), harness side and ground. ATTEMPT to recreate the hard fault by
flexing the wire harness and cycling the
ignition key frequently. ACTIVATE other
systems in the same wire harness.
REPAIR any concern found. REPEAT the
self-test. TEST the system for normal
operation. If DTC returns. INSTALL a new
PCM. REFER to Section 303-14 .
z Ignition ON.
z NOTE: Voltage is present ONLY when the ignition
z For 3.7L equipped vehicles , measure the
voltage between PCM C175B-42, circuit CBB53
(GY/BN), harness side and ground
z Ignition ON.
z NOTE: Voltage is present ONLY when the ignition
z For 5.0L and 6.2L equipped vehicles , measure
the voltage between PCM C1381B-42, circuit
CBB53 (GY/BN), harness side and ground

G3 CHECK THE START MOTOR REQUEST CIRCUIT
z Disconnect: Starter Motor Relay . GO to G4 .
z Measure the voltage between BJB starter relay
socket pin 2, circuit CDC26 (GY/OG) and ground. No
INSTALL a new PCM. REFER to Section
operation.

G4 CHECK THE START MOTOR REQUEST CIRCUIT
FOR A SHORT VOLTAGE
z Ignition OFF. Yes
z Disconnect: PCM C175B. REPAIR the circuit. CLEAR the DTCs.
z Ignition ON. REPEAT the self-test. TEST the system
z Measure the voltage between BJB starter relay for normal operation.
socket pin 1, circuit CDC12 (YE) and ground.
No
INSTALL a new PCM. REFER to Section
operation.
Component Tests
personal injury.
Always make the Digital Multimeter connections at the component terminal rather than at the wiring end of
the connector. Making a connection at the wiring end of the connector could result in false readings because
the meter will not pick up high resistance between the wiring connector and component.
Starter Motor — Feed Circuit Test
1. Make sure the battery is fully charged; carry out a battery Drain test. Refer to Section 414-01 .
2. Connect a remote starter switch between the starter solenoid C197B and the battery positive
terminal.
3. Connect the Digital Multimeter positive lead to the battery positive post. Connect the negative lead to
the starter solenoid "M" terminal.
4. Engage the remote starter switch. Read and record the voltage. The voltage reading should be 0.5
volt or less.
5. If the voltage reading is 0.5 volt or less, go to the starter motor-ground circuit component test.
6. If the voltage reading is greater than 0.5 volt, this is an indication of excessive resistance in the
connections, the positive battery cable or in the starter solenoid. Move the Digital Multimeter negative
lead to the starter solenoid C197A and repeat the test. If the voltage reading at starter solenoid
C197A is lower than 0.5 volt, the concern is either in the connections at the starter solenoid or in the
solenoid contacts.
7. Remove the cables from starter solenoid C197A, C197B and "M" terminals. Clean the cables and
connections and reinstall the cables to the correct terminals. Repeat Steps 3 through 6. If the voltage
drop reading is still greater than 0.5 volt when checked at the "M" terminal or less than 0.5 volt when
checked at C197A, the concern is in the solenoid contacts. Install a new starter motor. Refer to
Starter Motor — 3.5L GTDI, 3.7L or Starter Motor — 5.0L (4V), 6.2L (2V) in this section.
8. If the voltage reading taken at starter solenoid C197A is still greater than 0.5 volt after cleaning the
cables and connections at the solenoid, the concern is either in the battery cable connection or in the
positive battery cable itself.
9. Clean the positive battery cable connection. If this does not solve the problem, install a new battery
cables. Refer to Section 414-01 .
Starter Motor — Ground Circuit Test
A slow cranking condition can be caused by resistance in the ground or return portion of the cranking circuit.
Check the voltage drop in the ground circuit as follows:
1. Connect a remote starter switch between the starter solenoid C197B and the battery positive
terminal.
2. Connect the Digital Multimeter positive lead to the starter motor housing (the connection must be
clean and free of rust or grease). Connect the negative lead to the negative battery terminal.
3. Engage the remote starter switch and crank the engine. Read and record the voltage reading. The
reading should be 0.5 volt or less.
4. If the voltage drop is greater than 0.5 volt, clean the negative cable connections at the battery, the
body ground connections and the starter ground connection. Retest.
5. If the voltage drop is greater than 0.5 volt, install new cables. Refer to Section 414-01 . If the voltage
reading is less than 0.5 volt and the engine still cranks slowly, install a new starter motor. Refer to
Starter Motor — 3.5L GTDI, 3.7L or Starter Motor — 5.0L (4V), 6.2L (2V) in this section.

Starter Motor Drive Gear and Flywheel Ring Gear Inspection
1. Check the wear patterns on the starter drive and the flexplate ring gear. If the wear pattern is not
normal, install a new starter motor. For additional information, refer to Starter Motor — 3.5L GTDI,
3.7L or Starter Motor — 5.0L (4V), 6.2L (2V) in this section.
2. If the starter drive gear and the flywheel ring gear are not fully meshing or the gears are milled or
damaged, install a new starter motor. For additional information, refer to Starter Motor — 3.5L GTDI,
3.7L or Starter Motor — 5.0L (4V), 6.2L (2V) in this section. Install a new flexplate. For additional
information, refer to Section 303-01A , Section 303-01B , Section 303-01C or Section 303-01D .

Starter Motor — 3.5L GTDI, 3.7L
Part
1 11N087 Starter solenoid terminal cover
2 W706414 Starter solenoid B+ terminal nut - 12 Nm (106 lb-in)
3 W705790 Starter solenoid S-terminal nut - 5 Nm (44 lb-in)
4 14463 Starter solenoid S-terminal eyelet
5 14463 Starter solenoid B+ terminal eyelet
6 11002 Starter motor
7 14463 Starter motor ground cable eyelet
8 W714290 Starter motor mounting stud bolts (2 required) - 48
Nm (35 lb-ft)
9 W709450 Transmission fluid cooler tube bracket nut - 12 Nm
(106 lb-in)
10 7R081 Transmission fluid cooler inlet and outlet tubes
personal injury.
02 .
3. Remove the terminal cover.
4. Remove the nut and disconnect the starter solenoid B+ terminal eyelet.
5. Remove the nut and disconnect the starter solenoid S-terminal eyelet.
6. Remove the transmission fluid cooler tube bracket nut and position the transmission cooler inlet and
outlet tubes aside.
7. Remove the lower stud bolt and position starter motor ground cable eyelet aside.
8. NOTE: Tighten the upper bolt before tightening the lower fasteners.
Remove the upper stud bolt and the starter motor.


Starter Motor — 5.0L (4V), 6.2L (2V)

1 11N087 Terminal cover
2 W705790 Starter solenoid S-terminal nut
3 14463 Starter solenoid S-terminal eyelet
4 W706414 Starter solenoid B+ terminal nut
5 14463 Starter solenoid B+ terminal eyelet
6 N805024 Starter motor ground cable nut
7 14463 Starter motor ground cable eyelet
8 W704941 Starter motor mounting stud bolt
9 W704942 Starter motor mounting bolts (2 required)
10 11002 Starter motor
personal injury.
02 .
3. Remove the terminal cover.
5. Remove the nut and disconnect the starter solenoid B+ terminal eyelet.
6. Remove the nut and disconnect the starter motor ground cable eyelet.
7. NOTE: Tighten the upper bolt before tightening the lower fasteners.
Remove the stud bolt, the 2 bolts and the starter motor.
SECTION 303-07A: Engine Ignition — 3.5L GTDI 2014 F-150 Workshop Manual
Material
Capacity
Motorcraft® Silicone Brake Caliper ESE-M1C171- —
XG-3-A
Item Specification
Spark plug 12405
Spark plug gap 0.80 mm (0.031 in)
Ignition coil-on-plug bolts 7 62
Spark plugs 15 133
Engine Ignition
The Electronic Ignition (EI) system is a coil-on-plug ignition system. The coil-on-plug ignition system consists
of the:
z six ignition coil-on-plugs.

z six spark plugs.
The 6 separate ignition coil-on-plugs:
z change low voltage signals from the PCM to high voltage pulses.
z produce the high voltage pulses to the spark plugs.
z are connected directly to the spark plug.
z have replaceable ignition coil-on-plug seals.
The 6 spark plugs:
z change high voltage pulses into a spark which ignites the fuel and air mixture.
z originally equipped on the vehicle have a iridium-enhanced fine wire electrode for long life.
z gap is not adjustable.
Engine Ignition Components — Exploded View
NOTE: Ignition Components RH Side
Part
1 — Turbocharger regulator hose part of (9961)
2 — Turbocharger regulator hose part of (9961)
3 W714507 Ignition coil-on-plug bolt (3 required)
4 — Ignition coil-on-plug electrical connector (part of
6 12025 Coil-on-plug seal (3 required)
8 — Tie strap
NOTE: Ignition Components LH Side
Part
1 6758 Crankcase vent tube assembly
5 12025 Coil-on-plug seal (3 required)
7 6N041 Fuel injection pump noise insulator shield
8 — Fuel injection pump electrical connector (part of
12A581)
removal.
Ignition Coil-On-Plug
Material
Item Specification
XG-3-A
RH side
1. Cut and discard the tie strap from turbocharger regulator hose retainer at the valve cover.
2. Disconnect the 2 turbocharger regulator hoses.
LH side
3. Disconnect the 2 crankcase vent tube quick connect fittings and remove the crankcase vent tube
assembly. For additional information, refer to Section 310-00 .
4. Disconnect the fuel injection pump electrical connector.
5. Remove the fuel injection pump noise insulator shield.
Both sides
6. NOTE: Use compressed air to remove any foreign material from the ignition coil-on-plugs and
surrounding area before removing the ignition coil-on-plugs.
Disconnect the 6 ignition coil-on-plug electrical connectors.
removal.
Remove the 6 bolts and the 6 ignition coil-on-plugs.

8. Inspect the coil-on-plug seals for rips, nicks or tears. Remove and discard any damaged coil-on-plug
seals.
z To install, slide the new coil-on-plug seal onto the coil until it is fully seated at the top of the
coil-on-plug.

z Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before
attaching to the spark plugs.
Spark Plugs
1. Remove the 6 ignition coil-on-plugs. For additional information, refer to Ignition Coil-On-Plug in this
section.
2. NOTICE: Only use hand tools when removing or installing the spark plugs, or damage may
NOTICE: The spark plug procedure must be followed exactly or damage to the cylinder head
and spark plug will result.
NOTICE: Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug
thread or cylinder head damage can occur. Make sure the engine is warm (hand touch after
cooling down) prior to spark plug removal.
NOTICE: The spark plug gap is NOT adjustable. Damage can occur to the iridium tip if the gap
is adjusted. Replace the spark plug if the gap is out of specification.
spark plugs.
Remove the 6 spark plugs.

3. Inspect the 6 spark plugs. For additional information, refer to Section 303-00 .
SECTION 303-07B: Engine Ignition — 3.7L 2014 F-150 Workshop Manual

Material
Capacity
Silicone Brake Caliper Grease ESE-M1C171- —
and Dielectric Compound A
XG-3-A
Item Specification
Spark plug 12405
Spark plug gap 1.25-1.35 mm (0.049-0.053 in)
Spark plugs 15 133

Engine Ignition
of the:
z six ignition coil-on-plugs.

z six spark plugs.
z deliver the high voltage pulses to the spark plugs.
The 6 spark plugs:
z originally equipped on the vehicle have a platinum-enhanced fine wire electrode for long life.

NOTE: LH side shown, RH side similar
Part
9D930) (3 required)
4 12025 Ignition coil-on-plug seal (3 required)
removal.

Material
Item Specification
XG-3-A
RH side
1. NOTE: The upper intake manifold must be removed to access the RH ignition coil-on-plugs.
Remove the upper intake manifold. For additional information, refer to Section 303-01B .
Both sides
removal.
Remove the 6 ignition coil-on-plug bolts and the 6 ignition coil-on-plugs.

4. Inspect the ignition coil-on-plug seals for rips, nicks or tears. Remove and discard any damaged
ignition coil-on-plug seals.
z To install, slide the new ignition coil-on-plug seal onto the ignition coil-on-plug until it is fully
seated at the top of the ignition coil-on-plug.
5. NOTE: Verify that the ignition coil-on-plug spring is correctly located inside the ignition coil-on-plug
boot and that there is no damage to the tip of the boot.


Spark Plugs
1. Remove the ignition coil-on-plugs. For additional information, refer to Ignition Coil-On-Plug in this
section.
the spark plugs.
NOTE: If an original spark plug is used, make sure it is installed in the same cylinder from which it
was taken. New spark plugs can be used in any cylinder.

3. Inspect the spark plugs. Install new spark plugs as necessary. For additional information, refer to
Section 303-00 .
4. Adjust the spark plug gap as necessary.
SECTION 303-07C: Engine Ignition — 5.0L (4V) 2014 F-150 Workshop Manual
Material
Capacity
XG-3-A
Item Specification
Firing order 1-5-4-8-6-3-7-2
Spark plug gap 1.25 - 1.35 mm (0.049 - 0.053 in)
Spark plug type 12405
Spark plugs 14 124
Engine Ignition
of the:
z eight ignition coil-on-plugs.

z eight spark plugs.
The 8 spark plugs:
z originally equipped on the vehicle have a iridium-enhanced fine wire electrode for long life.
LH Ignition Components
NOTE: RH side shown, LH side similar
Part
9D930) (4 required)
4 12025 Ignition coil-on-plug seal (part of 12029) (4 required)
removal.
Material
Item Specification
XG-3-A
removal.
Remove the 8 bolts and the 8 ignition coil-on-plugs.

3. Inspect the ignition coil-on-plug seals for rips, nicks or tears. Remove and discard any damaged
ignition coil-on-plug seals.
z To install, slide the new ignition coil-on-plug seal onto the ignition coil-on-plug until it is fully
seated at the top of the ignition coil-on-plug .
4. NOTE: Verify that the ignition coil-on-plug spring is correctly located inside the ignition coil-on-plug
boot and that there is no damage to the tip of the boot.

Spark Plugs
1. Remove the ignition coil-on-plugs. For additional information, refer to Ignition Coil-On-Plug in this
section.
the spark plugs.
NOTE: If an original spark plug is used, make sure it is installed in the same cylinder from which it
was taken. New spark plugs can be used in any cylinder.

3. Inspect the spark plugs. Install new spark plugs as necessary. For additional information, refer to
Section 303-00 .
4. Adjust the spark plug gap as necessary.
SECTION 303-07D: Engine Ignition — 6.2L (2V) 2014 F-150 Workshop Manual
Material
Capacity
XG-3-A
Item Specification
Engine Ignition
Firing order 1-3-7-2-6-5-4-8
Spark plug 12405
Spark plug gap 1.07-1.17 mm
(0.042-0.046 in)
Spark plug 18 159
Engine Ignition
The electronic ignition system is a coil-on-plug ignition system. The coil-on-plug ignition system consists of
the:
z eight ignition coil-on-plugs.

z eight ignition wires.
z eight upper spark plugs.
z eight lower spark plugs.
z are connected directly to the upper spark plug.
z are connected by an ignition wire to the lower spark plug.
The 16 spark plugs:
z originally equipped on the vehicle have platinum-enhanced electrodes for long life.
NOTE: LH side shown, RH side similar
Part
1 12286 LH ignition wire (4 required)
9D930) (4 required)
3 W503282 LH ignition coil-on-plug bolt (4 required)

4 12029 LH ignition coil-on-plug (4 required)
5 12405 LH upper spark plug (4 required)
6 12405 LH lower spark plug (4 required)
removal.
Material
Item Specification
XG-3-A
2. Remove the intake air resonator. For additional information, refer to Section 303-12 .
3. Disconnect the 8 ignition wires.
4. Disconnect the 8 ignition coil-on-plug electrical connectors.
5. Remove the 8 ignition coil-on-plug bolts.

removal.
Remove the 8 ignition coil-on-plugs.
7. NOTE: Verify that the coil-on-plug spring is correctly located inside the ignition coil-on-plug boot and
that there is no damage to the tip of the boot.

z Apply a light coat of dielectric compound to the inside of the coil-on-plug boots.
Spark Plugs
Removal
NOTICE: The spark plug procedure must be followed exactly or damage to the cylinder head and
spark plug will result.
NOTICE: Do not remove the spark plugs when the engine is hot or cold soaked. Spark plug thread or
cylinder head damage can occur. Make sure the engine is warm (hand touch after cooling down)
prior to spark plug removal.
Upper spark plugs
1. Remove the ignition coil-on-plug. For additional information, refer to Ignition Coil-On-Plug in this
section.
Lower spark plugs
2. Disconnect the ignition wire from the lower spark plug.
All spark plugs
the spark plugs.
Remove the spark plug.
4. Inspect the spark plug. For additional information, refer to Section 303-00 .
Installation
All spark plugs
1. Adjust the spark plug gap as necessary. For the correct spark plug gap specification, refer to
Install the spark plug.

Lower spark plugs
3. Connect the ignition wire from the lower spark plug.
Upper spark plugs
4. Install the ignition coil-on-plug. For additional information, refer to Ignition Coil-On-Plug in this section.
SECTION 303-08: Engine Emission Control 2014 F-150 Workshop Manual

Engine Emission Control
NOTE: Do not permanently remove or render inoperative any part of the vehicle emission control system
including related hardware. Failure to comply may violate applicable state and federal law.
NOTE: The vehicle emission vacuum routing diagrams are contained in the Description and Operation
subsection of the Evaporative Emissions section. Refer to Section 303-13 .
The engine emission control system consists of the:
z PCV system.
PCV System
The PCV system:
z uses intake manifold vacuum to ventilate blow-by gases from the crankcase.
z returns the gases to the intake manifold for combustion.
The PCV valve:
z varies the amount of blow-by gases returned to the intake manifold based on available engine
vacuum.
SECTION 303-08: Engine Emission Control 2014 F-150 Workshop Manual

Positive Crankcase Ventilation (PCV) Valve
3.5L GTDI

1 6A664 PCV tube
2 6A666 PCV valve
3.7L

1 6A664 PCV tube
2 6A666 PCV valve
5.0L

1 6A664 PCV tube
2 6A666 PCV valve
6.2L

1 6A664 PCV tube
2 6A666 PCV valve
1. Disconnect the PCV tube quick connect coupling from the PCV. For additional information, refer to
Section 310-00 .
2. NOTICE: A new PCV valve must be installed if removed. During removal, the plastic retaining
ears of the PCV valve are sheared.
Rotate the PCV valve counterclockwise and remove the PCV valve.
z Discard the PCV valve.

z Install a new PCV valve.
SECTION 303-12: Intake Air Distribution and Filtering 2014 F-150 Workshop Manual
Adaptor-Turbocharger exhaust bypass 7 — 62
Air Cleaner (ACL) outlet pipe clamp 4 — 35
Charge Air Cooler (CAC) bracket bolts 40 30 —
CAC and Turbocharger pipe bracket-to-generator stud nut 48 35 —
CAC and Turbocharger pipe bracket-to-valve cover stud nuts 6 — 53
CAC pipe clamps 5 — 44
Mass Air Flow (MAF) sensor screws 2 — 18
Turbocharger pipe clamps 5 — 44
Resonator bolts 10 — 89
Resonator clamp 4 — 35
Intake Air Distribution and Filtering
The intake air system consists of the:
z Engine Air Cleaner (ACL).

z ACL element.
z ACL outlet pipe.
z Mass Air Flow (MAF) sensor.
z Manifold Absolute Pressure (MAP) sensor.
z Charge Air Cooler (CAC) - 3.5L Gasoline Turbocharged Direct Injection (GTDI).
z CAC pipes and tubes - 3.5L GTDI .
z turbocharger intake pipes - 3.5L GTDI .
z turbocharger intake tubes - 3.5L GTDI .
The intake air system:
z cleans intake air with a replaceable, dry-type ACL element.

z measures airflow and air temperature with a MAF sensor. Refer to Section 303-14 .
z measures manifold vacuum with a MAP sensor (3.5L GTDI engine) and converts it to an electronic
signal. This provides the PCM information on the engine load. Refer to Section 303-14 .
The engine ACL contains an ACL element made of treated, pleated paper. A new ACL element must be
installed periodically as scheduled. Engine performance and fuel economy are adversely affected when
maximum restriction of the ACL element is reached. The ACL housing is an integral part of the degas bottle
(3.5L Gasoline Turbocharged Direct Injection (GTDI), 3.7L and 5.0L engines) or the coolant expansion tank
(6.2L engines) and cannot be serviced separately. Refer to Section 303-03 .
The CAC subsystem (3.5L GTDI engine) cools and increases the density of the compressed turbocharged
air.
Charge Air Cooler (CAC) Cleaning
Material
Item Specification
(Canada)
Charge Air Cooler (CAC) Cleaning
1. Remove the Charge Air Cooler (CAC). For additional information, refer to Charge Air Cooler in this
section.
2. NOTICE: Do not use a high-pressure power washer to clean the Charge Air Cooler (CAC) or
the CAC may be damaged.
NOTE: Drain all contaminates such as coolant, fuel and oil prior to cleaning the Charge Air Cooler
(CAC).
NOTE: Thoroughly clean the joint clamp areas as well as the turbocharger connections and the
engine connection using metal brake parts cleaner.
Lay the CAC flat with the inlet and outlet ports pointing up.
3. NOTE: Plug or cap the CAC openings prior to agitating.
Add an appropriate amount of commercially available detergent cleaner such as Simple Green® Pro
HD, or equivalent, to the CAC . Follow the manufacturer's directions for cleaning. Fill the CAC to 40%
of its volume with water.
4. Raise one end of the CAC and agitate it by hand for at least 5 minutes.
5. Raise the opposite end of the CAC and agitate it by hand for at least 5 minutes.
6. Drain the CAC .
7. Flush the CAC thoroughly with clean water.
8. Repeat Steps 1 through 6 until no contaminates are found in the flush water.
9. Allow the CAC to air dry.
10. NOTE: The following leak test steps must be performed prior to installing the CAC .
NOTE: Use a commercially available kit, such as the SPX/OTC Charged Air Cooler Tester No. 5039,
or equivalent.
Install the commercially available CAC cooler tester on the CAC following the manufacturer's
installation instructions.
z Tighten the clamps to 5 Nm (44 lb-in).
11.
adapter to blow off or may damage the charge air cooler (CAC). Failure to follow this
Slowly apply air pressure to 150 kPa (22 psi).
12. Let the CAC stand for a few minutes and note any loss in pressure.
z Release the air pressure.
13. Repeat Steps 11 and 12 as many times as necessary to verify the readings. The reading is
considered verified when 3 consecutive tests show approximately the same pressure drop.
z If the pressure loss exceeds 20 kPa (3 psi) per minute, install a new CAC . For additional
information, refer to Charge Air Cooler in this section.
Air Cleaner — 3.5L GTDI
Material
Item Specification
turbocharger compressor vanes are susceptible to damage from even small particles. All
1.
injury.
NOTE: During normal vehicle operation, Motorcraft Specialty Orange Engine Coolant may change
2.
3.
4.
1. Tighten to 17 Nm (150 lb-in).
2. Tighten to 5Nm (44 lb-in).
6. Fill the degas bottle with a 50/50 mixture of coolant and distilled water.
Air Cleaner Outlet Pipe — 3.5L GTDI
1.
z Tighten to 5Nm (44 lb-in).
Charge Air Cooler
2.
3.
4.
5.
6. Disconnect the quick connect coupling as necessary. Refer to Section 310-00
7.
8.
9.
10.
Intake Air System Components — Exploded View
3.7L Air Cleaner (ACL) Assembly
NOTICE: Fully seat the Air Cleaner (ACL) element into the ACL housing. Failure to do so will result in
unusual engine noise.
NOTE: Disconnect the crankcase vent hose quick connect coupling from the air cleaner outlet pipe as
NOTE: Securely seal the ACL outlet pipe to prevent unmetered air from entering the engine.
NOTE: The ACL housing is part of the degas bottle assembly. Refer to Section 303-03 .
Part
1 — Air Cleaner (ACL) outlet pipe-toThrottle Body (TB)
clamp - 4 Nm (35 lb-in) (part of 9B659)
2 — Crankcase vent hose quick connect coupling (part of
6758)
3 9C490 Vacuum hose
4 — ACL -to- ACL outlet pipe clamp - 4 Nm (35 lb-in) (part
of 9B659)
5 9B659 ACL outlet pipe
6 — Mass Air Flow (MAF) sensor electrical connector (part
of 12A581)
7 9661 ACL upper tray
8 9601 ACL element
9 9628 Air cleaner tray retaining clips (3 required)
NOTE: Disconnect the crankcase vent hose quick connect coupling from the air cleaner outlet pipe as
NOTE: The ACL housing is part of the degas bottle assembly. Refer to Section 303-03 .
Part
1 — Air Cleaner (ACL) outlet pipe-to-Throttle Body (TB)
clamp - 4 Nm (35 lb-in) (part of 9B659)
2 6758 Crankcase vent hose

3 9C490 Vacuum hose
of 9B659)
of 12A581)
8 9601 ACL element
NOTE: Disconnect the crankcase vent hose quick connect coupling from the resonator as necessary. Refer
to Section 310-00 .
NOTE: The ACL housing is part of the coolant expansion tank assembly. Refer to Section 303-03 .
Part
1 — Air Cleaner (ACL) outlet pipe-to-resonator clamp - 4
Nm (35 lb-in) (part of 9B659)
of 9B659)
of 12A581)
6 9601 ACL element

8 — Crankcase ventilation tube quick connect coupling
(part of 6758)
10 W707522 Resonator bolts - 10 Nm (89 lb-in)
11 9P686 Resonator insulator
12 8W278 Heater hose retainer
13 — Resonator-to-throttle body clamp - 4 Nm (35 lb-in)
(part of 9F763)
14 9F763 Resonator
3.5L GTDI Air Cleaner (ACL) Assembly and ACL Outlet Pipes
NOTE: Disconnect the fuel vapor management hose and the crankcase vent hose quick connect couplings
from the LH ACL pipe-to-turbocharger pipe as necessary. Refer to Section 310-00 .
NOTE: Securely seal the ACL outlet pipe and the turbocharger pipes to prevent unmetered air from entering
the engine.
NOTE: The ACL housing is part of the coolant expansion tank assembly. Refer to Section 303-03 .
Part
1 — ACL outlet pipe clamp - 5 Nm (44 lb-in) (part of 9C623)
2 9C623 ACL outlet pipe
5 9J478 Air bypass hose assembly
6 9B659 RH ACL pipe-to-turbocharger pipe
7 9647 RH ACL and CAC pipe bracket
8 9E499 Vacuum hose
9 — RH ACL pipe-to-turbocharger pipe clamp - 5 Nm (44

lb-in) (part of 9B659)
10 — LH ACL pipe-to-turbocharger pipe (part of 9C623)
11 3E675 Crankcase vent tube assembly
12 — LH ACL pipe-to-turbocharger pipe - 5 Nm (44 lb-in)
(part of 9C623)
13 9647 LH ACL and CAC pipe bracket
3.5L GTDI Charge Air Cooler (CAC) and Tubes
Part
1 W503280 LH turbocharger-to- CAC pipe bracket bolt - 6 Nm (53
lb-in)
2 6F073 CAC -to-Throttle Body (TB) pipe
3 — CAC -to- TB pipe spring clip (part of 6F073)
4 — CAC pipe clamp - 5 Nm (44 lb-in) (part of 6C646) (4
required)
5 — CAC tube flex joint (part of 6C646) (4 required)
6 6C646 LH turbocharger-to- CAC pipe
7 9647 RH ACL and CAC pipe bracket
8 9647 LH ACL and CAC pipe bracket
9 — Turbocharger-to- CAC pipe clamp - 5 Nm (44 lb-in)

10 6C646 RH turbocharger-to- CAC pipe
11 — CAC -to- TB pipe clamp - 5 Nm (44 lb-in) (part of
6F073)
removal.
SECTION 303-13: Evaporative Emissions 2014 F-150 Workshop Manual

Evaporative Emission (EVAP) canister assembly bracket-to- EVAP canister assembly bolts 6 53
EVAP canister assembly-to-frame bolts 13 115
EVAP canister purge valve-to-intake manifold bolts 10 89

Evaporative Emissions
The Evaporative Emission (EVAP) system consists of the following components:
z EVAP canister (located in front of the fuel tank)

z EVAP canister purge valve (located on the intake manifold)
z Dual check valve (3.5L Gasoline Turbocharged Direct Injection (GTDI) engine) (part of the canister
purge valve)
z Vapor ejector (3.5L GTDI engine) (located in front of the engine)
z EVAP canister vent solenoid and dust separator assembly (located on the front of the EVAP canister)
z Fuel Tank Pressure (FTP) sensor and vapor tube assembly (located on top of the fuel tank)
z Vapor tubes
z Fresh air hose (located on top of the transmission)
The EVAP system:
z prevents hydrocarbon emissions from reaching the atmosphere.

z stores fuel vapors in the EVAP canister that are generated during vehicle operation or hot soak, until
they can be consumed by the engine during normal engine operation.
z routes the stored fuel vapors to the engine during engine operation.
z is controlled by the PCM which, using various sensor inputs, calculates the desired amount of purge
flow. The PCM regulates the purge flow, induced by the application of intake manifold vacuum, by
varying the duty cycle applied to the EVAP canister purge valve.
The fuel vapors are routed:
z from the fuel tank through the fill limit valve and fuel vapor vent valve. The fuel vapor vent valves are
part of the fuel tank assembly and cannot be serviced separately.
z to the EVAP canisters through a vapor line.
z to the engine when the EVAP canister purge valve is opened by the PCM.
The EVAP canister:
z contains activated carbon.

z stores fuel vapors.
The EVAP canister purge valve:
z is normally closed.
z regulates the purging of the EVAP canister.
z is controlled by the PCM.
The dual check valve (3.5L GTDI engine):
z routes fuel vapors to the intake manifold when the intake manifold is not pressurized.
z routes fuel vapors to the vapor ejector when the intake manifold is pressurized.
The vapor ejector (3.5L GTDI engine):
z is a venturi valve.
z uses pressurized air from the RH turbocharger-to-Charge Air Cooler (CAC) tube to route fuel vapors
to the Air Cleaner (ACL) outlet tube-to-LH turbocharger tube.
The EVAP canister vent solenoid:
z is controlled by the PCM.

z is normally open.
z seals the EVAP system for the inspection and maintenance (I/M 240) test and OBD II leak and
pressure tests.
The EVAP dust separator:
z prevents suspended dust and dirt particles from entering the EVAP system.
z is serviced as a separate item.
The FTP sensor:
z measures the pressure levels in the fuel tank continuously.

z serves as an input to the PCM.
Vehicle Emission Vacuum Routing
3.5L Gasoline Turbocharged Direct Injection (GTDI)
Part
1 6A505 LH valve cover
2 — Air Cleaner (ACL) outlet tube-to-LH turbocharger tube
(part of 9C623)
3 — Vapor ejector (part of 9C915)
4 9C646 RH turbocharger-to-Charge Air Cooler (CAC) tube

5 — Dual check valve (part of 9B325)
6 9B325 Evaporative Emission (EVAP) canister purge valve
8 6A666 PCV valve
10 9002 Fuel tank
11 — Fuel Tank Pressure (FTP) sensor (part of 9E325)
12 9034 Fuel tank filler pipe
13 9E857 EVAP canister
3.7L

2 9R530 Air Cleaner (ACL) outlet tube
3 9G866 Evaporative Emission (EVAP) canister purge valve
5 6A666 PCV valve
7 9002 Fuel tank
5.0L

1 9B659 Air Cleaner (ACL) outlet pipe
5 — PCV valve (part of LH valve cover)
6 9G866 Evaporative Emission (EVAP) canister purge valve
7 9002 Fuel tank
6.2L
Part
1 6A666 PCV valve
2 9F624 PCV fitting
4 9A589 Air Cleaner (ACL) outlet pipe-to-Throttle Body (TB)
adapter
5 — Brake booster
6 9S455 Intake manifold
7 9C915 Evaporative Emission (EVAP) canister purge valve
8 9D653 EVAP canister assembly
9 9F675 EVAP canister vent solenoid and dust separator
assembly
10 9K007 Fuel tank
11 — Fuel pump module
12 — Fuel vent valve

Evaporative Emission System Leak Test
Special Tool(s)
VACUTEC Smoke Machine Fuel
Evaporative Emission System
Tester

System (IDS)
Phase 1 — Leak Verification
1. Run the EVAP Test with the scan tool.
2. NOTE: Some small leaks may not be detected using the EVAP Test. If the system has passed the
test but a leak is still suspected, then proceed to Phase 2.
If the Evaporative Emission (EVAP) system failed the EVAP Test, then proceed to Phase 2.
Phase 2 — System Leak Check
1. Disconnect the upper vapor tube-to- EVAP canister purge valve quick connect coupling. For
2. Connect the VACUTEC Smoke Machine Fuel Evaporative Emission System Tester to the upper
EVAP canister purge valve fitting. For additional information, refer to the manufacturer's instructions.
3. NOTE: The battery ground cable was previously disconnected in the vapor tube quick connect
coupling procedure.
Connect the battery ground cable. For additional information, refer to Section 414-01 .
4. NOTE: In the scan tool, the EVAP canister purge valve is referred to as the EVAP vapor
management valve.
Open the EVAP canister purge valve with the scan tool.
5. Close the canister vent solenoid with the scan tool.
6. NOTE: The supplemental refueling adapter is located with the vehicle jack.
Install the supplemental refueling adapter into the Easy Fuel TM (capless) fuel tank filler pipe
assembly.
7. NOTE: If smoke does not exit the fuel tank filler pipe neck area after the system is pressurized, open
the canister vent solenoid with the scan tool to allow the air to purge. Once smoke is seen at the
canister vent solenoid, close the canister vent solenoid with the scan tool.
Introduce smoke from the VACUTEC Smoke Machine Fuel Evaporative Emission System Tester into
the EVAP system and verify that smoke is exiting the fuel tank filler pipe neck area. For additional
information, refer to the manufacturer's instructions.
8. Remove the supplemental refueling adapter once smoke is observed exiting the fuel tank filler pipe
neck area.
9. Continue to enter smoke into the system for 60 seconds to obtain pressure.
10. Press and release the remote start button in intervals of 15 seconds ON and 15 seconds OFF while
checking for exiting smoke.
11. Use the halogen light provided with the VACUTEC Smoke Machine Fuel Evaporative Emission
System Tester to follow the EVAP system path and look for smoke exiting at the source of the leak(s).
12. Repair any leaks as necessary.
13. Repeat the EVAP Leak Test until the system passes.

Dust Separator
1. NOTE: The Evaporative Emission (EVAP) canister vent solenoid and dust separator are an
assembly. This assembly is removed with the EVAP canister vent solenoid.
For additional information, refer to Evaporative Emission Canister Vent Solenoid in this section.

Evaporative Emission (EVAP) System Components — Exploded View
Evaporative Emission (EVAP) Canister Assembly — Removal
Part
1 — Evaporative Emission (EVAP) canister vent valve
electrical connector
2 9C985 EVAP canister assembly
3 W500224 EVAP canister assembly bracket bolt (4 required)
4 9E616 Fuel Tank Pressure (FTP) sensor and vapor tube
assembly-to- EVAP canister vapor tube quick connect
coupling
5 9S327 Fresh air tube
6 — Front vapor tube-to- EVAP canister quick connect
coupling (part of 9D676)
7 — Front fuel supply tube-to-center fuel supply tube quick
connect coupling (part of 9J280)
EVAP Canister, Brackets, Vent Solenoid and Dust Separator Assembly, Center Fuel Tube and Vapor
Tube Disassembly
Part
1 9A274 Center fuel supply tube
2 W500213 Evaporative Emission (EVAP) canister assembly front
bracket bolts (2 required)
3 9E817 EVAP canister assembly front bracket
4 9B328 EVAP canister vent solenoid and dust separator
assembly
5 9D925 EVAP canister vent solenoid and dust separator

assembly fitting
6 9B050 EVAP canister vapor tube
7 9D653 EVAP canister
8 9E817 EVAP canister rear assembly bracket
9 9D665 EVAP canister assembly vapor tube bracket
10 9R543 EVAP canister assembly bolt (3 required)

Evaporative Emission (EVAP) Vapor Ejector
Part
1 — Evaporative Emission (EVAP) vapor ejector quick-
connect coupling (part of 9G297) (3 required)
2 W520100 Evaporative Emission (EVAP) vapor ejector and hose
assembly bracket nut - 6 Nm (53 lb-in)
3 9G297 Evaporative Emission (EVAP) vapor ejector and hose
assembly
personal injury.
1. Disconnect the battery ground cable. Refer to Section 414-01 .
2. Remove the Air Cleaner (ACL) outlet pipe. Refer to Section 303-12 .
3. Remove the Charge Air Cooler (CAC)-to-Throttle Body (TB) pipe. Refer to Section 303-12 .
4. Disconnect the 3 Evaporative Emission (EVAP) vapor ejector and hose assembly quick-connect
fittings.
5. Remove the nut and the Evaporative Emission (EVAP) vapor ejector and hose assembly.
Installation
1. To install, reverse the removal steps.

z Carry out the Evaporative Emission System Leak Test. Refer to Evaporative Emission System
Leak Test .

Evaporative Emission Canister Purge Valve
3.5L Gasoline Turbocharged Direct Injection (GTDI) Engine

1 — Fuel vapor hose quick-connect coupling (3 required)
2 — Purge valve electrical connector (part of 12C508)
3 W500215 Purge valve bracket bolt - 10 Nm (89 lb-in)
4 9B325 Purge valve and hose assembly
5 — Dual check valve (Part of 9B325)
3.7L Engine
Part
1 — Evaporative Emission (EVAP) canister purge valve
2 9J280 EVAP canister-to- EVAP canister purge valve vapor
tube
3 W500015 EVAP canister purge valve bolt - 10 Nm (89 lb-in) (2
required)
4 9G866 EVAP canister purge valve
5.0L Engine
Part
2 9G271 EVAP canister-to- EVAP canister purge valve vapor
tube
required)
6.2L Engine
Part
2 9D676 EVAP canister-to- EVAP canister purge valve vapor
tube
required)
personal injury.
All engines
2. Disconnect the Evaporative Emission (EVAP) canister purge valve electrical connector.
3.5L Gasoline Turbocharged Direct Injection (GTDI) engine
3. Disconnect the 3 purge valve and hose assembly vapor hose quick-connect fittings.
4. Remove the bolt and the purge valve and hose assembly.
5. Disconnect the EVAP canister-to- EVAP canister purge valve vapor tube quick connect coupling from
the valve. For additional information, refer to Section 310-00 .
6. Remove the 2 EVAP canister purge valve bolts and remove the valve.
All engines

z Carry out the Evaporative Emission System Leak Test. For additional information, refer to
Evaporative Emission System Leak Test in this section.

Evaporative Emission Canister Vent Solenoid
personal injury.
02 .
3. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-Evaporative Emission
(EVAP) canister vapor tube quick connect coupling. For additional information, refer to Section 310-
00 .
4. Disconnect the fuel tank supply tube-to-center fuel supply tube quick connect coupling. For additional
5. Disconnect the front fuel supply tube-to-center fuel supply tube quick connect coupling. For additional
6. Disconnect the front vapor tube-to- EVAP canister quick connect coupling. For additional information,
7. Remove the vapor hose from the EVAP canister vent solenoid.
8. Disconnect the center fuel supply tube-to-frame pushpin retainer.
9. Disconnect the EVAP canister vent solenoid electrical connector and 2 pushpin retainers.
10. Remove the 4 EVAP canister assembly bolts and remove the EVAP canister from the vehicle.
11. Place the EVAP canister assembly on a workbench.
12. Open the front retainer and position the center fuel supply tube out of the retainer.
13. NOTE: Before tightening the front bracket bolts, extend the front bracket as far forward as possible.
Remove the 2 bolts and the EVAP canister assembly front bracket from the EVAP canister.
14. Remove the canister vent solenoid and dust box from the EVAP canister.


Evaporative Emission Canister
personal injury.
02 .
3. Disconnect the Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-Evaporative Emission
(EVAP) canister vapor tube quick connect coupling. For additional information, refer to Section 310-
00 .
4. Disconnect the fuel tank supply tube-to-center fuel supply tube quick connect coupling. For additional
5. Disconnect the front fuel supply tube-to-center fuel supply tube quick connect coupling. For additional
6. Disconnect the front vapor tube-to- EVAP canister quick connect coupling. For additional information,
7. Remove the vapor hose from the EVAP canister vent solenoid.
8. Disconnect the center fuel supply tube-to-frame pushpin retainer.
9. Disconnect the EVAP canister vent solenoid electrical connector and 2 pushpin retainers.
10. Remove the 4 EVAP canister assembly bolts and remove the EVAP canister from the vehicle.
11. Place the EVAP canister assembly on a workbench.
12. Disconnect the center vapor tube quick connect coupling from the EVAP canister and remove from
the EVAP canister assembly. For additional information, refer to Section 310-00 .
13. Open the 2 center fuel supply tube retainers and remove the center fuel supply tube from the EVAP
canister assembly.
14. NOTE: Before tightening the front bracket bolts, extend the front bracket as far forward as possible.
Remove the 5 bolts and the EVAP canister assembly brackets from the EVAP canister.
15. Remove the canister vent solenoid and dust box from the EVAP canister.


Fuel Tank Pressure Sensor
Part
1 — Fuel Tank Pressure (FTP) sensor and vapor tube
assembly-to-fuel tank vent valve quick connect coupling
(part of 9J279)
2 — FTP sensor and vapor tube assembly-to-fuel pump
module quick connect coupling (part of 9J279)
3 — FTP sensor (part of 9J279)
4 9J279 FTP sensor and vapor tube assembly
5 — FTP sensor and vapor tube assembly-to-fuel tank vent
valve quick connect coupling (part of 9J279)
personal injury.
1. Remove the fuel tank. For additional information, refer to Section 310-01 .
2. Disconnect the 2 Fuel Tank Pressure (FTP) sensor and vapor tube assembly-to-fuel tank vent valve
quick connect couplings. For additional information, refer to Section 310-00 .
3. Disconnect the FTP sensor and vapor tube assembly-to-fuel pump module quick connect coupling.
4. Remove the FTP sensor and vapor tube assembly from the fuel tank.

SECTION 303-14: Electronic Engine Controls 2014 F-150 Workshop Manual

Material
Capacity
High Temperature Nickel Anti- — —
Seize Lubricant
XL-2
LSP12 (Canada)
Penetrating and Lock Lubricant — —
(US); Penetrating Fluid (Canada)
XL-1 (US); CXC-51-A (Canada)
lb- lb-
A/C compressor bolts 25 18 —
Camshaft Position (CMP) sensor bolt 10 — 89
Catalyst Monitor Sensor (CMS) — 3.5L GTDI , 3.7L and 5.0L (4V) 48 35 —
CMS — 6.2L (2V) 46 34 —
Cylinder Head Temperature (CHT) sensor — 3.5L Gasoline Turbocharged Direct Injection 10 — 89
(GTDI) and 3.7L
CHT sensor — 5.0L (4V) and 6.2L (2V) 11 — 97
Cylinder head heat shield bolts 10 — 89
Cylinder head heat shield nut 10 — 89
Cylinder head heat shield stud bolt 10 — 89
Fuel Rail Pressure (FRP) sensor — 3.5L GTDI 33 24 —
Ground cable nut 9 — 80
Heated Oxygen Sensor (HO2S) — 3.5L GTDI , 3.7L and 5.0L (4V) 48 35 —
HO2S — 6.2L (2V) 46 34 —
Intake Air Temperature (IAT) sensor bolts — 3.5L GTDI 6 — 53
Knock Sensor (KS) bolt 20 — 177
Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor bolt — 3.5L 6 — 53
GTDI
Mass Air Flow (MAF) sensor screws — 3.7L, 5.0L (4V) and 6.2L (2V) 2 — 18
Powertrain Control Module (PCM)-to- PCM support bracket bolts — 3.5L GTDI 9 — 80
PCM stud bolts 9 — 80

Turbocharger Boost Pressure (TCBP)/Charge Air Cooler (CAC) Sensor screws — 3.5L 3 — 27
GTDI
Variable Camshaft Timing (VCT) solenoid bolt a — — —
VCT variable force solenoid bolt a — — —

Electronic Engine Controls
The electronic engine controls consist of the following:
z Camshaft Position (CMP) Sensor

z Catalyst Monitor Sensor (CMS)
z Crankshaft Position (CKP) Sensor
z Cylinder Head Temperature (CHT) Sensor
z Fuel Rail Pressure (FRP) Sensor — 3.5L Gasoline Turbocharged Direct Injection (GTDI)
z Heated Oxygen Sensor (HO2S)
z Intake Air Temperature (IAT) Sensor — 3.5L GTDI
z Knock Sensor (KS)
z Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) Sensor — 3.5L GTDI
z Mass Air Flow (MAF) Sensor — 3.7L, 5.0L (4V) and 6.2L (2V)
z PCM
z Turbocharger Boost Pressure (TCBP)/Charge Air Cooler (CAC) Sensor — 3.5L GTDI
z Variable Camshaft Timing (VCT) Oil Control Valve — 3.5L GTDI and 3.7L
z VCT Variable Force Solenoid — 5.0L (4V) and 6.2L (2V)
The CHT sensor:
z is mounted to the wall of the cylinder head and is not connected to any coolant passages.
z sends the PCM a signal indicating cylinder head temperature.
The CKP sensor:
z is mounted to the wall of the cylinder block.

z sends the PCM a signal indicating crankshaft position and engine speed.
The CMP sensor:
z is mounted to the cylinder head.

z sends the PCM a signal indicating camshaft position.
The CMS :
z is mounted to the catalytic converter.

z sends the PCM a signal indicating oxygen content in the exhaust after the exhaust leaves the
catalytic converter.
The FRP sensor (3.5L GTDI ):
z is mounted to the fuel rail.

z measures the pressure of the fuel rail and sends these signals to the PCM .
The HO2S :
z is mounted to the exhaust Y-pipe.

z sends the PCM a signal indicating oxygen content in the exhaust before the exhaust enters the
catalytic converter.
The IAT sensor (3.5L GTDI ):
z is mounted on the Air Cleaner (ACL).

z sends the PCM a signal indicating the temperature of the air entering the engine.
The KS :
z is mounted to the wall of the cylinder block.

z sends a signal to the PCM indicating engine detonation.
The MAF sensor:
z is mounted on the ACL .

z sends the PCM a signal indicating mass airflow rate of air entering the engine.
The MAP / IAT2 Sensor (3.5L GTDI ):
z is mounted on the top of the intake manifold.

z is a combination sensor.
z measures manifold pressure and converts it to an electrical signal. This provides the PCM information
on engine load.
z sends the PCM a signal indicating the temperature of the air entering the cylinders after passing
through the CAC .
The TCBP / CAC Sensor (3.5L GTDI only):
z is mounted to the CAC outlet tube.
z is a combination sensor.
z measures turbocharger boost pressure and sends this information to the PCM .
z measures the temperature of the charge air exiting the CAC and sends this information to the PCM .
The VCT Oil Control Valve (3.5L GTDI and 3.7L only)
z is mounted to the cylinder head.

z is an electronic solenoid that supplies force to actuate the VCT oil control valve. When the PCM
transmits a signal based on the engine speed and load, the solenoid moves the VCT oil control valve
activating either the advance circuit, retard circuit or hold position. The camshaft is then repositioned
in relation to crankshaft timing to allow for optimum engine performance with lower emissions and
reduced fuel consumption.
The VCT Variable Force Solenoid [5.0L (4V) and 6.2L (2V) only]:
z is mounted to the engine front cover.

z is an electronic solenoid that supplies force to actuate the VCT oil control valve. The PCM transmits a
signal based on the engine speed and load, the solenoid will move the VCT oil control valve
activating either the advance circuit, retard circuit or hold position. The camshaft is then repositioned
in relation to crankshaft timing to allow for optimum engine performance with lower emissions and
reduced fuel consumption.

Electronic Engine Controls
DTC Charts
PCM DTC Chart

DTC Description Action to Take
P0125 Insufficient Coolant Temp For Closed Loop Fuel REFER to Section 303-03 .
Control
P0128 Coolant Thermostat (Coolant Temp Below REFER to Section 303-03 .
Thermostat Regulating Temperature)
P0217 Engine Coolant Overtemperature Condition REFER to Section 303-03 .
P0504 Brake Switch A/B Correlation REFER to Section 419-03 .
P0512 Starter Request Circuit REFER to Section 303-06 .
P0532 A/C Refrigerant Pressure Sensor A Circuit Low REFER to Section 412-00 .
P0533 A/C Refrigerant Pressure Sensor A Circuit High REFER to Section 412-00 .
P0562 System Voltage Low REFER to Section 414-00 .
P0563 System Voltage High REFER to Section 414-00 .
P0572 Brake Switch A Circuit Low REFER to Section 419-03 .
P0573 Brake Switch A Circuit High REFER to Section 419-03 .
P0579 Cruise Control Multifunction Input "A" Circuit REFER to Section 419-03 .
Range/Performance
P0602 Powertrain Control Module Programming Error REFER to Section 418-01 .
P0605 Internal Control Module Read Only Memory REFER to Section 418-01 .
(ROM) Error
P0620 Generator Control Circuit REFER to Section 414-00 .
P0625 Generator Field Terminal Circuit Low REFER to Section 414-00 .
P0626 Generator Field Terminal Circuit High REFER to Section 414-00 .
P0645 A/C Clutch Relay Control Circuit REFER to Section 412-00 .
P0657 Actuator Supply Voltage A Circuit/Open REFER to Section 307-01 .
P065B Generator Control Circuit Range/Performance REFER to Section 414-00 .
P0701 Transmission Control System REFER to Section 307-01 .
Range/Performance
P0702 Transmission Control System Electrical REFER to Section 307-01 .
P0705 Transmission Range Sensor A Circuit (PRNDL REFER to Section 307-01 .
Input)
P0706 Transmission Range Sensor A Circuit REFER to Section 307-01 .
Range/Performance
P0707 Transmission Range Sensor A Circuit Low REFER to Section 307-01 .

P0708 Transmission Range Sensor A Circuit High REFER to Section 307-01 .
P0709 Transmission Range Sensor "A" Circuit REFER to Section 307-01 .
Intermittent
P0710 Transmission Fluid Temperature Sensor A REFER to Section 307-01 .
Circuit
Circuit Range/Performance
Circuit Low
Circuit High
P0715 Turbine/Input Shaft Speed Sensor A Circuit REFER to Section 307-01 .
P0717 Turbine/Input Shaft Speed Sensor A Circuit No REFER to Section 307-01 .
Signal
P0718 Turbine/Input Shaft Speed Sensor A Circuit REFER to Section 307-01 .
Intermittent
P0720 Output Shaft Speed Sensor Circuit REFER to Section 307-01 .
P0721 Output Shaft Speed Sensor Circuit REFER to Section 307-01 .
Range/Performance
P0722 Output Shaft Speed Sensor Circuit No Signal REFER to Section 307-01 .
P0729 Gear 6 Incorrect Ratio REFER to Section 307-01 .
P0740 Torque Converter Clutch Solenoid Circuit/Open REFER to Section 307-01 .
P0741 Torque Converter Clutch Solenoid Circuit REFER to Section 307-01 .
Performance/Stuck Off
P0742 Torque Converter Clutch Solenoid Circuit Stuck REFER to Section 307-01 .
On
Electrical
Intermittent
P0748 Pressure Control Solenoid A Electrical REFER to Section 307-01 .
P0750 Shift Solenoid A REFER to Section 307-01 .
P0751 Shift Solenoid A Performance/Stuck Off REFER to Section 307-01 .
P0752 Shift Solenoid A Stuck On REFER to Section 307-01 .
P0753 Shift Solenoid A Electrical REFER to Section 307-01 .
P0754 Shift Solenoid "A" Intermittent REFER to Section 307-01 .
P0755 Shift Solenoid B REFER to Section 307-01 .
P0756 Shift Solenoid B Performance/Stuck Off REFER to Section 307-01 .

P0757 Shift Solenoid B Stuck On REFER to Section 307-01 .
P0758 Shift Solenoid B Electrical REFER to Section 307-01 .
P0759 Shift Solenoid "B" Intermittent REFER to Section 307-01 .
P0760 Shift Solenoid C REFER to Section 307-01 .
P0761 Shift Solenoid C Performance/Stuck Off REFER to Section 307-01 .
P0762 Shift Solenoid C Stuck On REFER to Section 307-01 .
P0763 Shift Solenoid C Electrical REFER to Section 307-01 .
P0764 Shift Solenoid "C" Intermittent REFER to Section 307-01 .
P0765 Shift Solenoid D REFER to Section 307-01 .
P0766 Shift Solenoid D Performance/Stuck Off REFER to Section 307-01 .
P0767 Shift Solenoid D Stuck On REFER to Section 307-01 .
P0768 Shift Solenoid D Electrical REFER to Section 307-01 .
P0769 Shift Solenoid "D" Intermittent REFER to Section 307-01 .
P0770 Shift Solenoid E REFER to Section 307-01 .
P0771 Shift Solenoid E Performance/Stuck Off REFER to Section 307-01 .
P0772 Shift Solenoid E Stuck On REFER to Section 307-01 .
P0773 Shift Solenoid E Electrical REFER to Section 307-01 .
P0774 Shift Solenoid E Intermittent REFER to Section 307-01 .
P07A8 Transmission Friction Element "D" REFER to Section 307-01 .
P07A9 Transmission Friction Element "D" Stuck On REFER to Section 307-01 .
P07AA Transmission Friction Element "E" REFER to Section 307-01 .
P0815 Upshift Switch Circuit REFER to Section 307-05 .
P0816 Downshift Switch Circuit REFER to Section 307-05 .
P0826 Up and Down Switch Circuit REFER to Section 307-05 .
P0882 TCM Power Input Signal Low REFER to Section 307-01 .
P0883 TCM Power Input Signal High REFER to Section 307-01 .
P0960 Pressure Control Solenoid A Control REFER to Section 307-01 .
Circuit/Open
P0961 Pressure Control Solenoid A Control Circuit REFER to Section 307-01 .
Range/Performance
P0962 Pressure Control Solenoid A Control Circuit Low REFER to Section 307-01 .
P0963 Pressure Control Solenoid A Control Circuit High REFER to Section 307-01 .
P0973 Shift Solenoid A Control Circuit Low REFER to Section 307-01 .
P0974 Shift Solenoid A Control Circuit High REFER to Section 307-01 .
P0976 Shift Solenoid B Control Circuit Low REFER to Section 307-01 .
P0977 Shift Solenoid B Control Circuit High REFER to Section 307-01 .
P0979 Shift Solenoid C Control Circuit Low REFER to Section 307-01 .
P0980 Shift Solenoid C Control Circuit High REFER to Section 307-01 .

P0982 Shift Solenoid D Control Circuit Low REFER to Section 307-01 .
P0983 Shift Solenoid D Control Circuit High REFER to Section 307-01 .
P0984 Shift Solenoid "E" Control Circuit REFER to Section 307-01 .
Range/Performance
P0A5A Generator Current Sensor Circuit REFER to Section 414-00 .
Range/Performance
P0A5B Generator Current Sensor Circuit Low REFER to Section 414-00 .
P0A5C Generator Current Sensor Circuit High REFER to Section 414-00 .
P1285 Cylinder Head Overtemperature Condition REFER to Section 303-03 .
P1299 Cylinder Head Overtemperature Protection REFER to Section 303-03 .
Active
P1397 System Voltage Out Of Self Test Range REFER to Section 414-00 .
P1464 A/C Demand Out Of Self Test Range REFER to Section 412-00 .
P161A Incorrect Response from Immobilizer Control REFER to Section 419-01B .
Module
P1636 Inductive Signature Chip Communication Error REFER to Section 307-01 .
P1639 Vehicle ID Block Corrupted, Not Programmed REFER to Section 418-01 .
P163E Transmission Control Module Programming REFER to Section 307-01 .
Error
P163F Transmission ID Block Corrupted, Not REFER to Section 307-01 .
Programmed
P1700 Transmission Indeterminate Failure (Failed to REFER to Section 307-01 .
Neutral)
P1702 Transmission Range Sensor Circuit Intermittent REFER to Section 307-01 .
P1703 Brake Switch Out Of Self Test Range REFER to Section 419-03 .
P1711 Transmission Fluid Temperature Sensor Out Of REFER to Section 307-01 .
Self Test Range
Performance
P1780 Transmission Control Switch (O/D Cancel) REFER to Section 307-01 .
Circuit Out Of Self Test Range
P1783 Transmission Overtemperature Condition REFER to Section 307-01 .
P1910 Reverse Lamp Control Circuit/Open REFER to Section 307-01 .
P1921 Transmission Range Signal REFER to Section 307-01 .
P193D Cruise Control Multi-Function Input Signal REFER to Section 419-03 .
P2700 Transmission Friction Element A Apply Time REFER to Section 307-01 .
Range/Performance
P2701 Transmission Friction Element B Apply Time REFER to Section 307-01 .
Range/Performance
P2702 Transmission Friction Element C Apply Time REFER to Section 307-01 .
Range/Performance
P2703 Transmission Friction Element D Apply Time REFER to Section 307-01 .
Range/Performance
P2704 Transmission Friction Element E Apply Time REFER to Section 307-01 .
Range/Performance
P2758 Torque Converter Clutch Pressure Control REFER to Section 307-01 .
Solenoid Stuck On
P2760 Torque Converter Clutch Pressure Control REFER to Section 307-01 .
Solenoid Intermittent
U0300 Internal Control Module Software Incompatibility REFER to Section 418-01 .
All Other — REFER to the Powertrain Control/Emissions
DTCs Diagnosis (PC/ED) manual.

Camshaft Position (CMP) Sensor — 3.5L GTDI
Removal
1.
Installation
1. To install, reverse the removal steps.

Camshaft Position (CMP) Sensor — 5.0L (4V)
Removal
Both RH and LH intake Camshaft Position (CMP) sensors and RH exhaust CMP sensor
1. Disconnect the Camshaft Position (CMP) sensor electrical connector.
2. Remove the bolt and the CMP sensor.
LH exhaust Camshaft Position (CMP) sensor
3. Position the vehicle on a hoist. For additional information, refer to Section 100-02 .
4. If equipped with 4 wheel drive, index-mark the front flange to the pinion flange.
5. If equipped with 4 wheel drive, remove the 6 front flange-to-pinion flange bolts and 2 washers and
position the driveshaft aside.
z Discard the 6 bolts and 2 washers
6. Remove the 2 bolts and the LH heat shield from the rear of the LH cylinder head.
7. Disconnect the CMP sensor electrical connector.
8. Remove the 2 transmission support insulator nuts.
9. Remove the CMP bolt.
10. NOTE: Make sure the transmission jack contacts the outer ribs of the transmission fluid pan.
Position a suitable high-lift transmission jack under the transmission. Raise the transmission until the
CMP sensor can be removed.
z Remove the CMP sensor.
Installation
LH exhaust Camshaft Position (CMP) sensor
1. NOTE: The bolt must be torqued while the transmission is raised
Position the Camshaft Position (CMP) sensor and install the bolt.
2. Using the suitable high-lift transmission jack, lower the transmission and install the 2 transmission
support insulator nuts.
3. Connect the CMP sensor electrical connector.
4. Position the LH heat shield onto the rear of the LH cylinder head and install the 2 bolts.
5. If equipped with 4 wheel drive, position back the driveshaft, align the index mark and install 2 washers
and 6 new bolts.
Both RH and LH intake CMP sensors and RH exhaust CMP sensor
6. Position the CMP sensor and install the bolt.

7. Connect the CMP sensor electrical connector.

Crankshaft Position (CKP) Sensor — 5.0L (4V)
Removal
1. Remove the intake manifold. For additional information, refer to Section 303-01C .
3. Disconnect theCrankshaft Position (CKP) sensor electrical connector.
4. NOTE: The Crankshaft Position (CKP) sensor bolt is part of the CKP sensor and cannot be removed.
Loosen the bolt and remove the CKP sensor.
Installation
1. NOTE: The Crankshaft Position (CKP) sensor bolt is part of the CKP sensor and cannot be removed.
Position the CKP sensor and tighten the bolt.

3. Connect the CHT sensor electrical connector.
4. Install the intake manifold. For additional information, refer to Section 303-01C .

Engine Control Components — Exploded View, 3.5L GTDI
Special Tool(s)
Socket, Exhaust Gas Oxygen
Sensor
303-476 (T94P-9472-A)

Material
Item Specification
Lubricant
XL-2
Penetrating and Lock Lubricant —
Crankshaft Position (CKP) Sensor
NOTE: It is necessary to remove the LH turbo charger to access the Crankshaft Position (CKP) sensor. For
additional information, refer to Section 303-04E .
NOTE: After installing the Crankshaft Position (CKP) sensor, use the scan tool to perform the Misfire Monitor
Neutral Profile Correction procedure, following the on-screen instructions.
Part
1 W701542 Heat shield nut
2 W701669 Heat shield bolt
3 6K342 Heat shield
4 6C070 Rubber grommet cover
(part of 12C508)
6 W712315 CKP sensor bolt (part of 6D327)
7 6C315 CKP sensor (part of 6D327)
Cylinder Head Temperature (CHT) Sensor
NOTE: It is necessary to remove the RH fender splash shield to access the Cylinder Head Temperature
(CHT) sensor. For additional information, refer to Section 501-02 .
Part
2 6G004 CHT sensor - 10 Nm (89 lb-In)
Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS)
NOTE: If necessary, lubricate the Heated Oxygen Sensor (HO2S) and/or Catalyst Monitor Sensor (CMS)
with penetrating and lock lubricant to assist in removal.
NOTE: Apply anti-seize to the threads of the HO2S and/or CMS prior to installing.
NOTE: The correct torque wrench setting must be calculated when using the Exhaust Gas Oxygen Sensor
Socket to install the HO2S and/or CMS . Refer to the Torque Wrench Adapter Formulas in the Appendix.
Part
(part of 12C508)
2 — HO2S wiring harness electrical connector retainer
(part of 12C508)
3 9F472 HO2S
4 — HO2S electrical connector (part of 15525)
5 9F472 HO2S
6 — Catalyst Monitor Sensor (CMS) electrical connectors
(part of 15525)
7 9G444 CMS
Knock Sensor (KS)
NOTE: It is necessary to remove the lower intake manifold to access the Knock Sensor (KS). For additional
information, refer to Section 303-01A .
NOTE: LH cylinder head removed in graphic for clarity.
Part
1 — Knock Sensor (KS) electrical connector (part of
12C508)
2 12A699 KS
3 W704749 KS bolt (2 required)
Variable Camshaft Timing (VCT) Oil Control Solenoid
NOTE: It is necessary to remove the RH or LH valve cover to access the Variable Camshaft Timing (VCT)
oil control solenoid. For additional information, refer to Section 303-01A .
NOTE: Position the VCT oil control solenoid and tighten the bolts in 2 stages.

Part
1 W500215 LH intake Variable Camshaft Timing (VCT) oil control
solenoid bolt
2 6B297 LH intake VCT oil control solenoid
3 6B297 LH exhaust VCT oil control solenoid
4 W500215 LH exhaust VCT oil control solenoid bolt
removal.

Engine Control Components — Exploded View, 3.7L
Special Tool(s)
Sensor
303-476 (T94P-9472-A)

Material
Item Specification
Lubricant
XL-2
Camshaft Position (CMP) Sensor
NOTE: It is necessary to remove the upper intake manifold to access the RH exhaust or intake Camshaft
Position (CMP) sensor. For additional information, refer to Section 303-01B .
Part
1 — LH exhaust Camshaft Position (CMP) sensor electrical
2 — LH intake CMP sensor electrical connector (part of
12A581)
3 W503275 LH exhaust CMP sensor bolt
4 6B288 LH exhaust CMP sensor
5 W503275 LH intake CMP sensor bolt
6 6B288 LH intake CMP sensor
NOTE: After installing the Crankshaft Position (CKP) sensor, use the scan tool to perform the Misfire Monitor
Neutral Profile Correction procedure, following the on-screen instructions.
Part
1 W520101 Heat shield nut
2 W701669 Heat shield bolt
3 6K342 Heat shield
4 6C070 Rubber grommet cover
(part of 12A581)
6 W712315 CKP sensor bolt (part of 6C315)
7 6C315 CKP sensor
NOTE: It is necessary to remove the lower intake manifold to access the Cylinder Head Temperature (CHT)
sensor. For additional information, refer to Section 303-01B .
Part
2 6G004 CHT sensor
Part
1 — Heated Oxygen Sensor (HO2S) electrical connectors
(part of 15525)
2 9F472 HO2S
(part of 15525)
4 9G444 CMS
Knock Sensor (KS)
NOTE: It is necessary to remove the lower intake manifold to access the Cylinder Head Temperature (CHT)
sensor. For additional information, refer to Section 303-01B .
NOTE: LH cylinder head removed in graphic for clarity.
Part
1 — Knock Sensor (KS) electrical connector (part of
12A581)
2 12A699 KS
3 W704749 KS bolt (2 required)
Variable Camshaft Timing (VCT) Oil Control Solenoid
NOTE: It is necessary to remove the RH or LH valve cover to access the Variable Camshaft Timing (VCT)
oil control solenoid. For additional information, refer to Section 303-01B .
NOTE: Position the VCT oil control solenoid and tighten the bolts in 2 stages.

Part
1 W500215 LH intake Variable Camshaft Timing (VCT) oil control
solenoid bolt
2 6B297 LH intake VCT oil control solenoid
3 6B297 LH exhaust VCT oil control solenoid
4 W500215 LH exhaust VCT oil control solenoid bolt
removal.

Engine Control Components — Exploded View, 5.0L (4V)
Special Tool(s)
Sensor
303-476 (T94P-9472-A)

Material
Item Specification
Lubricant
XL-2
Part
1 — LH heat shield bolt - 10 Nm (89 lb-in) (2 required)
2 39686 LH heat shield
3 — LH exhaust Camshaft Position (CMP) sensor electrical
4 W503278 LH exhaust CMP sensor bolt - 10 Nm (89 lb-in)
5 6B288 LH exhaust CMP sensor
6 — LH intake CMP sensor electrical connector (part of
12A581)
7 W503278 LH intake CMP sensor bolt - 10 Nm (89 lb-in)
8 12K073 LH intake CMP sensor
9 — RH intake CMP sensor electrical connector (part of
12A581)
10 W503278 RH intake CMP sensor bolt - 10 Nm (89 lb-in)
11 18801 RH radio ignition interference capacitor
12 12K073 RH intake CMP sensor
13 — RH exhaust CMP sensor electrical connector (part of
12A581)
14 W503278 RH exhaust CMP sensor bolt - 10 Nm (89 lb-in)
15 6B288 RH exhaust CMP sensor
Part
(part of 12A581)
3 6C315 CKP sensor and bolt assembly - 10 Nm (89 lb-in)
NOTE: It is necessary to remove the intake manifold to perform this procedure. For additional information,
refer to Section 303-01C .
Part
2 6G004 CHT sensor
Part
(part of 15525)
2 9F472 HO2S
(part of 15525)
4 9G444 CMS
Knock Sensor (KS)
NOTE: It is necessary to remove the intake manifold to perform this procedure. For additional information,
Part
1 — RH Knock Sensor (KS) electrical connector (part of
14B485)
2 — LH KS electrical connector (part of 14B485)
3 W500110 RH KS bolt
4 W500110 LH KS bolt
5 12A699 RH KS
6 12A699 LH KS
Variable Camshaft Timing (VCT) Variable Force Solenoid
NOTICE: The Variable Camshaft Timing (VCT) variable force solenoid pins must be fully depressed
to avoid interference with the VCT valve tips when installing the solenoids. Failure to follow these
instructions can result in damage to the engine.
NOTE: The LH or RH valve cover must be removed to perform this procedure. For additional information,
NOTE: The bolts are part of the VCT variable force solenoid and cannot be removed.
NOTE: Position the VCT variable force solenoid and tighten the bolts in 2 stages.

Part
1 W700005 LH exhaustVariable Camshaft Timing (VCT) variable
force solenoid bolt (part of 6M280) (2 required)
2 6M280 LH exhaust VCT variable force solenoid
3 W700005 LH intake VCT variable force solenoid bolt (part of
6M280) (2 required)
4 6M280 LH intake VCT variable force solenoid
5 — VCT variable force solenoid pin (part of 6M280)
(depress prior to installing solenoid)
removal.

Engine Control Components — Exploded View, 6.2L (2V)
Special Tool(s)
Sensor
303-476 (T94P-9472-A)

Material
Item Specification
Lubricant
XL-2
LSP12 (Canada)
NOTE: Intake manifold removed from graphic for clarity.
NOTE: Lubricate the CMP sensor O-ring seal with clean engine oil prior to installation.
Part
1 — RH Camshaft Position (CMP) sensor electrical
2 W503276 RH CMP sensor bolt
3 12K073 RH CMP sensor
4 — LH CMP sensor electrical connector (part of 12C508)
5 W503276 LH CMP sensor bolt
6 12K073 LH CMP sensor
NOTICE: The Crankshaft Position (CKP) sensor must be positioned into the fitting on the crankshaft
rear seal retainer plate and be flush against the boss on the engine block before the bolt is installed.
If the CKP sensor is installed incorrectly, the CKP sensor can be damaged.
NOTE: The intake manifold must be removed to perform this procedure. For additional information, refer to
Section 303-01D .
NOTE: After installing the CKP sensor, use the scan tool to perform the Misfire Monitor Neutral Profile
Part
1 — Crankshaft Position (CKP) sensor electrical
connector
2 W503276 CKP sensor bolt
3 6C315 CKP sensor
Section 303-01D .
Part
connector (part of 14B485)
2 6G004 CHT sensor
Part
(part of 15525)
2 9F472 HO2S
(part of 15525)
4 9G444 CMS
Knock Sensor (KS)
Section 303-01D .
Part
1 — RH Knock Sensor (KS) electrical connector (part of
14B485)
2 W710119 RH KS bolt
3 12A699 RH KS
4 — LH KS electrical connector (part of 14B485)
5 W710119 LH KS bolt
6 12A699 LH KS
Variable Camshaft Timing (VCT) Variable Force Solenoid
NOTICE: The Variable Camshaft Timing (VCT) variable force solenoid pins must be fully depressed
to avoid interference with the VCT valve tips when installing the solenoids. Failure to follow these
instructions can result in damage to the engine.
NOTE: The LH or RH valve cover must be removed to perform this procedure. For additional information,
refer to Section 303-01D .
NOTE: The bolts are part of the VCT variable force solenoid and cannot be removed.
NOTE: Position the VCT variable force solenoid and tighten the bolts in 2 stages.

Part
1 W700005 Variable Camshaft Timing (VCT) variable force
solenoid bolt (part of 6B297) (2 required)
2 6M280 VCT variable force solenoid
removal.

Fuel Rail Pressure (FRP) Sensor — 3.5L GTDI
Material
Item Specification
LSP12 (Canada)
Part
1 — Fuel Rail Pressure (FRP) sensor electrical connector
(part of 12C508)
2 9G756 FRP sensor
Removal
4. Disconnect the Fuel Rail Pressure (FRP) sensor electrical connector.
5. NOTICE: During repair procedure, cleanliness is extremely important. Any foreign material,
including any material created while cleaning or removing components that enters the fuel
supply passages may cause engine failure.
NOTE: Use compressed air to remove any foreign material from around the FRP sensor area before
removal.
Remove and discard the FRP sensor.
Installation
1. Lubricate the tip and thread area of the new FRP sensor with clean engine oil prior to installation.
2. NOTICE: During repair procedure, cleanliness is extremely important. Any foreign material,
including any material created while cleaning or removing components that enters the fuel
supply passages may cause engine failure.
Install the FRP sensor.

3. Connect the FRP sensor electrical connector.

Manifold Absolute Pressure (MAP) / Intake Air Temperature 2 (IAT2) Sensor — 3.5L
GTDI
Material
Item Specification
LSP12 (Canada)
Part
1 — MAP / IAT2 sensor electrical connector (part of
12A581)
2 W505565 Manifold Absolute Pressure (MAP)/ Intake Air
Temperature 2 (IAT2) sensor bolt - 6 Nm (53 lb-in)
3 9F479 MAP / IAT2 sensor
Removal
NOTE: The Turbocharger Boost Pressure (TCBP)/Charge Air Cooler Temperature (CACT) sensor and the
Manifold Absolute Pressure (MAP)/ Intake Air Temperature 2 (IAT2) sensor are not interchangeable.
1. Disconnect the MAP / IAT2 sensor electrical connector.
2. Remove the bolt and the MAP / IAT2 sensor.
Installation
1. Lubricate the MAP / IAT2 sensor O-ring seal with clean engine oil.
2. Install the MAP / IAT2 sensor and the bolt.

3. Connect the MAP / IAT2 sensor electrical connector.

Mass Air Flow (MAF) Sensor — 3.7L, 5.0L (4V), 6.2L (2V)
Part
of 12A581)
2 W709287 MAF sensor screw (2 required)
3 12B579 MAF sensor
2. Remove the 2 screws and the MAF sensor.

Powertrain Control Module (PCM)
Special Tool(s)
3.5L Gasoline Turbocharged Direct Injection (GTDI) Powertrain Control Module (PCM)
Part
1 — Powertrain Control Module (PCM) electrical connector
(part of 14A464)
2 — PCM electrical connector (part of 12A581)
3 — PCM cover (part of 12A692)
4 W705790 Ground cable nut - 9 Nm (80 lb-in)
5 — Ground cable (part of 12A581)
6 W711897 PCM stud bolt (2 required) - 9 Nm (80 lb-in)
7 12A692 PCM support bracket
8 N605894 PCM -to- PCM support bracket bolt - 9 Nm (80 lb-in)
(2 required)
9 12B684 PCM
3.7L, 5.0L (4V) and 6.2L (2V) Powertrain Control Module (PCM)
Part
1 — Powertrain Control Module (PCM) electrical
connectors (part of 14A464 and 12A581)
2 W711897 PCM stud bolt (2 required)
3 12A650 PCM
4 12A696 PCM gasket
Removal
All engines
1. Retrieve the module configuration. Carry out the module configuration retrieval steps of the
Programmable Module Installation (PMI) procedure. For additional information, refer to Section 418-
01 .
Vehicles equipped with a 3.5L Gasoline Turbocharged Direct Injection (GTDI) engine
2. Disconnect the 2 Powertrain Control Module (PCM) electrical connectors.
3. Disengage and remove the PCM cover.
4. Remove the 2 PCM -to- PCM support bracket bolts and the PCM .
5. If the PCM support bracket is damaged, remove the nut and position the ground cable aside and
remove the 2 PCM stud bolts and slide the PCM support bracket out of the bulkhead.
Vehicles equipped with a 3.7L, 5.0L (4V) or 6.2L (2V) engine
6. Disconnect the Powertrain Control Module (PCM) electrical connectors.
7. Remove the stud bolts, the PCM and the gasket.
Installation
Vehicles equipped with a 3.7L, 5.0L (4V) or 6.2L (2V) engine
1. Install the gasket, the PCM and the 2 stud bolts.

2. Connect the PCM electrical connectors.
Vehicles equipped with a 3.5L Gasoline Turbocharged Direct Injection (GTDI) engine
3. If the PCM support bracket was removed, position the support bracket assembly into the bulkhead
and install the 2 stud bolts.
4. If the PCM support bracket was removed, position the ground cable and install the nut.
5. Position the PCM onto the support bracket and install the 2 bolts.
6. Install the PCM cover.
7. Connect the 2 PCM electrical connectors.
All engines
8. Carry out the transmission solenoid body strategy identification. For additional information, refer to
Section 307-01 .
9. NOTE: If the Programmable Module Installation (PMI) procedure was not successful in downloading
the data from the vehicles original PCM, then the oil life data of the vehicle is lost. If this occurs, and
the oil life cannot be determined through service history or customer interview, it is recommended the
vehicle engine oil and filter be changed and the oil change minder reset.
Restore the module configuration. Carry out the module configuration restore steps of the
Programmable Module Installation (PMI) procedure. For additional information, refer to Section 418-
01 .
10. Perform the Passive Anti-Theft System (PATS) Parameter Reset procedure. For additional
information, refer to Section 419-01B .
11. Using the scan tool, perform the Misfire Monitor Neutral Profile Correction procedure, following the
on-screen instructions.

Turbocharger Boost Pressure (TCBP) / Charge Air Cooler Temperature (CACT)

Sensor — 3.5L GTDI
Part
1 — Turbocharger Boost Pressure (TCBP)/ Charge Air
Cooler Temperature (CACT) sensor electrical
2 W506843 TCBP / CACT sensor screws - 3 Nm (27 lb-in)
3 9F479 TCBP / CACT sensor
Removal
NOTE: Turbocharger Boost Pressure (TCBP)/ Charge Air Cooler Temperature (CACT) sensor and the
Manifold Absolute Pressure (MAP)/Intake Air Temperature 2 (IAT2) sensor are not interchangeable.
1. Remove the ACL outlet tube. For additional information, refer to Section 303-12 .
2. Disconnect the Turbocharger Boost Pressure (TCBP)/Charge Air Cooler Temperature (CACT) sensor
3. Remove the 2 screws and the TCBP / CACT sensor.
Installation
1. Install the TCBP / CACT sensor and the 2 screws.

2. Connect the TCBP / CACT sensor electrical connector.

Turbocharger Bypass Valve
Removal
2.
3.
4.
5.
6.
Installation

Turbocharger Intake Pressure and Temperature Sensor (TCIPT) — 3.5L GTDI
Removal
1.
safety warnings in section 100-00 General Information. Failure to follow this instruction may
2.
3.
Installation
SECTION 307-01: Automatic Transaxle/Transmission — 6R80 2014 F-150 Workshop Manual

Material
Capacity
Motorcraft® MERCON® LV MERCON® 12.30L
Automatic Transmission Fluid LV (13.0 qt)
(Canada)
Item Specification
Fluid
NOTICE: Transmission fluids are not interchangeable. The use of any other fluid or cleaning agents
will cause internal transmission damage.
z Normal maintenance:
Transmission fluid change not necessary, filled for life.
z Severe duty maintenance:
Change the transmission fluid at 240,000 km (150,000 mi) intervals.
Fluid Filter
Internal to the transmission —
Assembly Weight
Description Specification
Transmission 84.24 kg (215 lb)
Clutch Application Chart

Inter- Low/
Forward A Direct B mediate C Reverse D Overdrive E
Gear (1,2,3,4) (3,5,R) (2,6) (1,R) (4,5,6) Low-OWC
Park H
Reverse D H
Neutral H
1st Gear D D Ha H
2nd Gear D D H O/R
3rd Gear D D D O/R
4th Gear D D D O/R
5th Gear D D D O/R
6th Gear D H D O/R

3rd Gear D D O/R
Manual
2nd Gear D H O/R
Manual
1st Gear D H H
Manual
Planetary Front planetary Front No. 2 sun Rear Input shaft-to- Rear
Components carrier-to-No. 3 carrier-to- gear planetary rear planetary planetary
sun gear No. 2 sun carrier carrier carrier
gear
a
Clutch released when vehicle speed is above 3 mph.
z D = Drive Clutch
z H = Hold Clutch
z O/R = Overrunning
Solenoid Operation Chart

Shift Solenoid
PCM
Selector Lever Commanded SSA NL SSB NH SSC NL SSD NH (CB SSE TCC
Position Gear (1,2,3,4) (3,5,R) (CB 2,6) L,R/C 4,5,6) NC NL
P P Off On Off Off Off Off
R R Off Off Off Off Off Off
N N Off On Off Off a Off Off
D 1 On On Off Off b Off Off
2 On On On On Off Off
3 On Off Off On On On/Off
4 On On Off Off On On/Off
5 Off Off Off Off On On/Off
6 Off On On Off On On/Off
Mc — — — — — — —
2 2 On On On On Off Off
1 1 On On Off Off On Off
a
Solenoid state will change if vehicle is moving forward with the selector lever in the NEUTRAL position.
b Solenoid is On when vehicle is above 3 mph.
c All gears available upon driver request.
CB = Clutch brake
NC = Normally closed
NH = Normally high
NL = Normally low
Gear Ratio
1st 4.17 to 1
2nd 2.34 to 1
3rd 1.52 to 1
4th 1.14 to 1
5th 0.87 to 1
6th 0.69 to 1
Reverse 3.40 to 1
Stall Speed
Engine Min Max
3.7L 2300 2580
5.0L 2400 2700
3.5L GTDI 2300 2580
6.2L 2,000 2,250
End Play
NOTE: All friction and steel plates use a wave design plate.
Item Specifications
Forward Clutch (A) 0.71-1.10 mm
(0.027-0.043 in)
Direct Clutch (B) 0.50-1.30 mm
(0.019-0.051 in)
Intermediate Clutch (C) 0.71-1.10 mm
(0.028-0.043 in)
Low/Reverse Clutch (D) 1.0-1.6 mm
(0.039-0.063 in)
Overdrive (O/D) Clutch (E) 0.50-0.90 mm
(0.019-0.035 in)
Forward Clutch, Direct Clutch and Intermediate Clutch Selective Snap Rings
Part Number Snap Ring Thickness
6L2Z-7D483-BA 3.0 mm (0.118 in)
6L2Z-7D483-CA 3.2 mm (0.125 in)
6L2Z-7D483-DA 3.4 mm (0.133 in)
6L2Z-7D483-EA 3.6 mm (0.141 in)
6L2Z-7D483-FA 3.8 mm (0.149 in)
6L2Z-7D483-GA 4.0 mm (0.157 in)
6L2Z-7D483-HA 4.2 mm (0.165 in)
Overdrive Clutch Selective Snap Rings

Part Number Snap Ring Thickness
6L2Z-7D483-M 1.7 mm (0.066 in)
6L2Z-7D483-N 1.9 mm (0.074 in)
6L2Z-7D483-P 2.1 mm (0.082 in)
6L2Z-7D483-Q 2.3 mm (0.09 in)
6L2Z-7D483-R 2.5 mm (0.098 in)
6L2Z-7D483-S 2.7 mm (0.106 in)
Low/Reverse Clutch Selective Pressure Plates

Part Number Pressure Plate Thickness
6L2Z-7B066-HA 5.1 mm (0.2 in)
6L2Z-7B066-M 5.3 mm (0.208 in)
6L2Z-7B066-JA 5.4 mm (0.212 in)
6L2Z-7B066-N 5.6 mm (0.22 in)
6L2Z-7B066-KA 5.7 mm (0.224 in)
6L2Z-7B066-P 5.9 mm (0.232 in)
6L2Z-7B066-LA 6.0 mm (0.236 in)
Clutch Plate Quantity 3.5L GTDI, 5.0L and 6.2L Engines

Number of Number of
Number of Separator Separator Plate Pressure Pressure Plate
Component Frictions Plates Thickness Plates Thickness
Forward Clutch 5 5 3.0 mm 1 3.0 mm
(A)
(0.118 in) (0.118 in)
Direct Clutch (B) 5 5 1.75 mm 1 3.9 mm
(0.068 in) (0.153 in)

Intermediate 5 5 3.0 mm 1 3.9 mm
Clutch (C)
(0.118 in) (0.153 in)
Low/Reverse (D) 5 5 1.75 mm Select 5.4 mm
(0.068 in) (0.212 in)

Select 5.7 mm
(0.224 in)
1.75 mm Select 6.0 mm
(0.068 in) (0.236 in)

Overdrive (O/D) 6 6 3.0 mm 1 6.15 mm
Clutch (E)
(0.118 in) (0.242 in)
Clutch Plate Quantity 3.7L Engine

Number of Number of
Number of Separator Separator Plate Pressure Pressure Plate
Component Frictions Plates Thickness Plates Thickness
Forward Clutch 4 4 3.0 mm 1 3.0 mm
(A)
(0.118 in) (0.118 in)
Direct Clutch (B) 4 4 1.75 mm 1 3.9 mm
(0.068 in) (0.153 in)

Intermediate 4 4 3.0 mm 1 3.9 mm
Clutch (C)
(0.118 in) (0.153 in)
Low/Reverse (D) 5 5 1.75 mm Select 5.4 mm
(0.068 in) (0.212 in)

Select 5.7 mm
(0.224 in)
1.75 mm Select 6.0 mm
(0.068 in) (0.236 in)

Overdrive (O/D) 6 6 3.0 mm 1 6.15 mm
Clutch (E)
(0.118 in) (0.242 in)
Shift Speeds
Throttle Position Shift Km/H MPH
Light Throttle 1-2 13-21 8-13

TP Voltage 2-3 26-34 16-21
1.25 Volts 3-4 35-43 22-27
4-5 56-64 35-40
5-6 71-79 44-49
5-6 a 100-105 62-65
Closed Throttle 6-5 56-64 35-40
5-4 40-48 25-30
4-3 13-21 8-13
3-2 3-11 2-7
2-1 2-6 1-4
Wide Open Throttle 1-2 45-53 28-33
2-3 87-95 54-59
3-4 140-148 87-92
a
Vehicles equipped with a 4.10:1 FDR
Detent spring bolts 12 — 106
EVAP canister bolt 20 — 177
Exhaust heat shield bolts 15 — 133
Flexplate inspection cover bolts 48 35 —
Flexplate-to-torque converter nuts 40 30 —
Front pump bolts a — — —
Fuel line bracket bolt 25 18 —
Isolator cap bolt 35 26 —
Main control bolts a — — —
Manual control lever nut 15 — 133
Molded leadframe bolts a — — —
Output shaft flange nut a — — —
Park pawl pin bolt 23 17 —
Park rod actuating plate 12 — 106
Pump plate assembly-to-pump body bolts 15 — 133
Selector lever cable bracket bolts 48 35 —
Solenoid bracket bolts 6 — 53
Transmission fluid cooler tube-to-transmission bolt a — — —
Transmission fluid cooler tube bracket nut 12 — 106
Transmission fluid fill plug 35 26 —
Transmission fluid pan bolts a — — —

Transmission insulator and retainer bolts 90 66 —
Transmission insulator and retainer nuts 103 76 —
Transmission-to-engine bolts 48 35 —

Gear Ratios
Power is transmitted from the torque converter to the planetary gearsets through the input shaft. Clutches
are used to hold and drive certain combinations of gearsets. This results in 6 forward ratios and one reverse
ratio which are transmitted to the rear planetary ring gear (output shaft). The planetary gearsets of this
transmission provide the following ratios:
z Reverse:
Front planetary gearset ratio of 1.52:1
Rear planetary gearset ratio of 2.24:1 (reverse direction)
Total ratio of 3.40:1 (reverse direction)
z 1st gear:
Rear planetary gearset ratio of 2.74:1
Total ratio of 4.17:1
z 2nd gear:
z 3rd gear:
Rear planetary gearset ratio of 1:1
z 4th gear:
Front planetary gearset provides ratios of 1:1 and 1.52:1 to different rear planetary gearset
members
z 5th gear:
Front planetary gearset provides ratios of 1:1 and 1.52:1 to different rear planetary gearset
members
z 6th gear:
Front planetary gearset ratio of 1:1

Hydraulic Circuits
Hydraulic Circuit Identification and Function
Hydraulic Circuit Identification Chart

Circuit
Name Description
BREVA BREV5 pressure from the drive enable valve to the clutch A regulator valve.
BREV5 BREV 5F pressure from the clutch A latch valve to the drive enable valve and the No. 2
shuttle ball.
BREV 5F Regulated line pressure from the CL B circuit directed to the A clutch latch valve by the B
clutch latch valve.
BREV5/SS1 BREV5 or SS1 pressure from the No. 2 shuttle ball to the solenoid multiplex valve.
CAPLY Apply circuit to the torque converter, also the return circuit during Torque Converter Clutch
(TCC) release.
CAPLY EX TCC release pressure from the bypass clutch control regulator valve to the converter release
regulator valve.
CAPLY F Line pressure from the PUMP circuit directed to the bypass clutch control regulator valve by
the main regulator valve.
CL A Regulated line pressure from the clutch A regulator valve to the clutch A latch valve and the
forward (A) clutch to apply the clutch.

CLA FB Regulated line pressure from the clutch A latch valve that feeds back to the clutch A
regulator valve.
CL B Regulated line pressure from the clutch B regulator valve to the clutch B latch valve and the
direct (B) clutch to apply the clutch.
CLB FB Regulated line pressure from the clutch B latch valve that feeds back to the clutch B
regulator valve.
CL C Regulated line pressure from the clutch C regulator valve to the intermediate (C) clutch to
apply the clutch.
CL D1 Regulated line pressure from the clutch D1 regulator valve to the clutch D1 latch valve and
the low/reverse (D) clutch to apply the clutch.
CL D1 FB Regulated line pressure from the clutch D1 latch valve that feeds back to the clutch D1
regulator valve.
CL DC Regulated solenoid output pressure from Shift Solenoid D (SSD) directed by the solenoid
multiplex valve to the D1 and D2 regulator and latch valves to apply the low/reverse (D)
clutch.
CLE Regulated line pressure from the clutch E regulator valve to the clutch E latch valve and the
overdrive (E) clutch to apply the clutch.
CLEC Regulated solenoid output pressure from the CLEC F circuit directed by the drive enable
valve to the clutch E regulator and latch valves to apply the clutch.
CLEC F Regulated solenoid output pressure from the VFS4 circuit directed to the drive enable valve
by the solenoid multiplex valve to move the clutch E regulator and latch valves to apply the
overdrive (E) clutch.
CLE FB Regulated line pressure from the clutch E latch valve that feeds back to the clutch E
regulator valve.
CL EXH Line pressure regulated to approximately 21 kPa (3 psi) by the D2 latch valve that supplies
exhaust pressure to the A, B, C, D1 and E clutch when the clutches are released.
COOLF Pressure from the lubrication control valve to the oil cooler or the thermal bypass valve that
feeds the lubrication circuit.
CREL Pressure supplied to the torque converter by the converter release regulator valve to release
the TCC .
CREL F Line pressure from the main regulator valve that supplies the converter release regulator
valve and the lubrication control valve.
DBACK CAPLY EX pressure directed to the drain back valve by the converter release regulator
valve.
DRIVE Line pressure directed by the manual valve to the A, C and E clutch regulator valves and the
No. 1 shuttle ball.
LUBE Transmission lubrication circuit supplied by the COOLF circuit after the fluid circulates the
transmission fluid cooler or is returned by the cooler bypass valve.
PUMP Line pressure supplied by the pump to the manual valve, solenoid pressure regulator valve,
main regulator valve, clutch D1 regulator valve, clutch D2 regulator valve and clutch D2 latch
valve.
REV Line pressure from the manual valve to the No. 1 shuttle ball and the solenoid multiplex
valve.
REV/DRIVE REV or DRIVE pressure from the No. 1 shuttle ball to the clutch B regulator valve.
SCHG Line pressure from the main regulator valve to the pump suction port.
SREG Line pressure from the solenoid regulator valve that supplies pressure to the 7 solenoids
Shift Solenoid A (SSA), Shift Solenoid B (SSB), Shift Solenoid C (SSC), SSD , Shift
Solenoid E (SSE), TCC solenoid and Line Pressure Control (LPC) solenoid.
SS1 Solenoid output pressure from SSE to the drive enable valve and to shuttle ball No. 2. to
direct SSD output pressure to clutch E regulator and latch valves to apply the overdrive (E)
clutch.
VFS1 Solenoid output pressure from SSA to the A clutch regulator and latch valve to apply the
forward (A) clutch.
VFS2 Solenoid output pressure from SSB to the B clutch regulator and latch valve to apply the
direct (B) clutch and is also routed to the D1 latch valve.
VFS2D SSB output pressure from the VFS2 circuit directed to the clutch B regulator valve by the D1
latch valve.
VFS3 Solenoid output pressure from SSC to the C clutch regulator valve to apply the intermediate
(C) clutch and is also routed to the clutch E latch valve.
VFS3E SSC output pressure from the VFS3 circuit directed to the clutch C regulator valve by the
clutch E latch valve.
VFS4 Solenoid output pressure from SSD to the solenoid multiplex valve to apply either the D or E
clutch.
VFS5 Solenoid output pressure from the LPC solenoid to the main regulator valve to control line
pressure.
VFS6 Solenoid output pressure from the TCC solenoid to the bypass clutch control regulator valve
and the converter release regulator valve to control the TCC .
Main Control Hydraulic Passage Identification
Line Pressure Hydraulic Circuits
The PCM controls line pressure with the Line Pressure Control (LPC) solenoid. Varying pressure from the
LPC solenoid effects shift feel while allowing sufficient pressure for clutch application.
When the engine is running, the pump supplies pressure to the main regulator valve through the PUMP
circuit. The position of the main regulator valve controls line pressure (in the PUMP circuit). Pressure from
the LPC through the VFS5 circuit controls the position of the main regulator valve.
The main regulator valve varies pressure in the SCHG circuit. The higher the pressure in the SCHG circuit,
the lower the line pressure (PUMP circuit) is. As SCHG pressure decreases, line pressure (PUMP circuit)
increases.
Lubrication Hydraulic Circuits
The main regulator valve supplies pressure to the lubrication control valve through the CREL F circuit. When
the Torque Converter Clutch (TCC) is applied, the lubrication control valve supplies the transmission
lubrication through the COOLF circuit to the LUBE circuit.
When the TCC is released, return fluid from the torque converter is supplied to the LUBE circuit through the
CAPLY, CAPLY EX and DBACK circuits.
Pressure in the LUBE circuit either circulates through the thermal bypass valve when Transmission Fluid
Temperature (TFT) is below operating temperature or through the transmission fluid cooler when the
transmission fluid is at or above operating temperature. Return fluid from the thermal bypass valve or the
transmission fluid cooler enters the input shaft through the pump assembly and flows through passages in
the input shaft, intermediate shaft and output shaft to provide lubrication for the transmission.
Torque Converter Hydraulic Circuits
When the TCC is released, line pressure is supplied to the converter release regulator valve from the
lubrication control valve through the CREL F circuit. The converter release regulator valve supplies pressure
to the torque converter through the CREL circuit to release the torque converter.
CREL pressure exits the torque converter through the CAPLY circuit and goes to the bypass clutch control
regulator valve. The bypass clutch control regulator valve directs the fluid back to the converter release
regulator valve through the CAPLY EX circuit. The converter release regulator valve directs the fluid to the
DBACK circuit where it supplies lubrication in the LUBE circuit.
When the TCC is applied, the TCC solenoid applies hydraulic pressure to the bypass clutch control regulator
valve and the converter release regulator valve through the VFS6 circuit to position the valves to apply the
TCC .
Line pressure is supplied to the bypass clutch control regulator valve from the main regulator valve. The
bypass clutch control regulator valve directs regulated line pressure to the TCC through the CAPLY circuit to
apply the TCC .
CAPLY pressure exits the torque converter through the CREL circuit and goes to the converter release
regulator valve.
For torque converter description and function, refer to Torque Converter in this section.
Solenoid Hydraulic Circuits
LINE pressure from the pump is directed to the individual shift, TCC solenoid and LPC solenoid by the
solenoid regulator valve through the SREG circuit. The PCM controlled solenoids, direct full or regulated
SREG pressure to the valves that they control.
For electrical operation of the solenoids, refer to Transmission Electronic Control System in this section.
The LPC solenoid sends varying pressure to the main regulator valve to control line pressure.
In the PARK and NEUTRAL position, the PCM supplies low current to Shift Solenoid D (SSD) to apply high-
regulated pressure to the solenoid multiplex valve which directs the pressure to the D1 regulator and latch
valves to apply the low/reverse clutch (D).
In the REVERSE position, the PCM supplies low current to Shift Solenoid B (SSB) to apply high-regulated
pressure to the clutch B regulator and latch valves to apply the direct clutch (B). The PCM also supplies low
current to SSD to apply high-regulated pressure to the solenoid multiplex valve which directs the pressure to
the D1 regulator and latch valves to apply the low/reverse clutch (D).
In 1st gear, the PCM supplies high current to Shift Solenoid A (SSA) to apply high-regulated pressure to the
clutch A regulator and latch valves to apply the forward clutch (A). The PCM also supplies low current to
SSD to apply high-regulated pressure to the solenoid multiplex valve which directs the pressure to the D1
regulator and latch valves to apply the low/reverse clutch (D).
In 2nd gear, the PCM supplies high current to SSA to apply high-regulated pressure to the clutch A regulator
and latch valves to apply the forward clutch (A). The PCM also supplies high current to Shift Solenoid C
(SSC) to apply high-regulated pressure to the clutch C regulator valve to apply the intermediate clutch (C).
In 3rd gear, the PCM supplies high current to SSA to apply high-regulated pressure to the clutch A regulator
and latch valves to apply the forward clutch (A). The PCM also supplies low current to Shift Solenoid B
(SSB) to apply high-regulated pressure to the clutch B regulator and latch valves to apply the direct clutch
(B).
In 4th gear, the PCM supplies high current to SSA to apply high-regulated pressure to the clutch A regulator
and latch valves to apply the forward clutch (A). The PCM also supplies low current to SSD to apply high-
regulated pressure to the solenoid multiplex valve which directs the pressure to the clutch E regulator and
latch valves to apply the overdrive clutch (E). The PCM turns on Shift Solenoid E (SSE) to apply pressure to
the solenoid multiplex valve and the drive enable valve to direct SSD pressure to the clutch E regulator and
latch valves.
In 5th gear, the PCM supplies low current to SSD to apply high-regulated pressure to the solenoid multiplex
valve which directs the pressure to the clutch E regulator and latch valves to apply the overdrive clutch (E).
The PCM turns on SSE to apply pressure to the solenoid multiplex valve and the drive enable valve to direct
SSD pressure to the clutch E regulator and latch valves. The PCM also supplies low current to SSB to apply
high-regulated pressure to the clutch B regulator and latch valves to apply the direct clutch (B).
In 6th gear, the PCM supplies low current to SSD to apply high-regulated pressure to the solenoid multiplex
valve which directs the pressure to the clutch E regulator and latch valves to apply the overdrive clutch (E).
The PCM turns on SSE to apply pressure to the solenoid multiplex valve and the drive enable valve to direct
SSD pressure to the clutch E regulator and latch valves. The PCM also supplies high current to SSC to
apply high-regulated pressure to the clutch C regulator valve to apply the intermediate clutch (C). To apply
the TCC , the PCM supplies high current to the TCC solenoid to apply high-regulated pressure to the
converter release regulator valve and the bypass clutch control regulator valve to apply the TCC .
In 3rd gear fail safe, all solenoids are off. SSB , in the off position, applies high pressure to the clutch B
regulator and latch valves to apply the direct clutch (B). The forward clutch (A) is hydraulically applied in 3rd
gear fail safe. PCA provides maximum solenoid pressure to the main regulator valve for maximum line
pressure. Also, SSD is on which applies high pressure to the solenoid multiplex valve which is directed to
the drive enable valve where it is blocked.
Forward Clutch (A) Hydraulic Circuits
To apply the forward clutch (A), the manual valve must be in the DRIVE, 3, 2 or 1 position to provide line
pressure to the clutch A regulator valve through the DRIVE circuit.
For the forward clutch (A) to apply, SSA provides regulated solenoid pressure from the SREG circuit to the
clutch A regulator and latch valves through the VFS1 circuit to position the valves to apply the forward clutch
(A). As the forward clutch is applied, SSA increases pressure to the clutch A regulator and latch valves.
The clutch A regulator valve provides regulated line pressure to the CL A circuit to apply the forward clutch
(A).
The forward clutch (A) is released when the manual valve is in the NEUTRAL, REVERSE or PARK position
or the when the manual valve is in the DRIVE position with the transmission in 5th or 6th gear.
SSA lowers pressure to the clutch A regulator and latch valve to position the valves to lower the regulated
line pressure in the CL A circuit to release the clutch.
When the forward clutch (A) is released, the clutch A regulator valve directs exhaust circuit pressure from
the CL EXH circuit to the CL A circuit to fill the circuit and the forward clutch (A) with fluid at low pressure,
approximately 21 kPa (3 psi).
Direct Clutch (B) Hydraulic Circuits
To apply the direct clutch (B), the manual valve can be in the REVERSE, DRIVE, 3, 2 or 1 position to
provide line pressure to the clutch B regulator valve through the REV/DRIVE circuit.
For the direct clutch (B) to apply in reverse, SSB provides regulated solenoid pressure from the SREG
circuit to the clutch B regulator and latch valves through the VFS2 circuit to position the valves to apply the
direct clutch (B). As the direct clutch is applied, SSB increases pressure to the clutch B regulator and latch
valves.
The clutch B regulator valve provides regulated line pressure to the CL B circuit to apply the direct clutch
(B).
When the direct clutch (B) is applied in 3rd and 5th gear, regulated solenoid pressure from the D1 latch
valve is supplied to the clutch B regulator valve through the VFS2D circuit and opposes pressure from the
VFS2 circuit for clutch B valve positioning.
The direct clutch (B) is released when the manual valve is in the PARK or NEUTRAL position or when the
manual valve is in the DRIVE position with the transmission in 1st, 2nd, 4th or 6th gear.
In NEUTRAL or PARK, the manual valve does not supply line pressure to the clutch B regulator valve. SSB
lowers pressure to the clutch B regulator and latch valve to position the valves to lower the regulated line
pressure in the CL B circuit to release the clutch.
In 1st, 2nd, 4th or 6th gear, the manual valve supplies line pressure to the clutch B regulator valve. SSB
lowers pressure to the clutch B regulator and latch valve to position the valves to lower the regulated line
pressure in the CL B circuit to release the clutch.
When the direct clutch (B) is released in 1st, 2nd, 4th or 6th gear, the clutch (B) regulator valve directs
exhaust circuit pressure from the CL EXH circuit to the CL B circuit to fill the circuit and the direct clutch (B)
with fluid at low pressure, approximately 21 kPa (3 psi).
Intermediate Clutch (C) Hydraulic Circuits
To apply the intermediate clutch (C), the manual valve can be in the DRIVE, 3, 2 or 1 position to provide line
pressure to the clutch C regulator valve through the DRIVE circuit.
SSC provides regulated solenoid pressure from the SREG circuit to the clutch C regulator valve through the
VFS3 circuit to position the valve to apply the intermediate clutch (C). As the intermediate clutch (C) is
applied, SSC increases pressure to the clutch C regulator valve.
The clutch C regulator valve provides regulated line pressure to the CL C circuit to apply the intermediate
clutch (C).
Regulated solenoid pressure from the clutch E latch valve is supplied to the clutch C regulator valve through
the VFS3E circuit and opposes VFS3 pressure for clutch C regulator valve positioning in 6th gear only.
To release the intermediate clutch (C) when the manual valve is in the DRIVE, 3, 2 or 1 position SSC lowers
pressure to the clutch C regulator valve to position the valve to lower the regulated line pressure in the CL C
circuit to release the clutch.
When the intermediate clutch (C) is released, the clutch C regulator valve directs exhaust circuit pressure
from the CL EXH circuit to the CL C circuit to fill the CL C circuit and the intermediate clutch (C) with fluid at
low pressure, approximately 21 kPa (3 psi).
In PARK, REVERSE or NEUTRAL, the manual valve does not supply line pressure to the clutch C regulator
valve.
Low/Reverse Clutch (D) Hydraulic Circuits
To apply the low/reverse clutch (D), the manual valve can be in any position. Line pressure is supplied to the
D1 regulator and latch valves by the pump through the PUMP circuit.
SSD provides regulated solenoid pressure from the SREG circuit to the solenoid multiplex valve through the
VFS4 circuit where it is directed to the D1 regulator and latch valves through the CL DC circuit to position
the valves to apply the low/reverse clutch (D). As the low/reverse clutch (D) is applied, SSD increases
pressure to the D1 clutch regulator and latch valves.
The clutch D1 regulator valve provides regulated line pressure from the PUMP circuit to the CL D1 circuit to
apply the low/reverse clutch (D).
To release the low/reverse clutch (D), the manual valve can be in the DRIVE, 3 or 2 position. SSD lowers
pressure to the VFS4 circuit which lowers pressure in the CL DC circuit to position the D clutch regulator and
latch valves to lower pressure in the CL D1 circuit and release the low/reverse clutch (D).
When the low/reverse clutch (D) is released, the clutch D2 latch valve directs line pressure regulated to
approximately 21 kPa (3 psi) to the CL EXH circuit which fills the volume of the unused clutches and circuits.
When the low/reverse clutch (D) is released, the CL EXH circuit supplies the D1 regulator valve which fills
the CL D1 circuit and the low/reverse (D) clutch.
Overdrive Clutch (E) Hydraulic Circuits
To apply the overdrive clutch (E), the manual valve must be in the DRIVE position. Line pressure is supplied
to the clutch E regulator valve.
SSD provides regulated solenoid pressure from the SREG circuit to the solenoid multiplex valve through the
VFS4 circuit. SSE supplies pressure to the solenoid multiplex valve and the drive enable valve to position
the valves to direct pressure from the VFS4 circuit to the CLEC F and CLEC circuits to position the clutch E
regulator and latch valves to apply the overdrive clutch (E). As the overdrive clutch (E) is applied, SSD
increases pressure to the clutch E regulator and latch valve.
The clutch E regulator valve provides regulated line pressure from the DRIVE circuit to the CLE circuit to
apply the overdrive clutch (E).
To release the overdrive clutch (E), the manual valve can be in any position. SSD lowers pressure to the
VFS4 circuit which lowers pressure in the CLEC and CLEC F circuits and releases the overdrive clutch (E).
SSE blocks SREG pressure to the solenoid multiplex valve and the drive enable valve to allow SSD to
control low/reverse clutch (D) operation.
When the overdrive clutch (E) is released, the clutch E regulator valve directs exhaust circuit pressure from
the CL EXH circuit to the CL E circuit to fill the circuit and the clutch with fluid at low pressure, approximately
21 kPa (3 psi).

Hydraulic System
Pump Assembly and Transmission Fluid Filter
This transmission has a gear type pump that supplies transmission fluid pressure to the hydraulic system.
The inner (drive) gear is turned by the torque converter hub.
The transmission fluid pump has the following parts:
z Pump body, with inner (drive) and outer (driven) gears

z Centering plate
z Intermediate plate
z Stator shaft
The transmission fluid pump draws transmission fluid from the sump area, formed by the transmission fluid
pan, through the transmission fluid filter, which is installed into the intermediate plate portion of the pump
assembly and sealed by a rubber seal. A magnet attached to the transmission fluid pan collects any metallic
material in the transmission fluid.
Pump Assembly and Transmission Fluid Filter Components
1 7A103 Transmission fluid pump assembly

2 7A098 Transmission fluid filter
3 — Transmission fluid filter seal (part of 7A098)
4 — Transmission fluid pump body (part of 7A103)
5 — Inner (drive) gear (part of 7A103)
6 — Outer (driven) gear (part of 7A103)
7 — Centering plate (part of 7A103)
8 — Intermediate plate (part of 7A103)
9 — Filter suction port
10 — Stator shaft (part of 7A103)
Transmission Fluid Level Indicator
A removable dipstick-type fluid level indicator is located on the right front area of the transmission case. It is
held in by an external fluid fill plug. The transmission fluid level indicator is removed with the transmission
fluid fill plug. The transmission fluid level indicator is removed from the fill plug to check the transmission
fluid level.
The transmission fluid level is correctly checked when the transmission is at normal operating temperature,
89ºC-102ºC (193ºF-215ºF), and the vehicle is on a level surface.
The correct transmission fluid level is at the upper level of the crosshatch marks on the transmission fluid
level indicator.
Transmission Fluid Level Indicator

1 — Transmission fluid fill plug
2 7A010 Transmission fluid level indicator
3 — Transmission fluid level indicator FULL line
Main Control Assembly
The hydraulic system of this transmission includes the fluid pump, a main control assembly and fluid
passages in the transmission case and center support to apply the clutches.
The main control assembly has an upper valve body assembly, a separator plate and a lower valve body
assembly. The lower valve body assembly has 7 solenoids to control the valves in the main control.
TheTurbine Shaft Speed (TSS), Output Shaft Speed (OSS), Transmission Range (TR) and Transmission
Fluid Temperature (TFT) sensors are all part of the main control assembly leadframe.

1 7A100 Main control
1 7G276 Molded leadframe
2 — Transmission control valve body (upper)
3 7E195 Transmission control valve check ball (8 required)
4 7Z490 Transmission control valve body separator plate
5 — Transmission control valve body (lower)
6 — Transmission control valve assembly
7 7H187 Transmission control filter assembly
8 7B155 Transmission fluid filter
9 — Transmission solenoid damper valve assembly
10 7G383 Shift Solenoid A (SSA)
11 7G383 Shift Solenoid B (SSB)
12 7G383 Shift Solenoid C (SSC)
13 7G383 Line Pressure Control (LPC) solenoid
14 7G383 Shift Solenoid D (SSD)
15 7G484 Shift Solenoid E (SSE)
16 7G383 Torque Converter Clutch (TCC) solenoid
17 — Forward (A) clutch latch valve assembly
18 — Direct (B) clutch latch valve assembly
19 — Solenoid regulator valve
20 — Low/reverse (D1) clutch latch valve assembly
21 — Drive enable valve
22 — Solenoid multiplex valve
23 — Forward (A) clutch regulator valve assembly
24 — Overdrive (E) clutch regulator valve assembly
25 — Overdrive (E) clutch latch valve assembly
26 — Bypass clutch control regulator valve assembly

27 — Main regulator valve assembly
28 — Converter release regulator valve assembly
29 — Lubrication control valve assembly
30 — Manual valve assembly
31 — Low/reverse (D2) clutch latch valve assembly
32 — Direct (B) clutch regulator valve assembly
33 — Low/reverse (D1) clutch regulator valve assembly
34 — Intermediate (C) clutch regulator valve

Identification Tags
All vehicles come equipped with a Safety Compliance Certification Label. The location on the label marked
TR is reserved for the transmission code. To determine the correct transmission for this vehicle, refer to the
Owner's Literature, Transmission Code Designations. All transmissions are equipped with an identification
tag located on the transmission case. For transmission part number, serial number and build date, refer to
the transmission identification tag located on the transmission case.
Item Description
1 Part number
2 Build date
3 Serial number
Solenoid Strategy Identification Tag
NOTE: Letters are not used in the 13 digit solenoid body strategy. The characters consist of all numbers.
PCM controlled transmissions have a solenoid strategy identification tag located on the left side of the
transmission case. Compare the 13 digit number on the tag with the 13 digit number displayed on the scan
tool to determine the correct solenoid strategy for the transmission. If the scan tool matches the service tag
then the solenoid strategy is correct. If the solenoid strategy retrieved from the scan tool does not match the
solenoid strategy identification tag, the transmission fluid pan must be removed to compare what the scan
tool displays to the solenoid strategy number etched on the main control. Refer to Fluid Pan, Gasket and
Filter in this section. If the solenoid strategy identification etched on the main control matches what the scan
tool displays, then the solenoid strategy is correct. If the solenoid strategy identification etched on the main
control does not match the scan tool, then a Solenoid Strategy Data Download is required. Refer to Solenoid
Body Strategy for the download procedure in this section.
Original Solenoid Body Tag
Item Description
1 13 digit solenoid strategy
2 12 digit solenoid body identification
A replacement solenoid body tag is provided when the main control is serviced. The replacement solenoid
body tag is placed over the original solenoid body tag.
Replacement Solenoid Body Tag
Item Description
1 13 digit solenoid strategy
2 12 digit solenoid body identification
Main Control Solenoid Body Strategy Identification
If the solenoid body strategy etched on the main control does not match what the scan tool displays, the
solenoid body strategy must be downloaded into the PCM or harsh shifts will result.

Major Components
Major Components
This transmission has the following major components:
z Transmission case with integral torque converter housing

z Torque converter
z Fluid pump
z Three drive clutches:
Forward clutch (A)
Direct clutch (B)
Overdrive clutch (E)
z Three brake clutches:
Intermediate clutch (C)
Low/reverse clutch (D)
One-Way Clutch (OWC)
z Two planetary gearsets:
Front single planetary gearset (1 sun gear, 1 carrier, 1 ring gear)
Rear ravigneaux planetary gearset (2 sun gears, 1 carrier with 2 sets of pinion gears and 1 ring
gear)
z Main control:
Upper valve body
Lower valve body
Transmission Range (TR) sensor
Turbine Shaft Speed (TSS) sensor
Output Shaft Speed (OSS) sensor
Transmission Fluid Temperature (TFT) sensor
Line Pressure Control (LPC) solenoid
Torque Converter Clutch (TCC) solenoid
Five electronically controlled shift solenoids
In addition to the torque converter, the other shift elements are:
z three rotating multi-plate clutches: forward (A), direct (B) and overdrive (E).
z two fixed multi-disc brakes: intermediate (C) and low/reverse (D).
All gear shifts from 1st to 6th or from 6th to 1st are power-on overlapping shifts. That is, during the shift, one
of the clutches must continue to transmit the drive at lower main pressure until the other clutch is able to
accept the input torque.
The shift elements, clutches or brakes are engaged hydraulically. The transmission fluid pressure builds up
between the cylinder and the piston, pressing the clutches together.
The purpose of these shift elements is to carry out in-load shifts with no interruption to traction.
Multi-plate clutches; forward, direct and overdrive, supply power from the engine to the planetary geartrain.
Multi-disc brakes, intermediate and low/reverse, press against the transmission housing in order to achieve
a torque reaction effect.
Multi-Plate Clutch
Clutches; overdrive (E), forward (A) and direct (B) are balanced in terms of dynamic pressure. That is, their
pistons are exposed to the transmission fluid flow on both sides, in order to prevent pressure buildup in the
clutch as speed increases. This equalization process is achieved by a baffle plate and pressure-free
transmission fluid supplied by a lubricating passage, through which the space between piston and baffle
plate is filled with transmission fluid.
The advantages of this dynamic pressure equalization are:
z reliable clutch engagement and release in all speed ranges.

z improved shift refinement.
Shift Overlap Control
The electro-hydraulic shift action is obtained by means of various valves in the main control valve body,
actuated by pressure regulators. They engage or disengage the relevant clutches or brakes at the correct
moments.
Hydraulic Systems
Fluid Pump
The torque converter is supported in the fluid pump by a needle roller bearing. The fluid pump is driven
directly from the engine by the torque converter shell and supplies transmission fluid to the transmission and
the hydraulic control unit.
The fluid pump draws in transmission fluid through a transmission fluid filter and delivers it at high pressure
to the main pressure valve in the main control valve body unit. The valve adjusts the pressure and returns
excess transmission fluid to the transmission fluid pan.
Fluid Filter
All transmission fluid that is picked up from the transmission fluid pan passes through the transmission fluid
filter. The transmission fluid filter and its accompanying seal are part of the transmission fluid path from the
pan to the transmission fluid pump.
Single Planetary Gearset
The single planetary gear overdrive carrier is driven by the input shaft. The single planetary gear set
consists of the following components:
z One sun gear

z Four planetary gears meshing with the sun gear
z One planetary carrier
z One ring gear
Ravigneaux Planetary Gearset
The ravigneaux planetary gearset is splined to the output shaft and consists of the following components:
z Two sun gears of different sizes

z Three long planetary gear pinions meshing with the large sun gear and the ring gear
z Three short planetary gear pinions meshing with the small sun gear and the long pinions
z One planetary carrier
z One ring gear
Output Shaft
The output shaft provides torque to the driveshaft and rear axle assembly. It is splined to the ring gear of the
rear/ravigneaux planetary gearset.
Major Components Cutaway View
Item Description
1 Torque converter
2 Front pump assembly

3 Forward clutch (A)
4 Front planetary gearset
5 Overdrive clutch (E)
6 Direct clutch (B)
7 Intermediate clutch (C)
8 One-Way Clutch (OWC)
9 Low/reverse clutch (D)
10 Rear planetary gearset
11 Transmission case
12 Main control assembly
13 Transmission fluid filter

Mechanical Components and Functions
Planetary Gearset
This transmission has 2 planetary gearsets (front and rear) to provide operation in reverse and 6 forward
speeds.
The front planetary gearset is a single planetary gearset and has the following components:
z Front planetary No. 1 sun gear

z Front planetary carrier
z Front planetary ring gear (part of the input shaft assembly)
The input shaft rotates the front ring gear as a driving member. The front sun gear is connected to the fluid
pump and is held stationary. The front ring gear rotates the front planetary carrier assembly with a reduction
ratio of 1.52:1.
The front planetary carrier assembly is the only output member of the front planetary gearset in reverse, 1st,
2nd and 3rd gear. The front planetary gearset provides a 1.52:1 gear ratio to the rear planetary gearset.
In 4th and 5th gear, both the front ring gear and front planetary carrier assembly are output members of the
front planetary gearset. The front planetary gearset provides both a 1:1 and 1.52:1 gear ratio to different
members of the rear planetary gearset.
In 6th gear, the front ring gear is the only output member of the front planetary gearset. The front planetary
gearset provides a 1:1 gear ratio to the rear planetary gearset.
The rear planetary gearset is a ravigenaux planetary gearset and has the following components:
z Rear planetary No. 2 sun gear

z Rear planetary No. 3 sun gear
z Rear planetary carrier assembly (2 sets of pinion gears)
z Rear planetary ring gear assembly
Power flow through the rear planetary gearset is as follows:
z In reverse, rear sun gear No. 2 is driven, the rear planetary carrier is held and the ring gear is the
output (2.24:1 with reverse direction)
z In 1st gear, sun gear No. 3 is driven, the rear planetary carrier is held and the ring gear is the output
(2.74:1)
z In 2nd gear, sun gear No. 3 is driven, sun gear No. 2 is held and the ring gear is the output (1.54:1)
z In 3rd gear, sun gear No. 3 and sun gear No. 2 are driven and the ring gear is the output (1:1)
z In 4th gear, sun gear No. 3 and the rear planetary carrier are driven and the ring gear is the output
(1.14:1)
z In 5th gear, sun gear No. 2 and the rear planetary carrier are driven and the ring gear is the output
(0.87:1)
z In 6th gear, the rear planetary carrier is driven, sun gear No. 2 is held and the ring gear is the output
(0.69:1)
Planetary Gearset Exploded View
Item Description
1 Front planetary No. 1 sun gear
2 Front planetary carrier
3 Front planetary ring gear (part of input shaft assembly)
4 Rear planetary No. 2 sun gear
6 Rear planetary carrier
7 Rear planetary ring gear
8 Output shaft
Forward Clutch (A)
The forward clutch (A) connects the front planetary carrier to the rear No. 3 sun gear. This provides a gear
reduction ratio of 1.52:1 from the input shaft to rear sun gear No. 3. The forward clutch (A) is applied in 1st,
2nd, 3rd and 4th gears.
Regulated hydraulic pressure from the regulator valve in the valve body pushes the forward clutch (A) piston
against the forward clutch (A) pack to apply the clutch. The front planetary carrier and the rear No. 3 sun
gear are connected as a result of the clutch being applied.
Forward Clutch (A) Exploded View
Item Description
1 Forward clutch cylinder
2 Forward clutch piston
3 Forward clutch piston return spring
4 Forward clutch balance piston
5 Front planetary carrier assembly
6 Forward clutch wave spring
7 Forward clutch friction and steel plates
8 Forward clutch pressure plate
9 Rear planetary No. 3 sun gear hub and shaft assembly
Direct Clutch (B)
The direct clutch (B) connects the front planetary carrier to the rear No. 2 sun gear. This provides a gear
reduction ratio of 1.52:1 from the input shaft to rear sun gear No. 2. The direct clutch (B) is applied in
reverse, 3rd and 5th gears.
Regulated hydraulic pressure from the regulator valve in the valve body pushes the direct clutch (B) piston
against the direct clutch (B) pack to apply the clutch. The front planetary carrier and the rear No. 2 sun gear
are connected as a result of the clutch being applied.
Direct Clutch (B) Exploded View
Item Description
1 Forward clutch cylinder
2 Forward clutch balance piston
3 Front planetary carrier assembly
4 Direct clutch hub
5 Direct clutch pressure plate
6 Direct clutch friction and steel plates
7 Direct clutch wave spring
8 Direct clutch balance piston
9 Direct clutch piston return spring
10 Direct clutch piston
11 Direct clutch cylinder
12 Rear planetary sun gear No. 2
Intermediate Clutch (C)
The intermediate clutch (C) holds the rear planetary No. 2 sun gear stationary to the transmission case. The
intermediate clutch (C) is applied in 2nd and 6th gears.
Regulated hydraulic pressure from the regulator valve in the valve body pushes the intermediate clutch (C)
piston against the intermediate clutch (C) pack to apply the clutch.
Intermediate Clutch (C) Exploded View
Item Description
1 Direct clutch cylinder
2 Intermediate clutch pressure plate
3 Intermediate clutch friction and steel plates
4 Intermediate clutch wave spring
5 Intermediate clutch piston return spring
6 Intermediate clutch piston
7 Center support assembly
8 Rear planetary sun gear No. 2
9 Transmission case
Low/Reverse Clutch (D) and Low/One-Way Clutch (OWC)
The low/reverse clutch (D) holds the rear planetary carrier stationary to the transmission case. The
low/reverse clutch (D) is applied in park, reverse, neutral and 1st gear below 5 kph (3 mph).
Regulated hydraulic pressure from the regulator valve in the valve body pushes the low/reverse clutch (D)
piston against the low/reverse clutch (D) pack to apply the clutch.
The low/ OWC is a brake clutch that holds the rear planetary carrier in one direction and allows it to
freewheel in the opposite direction eliminating engine braking in 1st gear when the transmission is in drive,
above 5 kph (3 mph) only.
Low/Reverse Clutch (D) and Low/One-Way Clutch (OWC) Exploded View
Item Description
1 Center support assembly
2 Low/reverse clutch piston
3 Low/reverse clutch piston return spring
4 Low/reverse clutch piston retainer
5 Low/ OWC
6 Low/reverse clutch wave spring
7 Low/reverse clutch friction and steel plates
8 Low/reverse clutch pressure plate
9 Rear planetary carrier assembly
10 Transmission case
Overdrive Clutch (E)
The overdrive clutch (E) connects the input shaft with the rear planetary carrier. The overdrive clutch (E) is
applied in 4th, 5th and 6th gears.
Regulated hydraulic pressure from the regulator valve in the valve body pushes the overdrive clutch (E)
piston against the overdrive clutch (E) pack to apply the clutch.
Overdrive Clutch (E) Exploded View
Item Description
1 Input shaft assembly
2 Overdrive clutch piston
3 Overdrive clutch piston return spring
4 Overdrive clutch balance piston
5 Overdrive clutch friction and steel plates
6 Overdrive clutch pressure plate
7 Intermediate shaft
8 Rear planetary carrier assembly
External Sealing
The pump assembly has a lip-type seal for the torque converter impeller hub. The pump assembly uses a
large O-ring to seal the transmission case. The pump bolts also seal the pump to the transmission case.
The manual control lever shaft has a lip seal for its bore in the transmission case.
The transmission fluid pan uses a reusable gasket.
The output shaft flange has a lip-type seal that seals the flange to the transmission case.
The transmission case plug provides access to the park pawl shaft. The plug has a seal that is serviced as
an assembly with the plug.
The transmission bulkhead connector sleeve has seals for the transmission case bore.
The plug for the fluid level indicator uses an O-ring seal.
External Sealing (Gaskets, O-rings and Seals)
Item Description
1 Torque converter
2 Front pump oil seal
3 Front pump-to-case bolt (13 required)

5 Pump assembly inner oil seal
7 Front pump outer oil seal
8 Transmission case
9 Manual control lever shaft seal
10 Manual control lever (Manual control lever installation position is vehicle/model dependent.)
11 Manual control lever nut
12 Transmission fluid pan gasket
13 Transmission fluid pan
14 Line pressure tap plug
15 Output shaft flange retaining nut RWD
16 Output shaft flange RWD
17 Output shaft flange seal RWD
18 Output shaft seal (model dependent)
19 Transmission case plug (park pawl shaft access)
20 Transmission bulkhead connector sleeve
21 Transmission bulkhead connector sleeve seals
22 Transmission fluid level indicator
23 Transmission fluid level indicator plug seal (part of transmission fluid level indicator)
24 Transmission fluid level indicator plug (part of transmission fluid level indicator)
Bushings, Bearings and Thrust Washer Locations
This transmission supports the rotating components of the transmission with bushings, bearings and thrust
washers.
The pump assembly support thrust washer controls the amount of end play for components between the
pump assembly and the center support (forward/overdrive clutch assembly, direct clutch cylinder).
The T8 thrust bearing outer race controls the amount of end play for components between the center
support and the rear of the transmission case (rear planetary gearset assembly, output shaft assembly).
Item Description
1 Front pump selective washer
2 Bearing T1
3 Bearing T3
4 Bearing T6
5 Thrust bearing outer race
6 Roller bearing T8
7 Thrust bearing T10
8 Output shaft bearing assembly ( 4WD vehicles and late build RWD vehicles)
9 Output shaft ball bearing assembly (late build RWD vehicles)
10 Output shaft bearing assembly (early build RWD vehicles)
11 Front oil pump bearing assembly (part of pump assembly)
12 Input shaft bushing (part of pump assembly)
13 Bearing T2
14 Bearing T4
15 Roller bearing T5
16 Rear planetary carrier selective washer
17 Thrust bearing T7
18 Roller bearing T9
19 Outer race bearing T9
20 Bearing T11
21 Thrust bearing T12 (early build RWD )
Lubrication
This transmission provides lubrication for rotating mechanical components through one main hydraulic
circuit. The general flow of lubrication moves from the front of the transmission, through the input and
intermediate shafts, to the rear of the transmission.
Transmission fluid from the pump assembly and the torque converter exit the transmission case to go to the
transmission fluid cooler through the bottom of the transmission fluid cooler tube and returns to the
transmission through the top of the transmission fluid cooler tube.
With lower transmission fluid temperatures, the thermal bypass valve in the transmission case bypasses the
transmission fluid cooler tubes and redirects the fluid to the lubrication circuit. As transmission fluid
temperature increases, the thermal bypass valve directs the fluid to the transmission fluid cooler.
Transmission fluid from the transmission fluid cooler or the thermal bypass valve enters the main lubrication
circuit from the top of the transmission fluid cooler tube port.
Transmission fluid in the lubrication circuit flows to each of the balance pistons for the forward (A), direct (B)
and overdrive (E) clutches. The balance pistons prevent unwanted clutch application when the clutch
cylinder rotates at high speeds and hydraulic controls have released the clutch.
Lubrication Passages
Item Description
1 Transmission fluid cooler return (inlet from the transmission fluid cooler)
2 Transmission fluid cooler pressure (outlet to the transmission fluid cooler)
Park
The park gear is part of the output shaft assembly. The park gear has lugs on its overdrive surface that the
park pawl engages to lock the output shaft.
The park lock prevents the vehicle wheels from rotating by allowing the transmission case to hold the output
shaft stationary through the park pawl. When the park pawl is engaged in the park gear, the output shaft is
held stationary.
When the manual control lever is rotated to the PARK position, the park lock works as follows:
z The detent assembly (connected to the manual control shaft) rotates and pushes the park pawl
actuator rod into the park pawl. The actuator rod is spring loaded.
z The actuator rod is guided into the park pawl by the park pawl abutment.
z When the park pawl actuator rod is pushed into the park pawl, the park pawl pivots into the park gear
and engages with the lugs.
z The park pawl holds the output shaft to the transmission case.
Item Description
1 Transmission case
2 Output shaft park gear assembly
3 Park pawl
4 Park pawl return spring
5 Park pawl pin
6 Plug — park pawl pin
7 Park pawl actuator rod
8 Manual valve detent spring
9 Manual valve detent lever assembly
10 Manual control lever shaft
11 Manual control lever (Manual control lever installation position is vehicle/model dependent.)
12 Park rod actuating plate

Range Selection
The transmission has 7 range positions: P, R, N, D, M, 2 and 1.
Park
In the PARK position:
z there is no power flow through the transmission.

z the park pawl locks the output shaft to the case.
z the engine can be started.
z the ignition key can be removed.
Reverse
In the REVERSE position:
z the vehicle can be operated in a rearward direction, at a reduced gear ratio.

z backup lamps are illuminated.
Neutral
In the NEUTRAL position:
z there is no power flow through the transmission.

z the output shaft is not held and is free to turn.
z the engine can be started.
D Position
The D is the normal position for most forward driving.
The D position provides:
z automatic shifts 1-6 and 6-1.

z apply and release of the torque converter clutch.
z maximum fuel economy during normal operation.
z engine braking in all gears.
Position M — SelectShift™
This position provides:
z manual control of the transmission.

z engine braking.
Position 3— 3rd Gear (column-shift only) (For vehicles without SST)
z manual 3rd gear.
Position 2 — 2nd Gear
z manual 2nd gear.
Position 1 — 1st Gear
z first gear operation only.

z engine braking for descending steep grades.
Gear Availability

Shift Patterns
Downshifts
Under certain conditions, the transmission will downshift automatically to a lower gear range (without moving
the range selector lever). There are 3 categories of automatic downshifts:
z Coastdown
z Torque demand
z Forced or kickdown shifts
Coastdown
The coastdown downshift occurs when the vehicle is coasting down to a stop.
Torque Demand
The torque demand downshift occurs (automatically) during part throttle acceleration when the demand for
torque is greater than the engine can provide at that gear ratio.
Kickdown
For maximum acceleration, the driver can force a downshift by pressing the accelerator pedal to the floor. A
forced downshift into a lower gear is possible below calibrated speeds. Specifications for downshift speeds
are subject to variations due to tire size, engine and transmission calibration requirements.

Torque Converter
The torque converter is a 4-element unit containing a 2-plate clutch. The clutch can be controlled and
engaged in any gear, 2nd through 6th. Calibration parameters may be set to allow lockup in a higher gear
only. The clutch is applied by removing fluid pressure from one side of the plate. The torque converter
transmits and multiplies torque. The torque converter includes the following 4 elements:
z Impeller assembly
z Turbine assembly
z Reactor assembly
z Torque Converter Clutch (TCC)
Rotation of the torque converter housing and impeller set the transmission fluid in motion by driving the
impeller blades and pump.
The turbine is driven by the transmission fluid from the impeller and transmits power to the input shaft.
The reactor redirects transmission fluid flow returned from the turbine to the impeller so that it rotates in the
same direction as the impeller. This action assists in torque multiplication.
The reactor has a One-Way Clutch (OWC) to hold it stationary during torque multiplication and allows it to
rotate at higher vehicle speeds.
Torque Converter Clutch (TCC)
The TCC has a cover assembly with a 2-plate clutch and a turbine and damper assembly that connects to
the transmission input shaft.
The TCC connects the cover to the turbine when the TCC is applied.
During TCC release, transmission fluid flows through the torque converter in one direction to release the 2-
plate clutch.
During TCC apply, transmission fluid flows through the torque converter in the opposite direction to apply the
2-plate clutch.
The TCC operates in 3 stages:
z Full release
z Controlled modulation
z Full apply
The PCM controls TCC operation using the TCC solenoid. TCC solenoid operation provides the modulation
of hydraulic pressure to change the position of the bypass clutch control regulator valve. The valve changes
the pressure and direction of transmission fluid flow in the torque converter. TCC may be applied in forward
gears, 2nd through 6th.

Transmission Description
6R80 Transmission
This transmission has the following features:
z Six forward speeds

z Torque converter with an integral converter clutch
z Electronic shift and pressure controls
z Single planetary gear set
z Double planetary gear set
z Two fixed multi-disc clutches
z Three multi-plate clutches
z One-Way Clutch (OWC)
Hydraulic functions are directed by electronic solenoids to control the following:
z Engagement feel
z Shift feel
z Shift scheduling
z Modulated Torque Converter Clutch (TCC) applications
The 6R80 transmission has a main control assembly which contains:
z Turbine Shaft Speed (TSS) sensor

z Output Shaft Speed (OSS) sensor
z An internal Transmission Range (TR) sensor
z Transmission Fluid Temperature (TFT) sensor
z Line Pressure Control (LPC)
z TCC solenoid
z Five electronically controlled shift solenoids
Engine power reaches the transmission by a torque converter with an integral converter clutch. The 6
forward gears and one reverse gear are obtained from 2 planetary gearsets.
This 6-speed electronically controlled automatic transmission is comprised of a PCM, main control valve
body assembly, torque converter, 1 solenoid valve and 6 pressure regulators. Gear selection is achieved by
controlling transmission fluid to operate various internal clutches. The PCM operates the electrical
components and provides for the control of gear selection and shift pressure, which increases refinement
and torque converter slip.
In the event of a system fault, the PCM also provides for Failure Mode Effect Management to maintain
maximum functional operation of the transmission with a minimum power reduction. In the event of a total
loss of control or electrical power, the basic transmission functions park, reverse, neutral and drive are
retained. Also 3rd or 5th gear is retained by the transmissions hydraulic system. The default gear retained is
dependent upon the gear selected at the time of a failure.

Transmission Electronic Control System
Powertrain Control System
The PCM controls the electronic functions of this transmission. A plastic molded leadframe is bolted to the
main control assembly. The leadframe contains the Turbine Shaft Speed (TSS), Output Shaft Speed (OSS),
Transmission Fluid Temperature (TFT) and Transmission Range (TR) sensors.
The PCM receives input signals from engine and transmission sensors and uses these inputs to control line
pressure, shift time, Torque Converter Clutch (TCC), and shift solenoids. The PCM also provides power and
ground for the reverse lamp relay coil and provides a PARK/NEUTRAL start enable signal.
The following is a list of direct engine and driver inputs to the PCM along with module information from the
vehicle Controller Area Network (CAN):
z Engine speed
z Engine torque
z Engine coolant temperature
z Throttle position
z Accelerator pedal
z Brake pedal
z ABS wheel speed
z Traction control status
The PCM also:
z monitors inputs and outputs for the presence of faults.

z stores DTCs related to detected faults.
z provides outputs on the CAN for transmission range, output shaft speed, turbine shaft speed,
transmission fluid temperature, current gear and A/C inhibit.
z provides On-Board Diagnostic (OBD) information using the CAN to illuminate the Malfunction
Indicator Lamp (MIL) or Transmission Control Indicator Lamp (TCIL).
z provides diagnostic information to a scan tool through the Data Link Connector (DLC).
If the PCM detects a system or component fault, it substitutes a default value or signal using Failure Mode
and Effect Management strategies.
The PCM also uses Failure Mode and Effect Management strategies to compensate for electrical or
mechanical shift solenoid and apply component faults that result in alternate shift patterns.
If the transmission loses complete electronic control, it operates in a fail-safe mode with:
z Maximum line pressure in all transmission ranges

z Functional PARK, REVERSE and NEUTRAL positions
z Operation in 3rd or 5th gear (depending on the failure conditions) when the selector lever is in the
DRIVE, 3, 2 or 1 position
z TCC is released in all transmission ranges and gears
Molded Leadframe

1 — Turbine Shaft Speed (TSS) sensor
2 — Output Shaft Speed (OSS) sensor
4 — Transmission Fluid Temperature (TFT) sensor
5 — Transmission Range (TR) sensor
6 — Leadframe connector
7 — Terminal 1
8 — Terminal 16

Shift Solenoid
PCM
a Solenoid state will change if vehicle is moving forward with the selector lever in the NEUTRAL position.
CB = Clutch brake
NH = Normally high
NL = Normally low
The following are brief descriptions of the sensors and actuators used to control transmission operation.
Line Pressure Control (LPC) Solenoid
The Line Pressure Control (LPC) solenoid, is a Variable Force Solenoid (VFS) that varies hydraulic pressure
by actuating a hydraulic valve.
The PCM applies variable current to the LPC solenoid which varies pressure in the VFS5 hydraulic circuit to
the main regulator valve. Refer to Hydraulic Circuits in this section.
The LPC solenoid uses inversely proportional operation. As the current from the PCM decreases, the
pressure from the solenoid increases. As the current from the PCM increases, the pressure from the
solenoid decreases. The LPC solenoid is supplied hydraulic pressure from the SREG circuit.
With zero current, the LPC solenoid fully opens the hydraulic valve which applies the maximum amount of
hydraulic pressure to the main regulator valve through the VFS5 hydraulic circuit and applies maximum line
pressure in the PUMP hydraulic circuit. With maximum current to the solenoid, the hydraulic valve fully
closes the outlet port for minimum pressure to the VFS5 hydraulic circuit, lowering the line pressure in the
PUMP hydraulic circuit.
LPC Inversely Proportional VFS
Torque Converter Clutch (TCC) Solenoid
The TCC solenoid is a VFS that varies hydraulic pressure by actuating a hydraulic valve.
The PCM applies variable current to the TCC solenoid which varies pressure in the VFS6 hydraulic circuit to
the converter release regulator valve and the bypass clutch control regulator valve. Refer to Hydraulic
Circuits in this section.
The TCC solenoid uses proportional operation. As the current from the PCM decreases, the pressure from
the solenoid decreases. As the current from the PCM increases, the pressure from the solenoid increases.
The TCC solenoid is supplied hydraulic pressure from the SREG circuit.
With zero current, the TCC solenoid fully closes the hydraulic valve which applies the minimum amount of
hydraulic pressure to the converter release regulator valve and the bypass clutch control regulator valve
through the VFS6 hydraulic circuit and releases the TCC . With maximum current to the solenoid, the
hydraulic valve fully opens the outlet port for maximum pressure to the VFS6 hydraulic circuit to apply the
TCC .
Torque Converter Clutch (TCC) Proportional VFS
Shift Solenoid A (SSA), Shift Solenoid B (SSB), Shift Solenoid C (SSC) and Shift Solenoid D (SSD)
Shift solenoids A through D are VFS that vary hydraulic pressure by actuating a hydraulic valve.
The PCM applies variable current to the shift solenoids which varies pressure in the hydraulic circuit to the
regulator and latch valves of the clutch that it controls. Refer to Hydraulic Circuits in this section.
SSA and SSC use proportional operation. As the current from the PCM decreases, the pressure from the
solenoid decreases. As the current from the PCM increases, the pressure from the solenoid increases. SSA
and SSC are supplied hydraulic pressure from the SREG circuit.
With zero current, SSA and SSC fully close the hydraulic valves which applies zero amount of hydraulic
pressure to the regulator and latch valves of the clutch that it controls and releases the clutch. With
maximum current to the solenoids, the hydraulic valves fully open for maximum pressure to the regulator
and latch valves to apply the clutch.
Shift Solenoid A (SSA) and Shift Solenoid C (SSC) Proportional VFS
Item Description
1 Shift Solenoid A (SSA) Variable Force Solenoid (VFS)
2 Shift Solenoid C (SSC) VFS
SSB and SSD use inverse proportional operation. As the current from the PCM decreases, the pressure
from the solenoid increases. As the current from the PCM increases, the pressure from the solenoid
decreases. SSB and SSD are supplied hydraulic pressure from the SREG circuit.
With zero current, SSB and SSD fully open the hydraulic valves which applies maximum hydraulic pressure
to the regulator and latch valves to apply the clutch that it controls. With maximum current to the solenoids,
the hydraulic valve fully closes to apply zero amount of hydraulic pressure to the regulator and latch valves
of the clutch that it controls and releases the clutch.
Shift Solenoid B (SSB) and Shift Solenoid D (SSD) Inverse Proportional VFS
Item Description
1 Shift Solenoid B (SSB) Variable Force Solenoid (VFS)
2 Shift Solenoid D (SSD) VFS
Shift Solenoid E (SSE)
SSE is an ON/OFF solenoid. When SSE is in the OFF position, SSD controls the regulator and latch valves
to apply the low/reverse clutch. When SSE is in the ON position, SSD controls the regulator and latch valves
to apply the overdrive (456) clutch. Refer to Hydraulic Circuits in this section.
SSE is supplied hydraulic pressure from the SREG circuit. When SSE is OFF, the solenoid supply is blocked
and the outlet port (SS1 circuit) is connected to the exhaust port. When SSE is ON, the exhaust port is
blocked and the solenoid supply is connected to the outlet port (SS1 circuit).
Shift Solenoid E (SSE) ON/OFF Solenoid
Turbine Shaft Speed (TSS) Sensor
The TSS sensor is a Hall-effect type sensor that provides a signal to the PCM that changes in frequency as
the rotating speed of the forward (1,2,3,4) clutch cylinder varies.
The PCM compares the TSS sensor signal with the engine speed information to determine the amount of
slip occurring in the torque converter.
The PCM also compares the TSS sensor signal with the OSS sensor signal to determine the gear ratio
provided by the rear planetary gearset.
The PCM uses the TSS sensor signal as an input for its strategies for shifts and TCC operation. The PCM
also uses the TSS sensor signal for transmission fault detection and diagnostics.
Refer to the component illustration at the beginning of this procedure for the location of the TSS sensor.
Output Shaft Speed (OSS) Sensor
The OSS sensor is a Hall-effect type sensor that provides a signal to the PCM that changes in frequency as
the rotating speed of the output shaft ring gear varies.
The PCM also compares the OSS sensor signal with the TSS sensor signal to determine the gear ratio
provided by the rear planetary gearset.
The PCM uses the OSS sensor signal as an input for its strategies for shifts and TCC operation. The PCM
also uses the OSS sensor signal for transmission fault detection and diagnostics.
Refer to the component illustration at the beginning of this procedure for the location of the OSS sensor.
Transmission Fluid Temperature (TFT) Sensor
The TFT sensor is a temperature dependent resistor that is in contact with transmission fluid in the
transmission sump area.
The PCM monitors the voltage across the TFT sensor, which changes as transmission fluid temperature
varies.
The PCM uses the TFT sensor signal as an input for its strategy for shifting and TCC operation. The PCM
also uses the TFT sensor signal for transmission fault detection and diagnostics.
Refer to the component illustration at the beginning of this procedure for the location of the TFT sensor.
Transmission Range (TR) Sensor
The TR sensor has a set of Hall-effect sensors that have a pattern of ON/OFF states which are dependant
on the PARK, REVERSE, NEUTRAL, DRIVE, 3, 2 or 1 position of the manual valve.
The TR sensor also provides signals for the starting system and the reverse lights.
The PCM uses the TR sensor signal as an input for its strategy for shifting and TCC operation. The PCM
also uses the TR sensor signal for transmission fault detection and diagnostics.
Refer to the component illustration at the beginning of this procedure for the location of the TR sensor.

Transmission Operation
Transmission Operation Overview
Transmission operation is controlled by the PCM.
Torque Converter
This transmission uses a torque converter with the following elements:
z Impeller
z Turbine
z Reactor
z Torque Converter Clutch (TCC)
For component information, refer to Torque Converter in this section.
Planetary Gearsets
Operation of this transmission involves the use of 2 planetary gearsets that have the following components:
z Front (single planetary gearset)

One sun gear
One planetary carrier with 4 gears
One ring gear
z Rear (ravigneaux planetary gearset)
Two sun gears of different sizes
Three short planetary gear pinions meshing with the sun gears
Three long planetary gear pinions meshing with the sun gears
One planetary carrier
One ring gear
Apply Clutches
This transmission uses the following clutches to operate the 2 planetary gearsets:
z Forward clutch (A)

z Direct clutch (B)
z Intermediate clutch (C)
z Low/reverse clutch (D)
z Overdrive clutch (E)
z Low One-Way Clutch (OWC)
For information about planetary gearsets or the apply clutches, refer to Mechanical Components and
Functions in this section.
Hydraulic System
The hydraulic operation of this transmission includes the following components:
z Main control assembly

z Pump assembly with filter
z Torque converter
z Apply components (clutches)
For component information, refer to Hydraulic System in this section.
Electronic Operation
The PCM controls the operation of this transmission with the following solenoids:
z Line Pressure Control (LPC) solenoid

z Shift Solenoid A (SSA)
z Shift Solenoid B (SSB)
z Shift Solenoid C (SSC)
z Shift Solenoid D (SSD)
z Shift Solenoid E (SSE)
z TCC solenoid
For solenoid information, refer to Transmission Electronic Control System in this section.
Park Position
Mechanical Operation
Apply components:
z Park pawl engaged holding the park gear (output shaft) stationary
z Low/reverse clutch (D) applied
Planetary Gearset Operation
Front planetary gearset driving components:
z Ring gear (input shaft)
Front planetary gearset driven components:
z Planetary carrier
Front planetary gearset held components:
z Sun gear (splined to pump assembly)
Rear planetary gearset driving components:
z None
Rear planetary gearset driven components:
z None
Rear planetary gearset held components:
z Planetary carrier
z Ring gear (output shaft)
Park Position Clutch Application Chart

Inter- Low/
Gear (1,2,3,4) (3,5,R) (2,6) (1,R) (4,5,6) Low-OWC
Park H
gear
z H = Hold Clutch
For component information, refer to Mechanical Components and Functions in this section.
Park Position Power Flow
Hydraulic Operation
Line pressure hydraulic circuits:
z The position of the main regulator valve controls line pressure. The position of the main regulator
valve is dependent on the pressure applied to it by the LPC solenoid through the VFS5 circuit.
z The main regulator valve varies pressure in the PUMP circuit by controlling hydraulic flow from the
SCHG circuit into the pump suction circuit.
z Line pressure is supplied to the:
manual valve.
lubrication control valve.
converter release regulator valve.
bypass clutch control regulator valve.
solenoid pressure regulator valve.
D1 latch and regulator valves.
Torque converter circuits:
z When the TCC is released, the converter release regulator valve applies pressure to the torque
converter through the CREL circuit to release the TCC .
z CREL pressure exits the torque converter through the CAPLY circuit to the bypass clutch control
regulator valve.
z The bypass clutch control regulator valve directs the pressure from the CAPLY circuit back to the
converter release regulator valve through the CAPLY EX circuit.
z The converter release regulator valve directs the pressure from the CAPLY EX circuit to the drain
back valve through the DBACK circuit.
Cooler and lubrication hydraulic circuits:
z The lubrication control valve directs line pressure to the transmission fluid cooler or the thermal
bypass valve through the COOLF circuit.
z When the transmission fluid exits the transmission fluid cooler or thermal bypass valve, it provides
lubrication to the transmission through the LUBE circuit. For information about transmission
lubrication, refer to Mechanical Components and Functions in this section.
Solenoid hydraulic circuits:
z The solenoid pressure regulator valve supplies regulated line pressure to the shift, LPC and TCC
solenoids through the SREG hydraulic circuit.
z The LPC solenoid applies varying pressure to the main regulator valve through the VFS5 hydraulic
circuit. The LPC solenoid regulates line pressure by controlling the position of the main regulator
valve.
z SSD supplies pressure to the solenoid multiplex valve through the VFS4 circuit.
z The position of the solenoid multiplex valve allows pressure from the VFS4 circuit to be directed to
the D1 and D2 latch and regulator valves through the CL DC circuit to position the valves for
low/reverse clutch (D) application.
Clutch hydraulic circuits:
z Line pressure is supplied by the pump to the D1 latch and regulator valves.
z Regulated line pressure from the D1 regulator valve is supplied to the low/reverse clutch (D) to apply
the clutch.
For hydraulic circuit information, refer to Hydraulic Circuits in this section.
Electrical Operation
Solenoid operation:
Park Position Solenoid Operation Chart

Shift Solenoid
PCM
Position Gear (1,2,3,4) (3,5,R) (CB 2,6) L/R 4,5,6) NC NL
P P Off On Off On On Off
CB = Clutch brake
NH = Normally high
NL = Normally low
Printable / zoomable view of this graphic
Reverse Position
Apply components:

z Direct clutch (B) applied
z Planetary carrier
z Sun gear No. 2
z Planetary carrier
Reverse Position Clutch Application Chart

Inter- Low/
Gear (1,2,3,4) (3,5,R) (2,6) (1,R) (4,5,6) Low-OWC
Reverse D H
gear
z D = Drive Clutch
z H = Hold Clutch
Reverse Position Power Flow
Hydraulic Operation
manual valve.
z In reverse, the manual valve directs line pressure to the No. 1 shuttle valve and the solenoid multiplex
valve through the REV circuit.
z The No. 1 shuttle ball directs line pressure to the clutch B regulator valve.
regulator valve.
solenoid through the SREG hydraulic circuit.
valve.
the D1 and D2 latch and regulator valves through the CLDC circuit to position the valves for
low/reverse clutch (D) application.
z SSB supplies pressure to the clutch B regulator and latch valves to position the valves for direct
clutch (B) application.
the clutch.
z Line pressure is supplied by the manual valve to the clutch B latch and regulator valves.
z Regulated line pressure from the clutch B regulator valve is supplied to the direct clutch (B) to apply
the clutch.
Solenoid operation:
Reverse Position Solenoid Operation Chart

Shift Solenoid
PCM
R R Off Off Off Off On Off
CB = Clutch brake
NH = Normally high
NL = Normally low
Neutral Position
Apply components:
z Planetary carrier
z None
z None
z Planetary carrier
Neutral Position Clutch Application Chart

Inter- Low/
Gear (1,2,3,4) (3,5,R) (2,6) (1,R) (4,5,6) Low-OWC
Neutral H
gear
z H = Hold Clutch
Neutral Position Power Flow
Hydraulic Operation
manual valve.
regulator valve.
z LPC solenoid applies varying pressure to the main regulator valve through the VFS5 hydraulic circuit.
LPC solenoid regulates line pressure by controlling the position of the main regulator valve.
the D1 latch and regulator valves through the CL DC circuit to position the valves for low/reverse
clutch (D) application.
the clutch.
Solenoid operation:
Neutral Position Solenoid Operation Chart

Shift Solenoid
PCM
N N Off On Off On a On a Off
a
Solenoid state changes if vehicle is moving forward with the selector lever in the NEUTRAL position.
CB = Clutch brake
NH = Normally high
NL = Normally low
1st Gear
Apply components:
z Low/reverse clutch (D) applied Below 5 kph (3 mph) only

z Low/One-Way Clutch (OWC)
z Forward clutch (A) applied
z Planetary carrier
z No. 3 sun gear
z Planetary carrier
1st Gear Clutch Application Chart

Inter- Low/
Gear (1,2,3,4) (3,5,R) (2,6) (1,R) (4,5,6) Low-OWC
1st Gear D D Ha H
1st Gear D H H
Manual
gear
a Clutch released when vehicle speed is above 3 mph.
z D = Drive Clutch
z H = Hold Clutch
z O/R = Overrunning
Power Flow
Hydraulic Operation
manual valve.
z In drive, the manual valve directs line pressure to the No. 1 shuttle valve and clutch A, C and E
regulator valves.
regulator valve.
valve.
z Below 5 kph (3 mph), SSD supplies pressure to the solenoid multiplex valve through the VFS4 circuit.
Above 5 kph (3 mph), amperage to SSD is increased to decrease pressure to the solenoid multiplex
valve and clutch D1 regulator valve to release the low/reverse clutch (D).
the D1 latch and regulator valves through the CLDC circuit to position the valves for low/reverse
clutch (D) application.
z SSA supplies pressure to the clutch A regulator and latch valves to position the valves for forward
clutch (A) application.
z Below 5 kph (3 mph), regulated line pressure from the D1 regulator valve is supplied to the
low/reverse clutch (D) to apply the clutch. Above 5 kph (3 mph) the D1 regulator valve exhausts to
release the low/reverse clutch and the Low/ OWC continues to hold the rear planetary carrier with no
engine braking.
z Regulated line pressure from the clutch A regulator valve is supplied to the forward clutch (A) to apply
the clutch.
Solenoid operation:
1st Gear Solenoid Operation Chart

Shift Solenoid
PCM
D 1 On On Off Off b On Off
CB = Clutch brake
NH = Normally high
NL = Normally low
2nd Gear
Apply components:

z Intermediate clutch (C) applied
z Planetary carrier
z No. 3 sun gear
z Planetary carrier
z No. 2 sun gear
2nd Gear Clutch Application Chart

Inter- Low/
Gear (1,2,3,4) (3,5,R) (2,6) (1,R) (4,5,6) Low-OWC
2nd Gear D D H O/R
and Manual 2
gear
z D = Drive Clutch
z H = Hold Clutch
z O/R = Overrunning
Power Flow
Hydraulic Operation
manual valve.
regulator valves.
regulator valve.
valve.
z SSC supplies pressure to the clutch C regulator valve to position the valve for intermediate clutch (C)
application.
the clutch.
z Regulated line pressure from the clutch C regulator valve is supplied to the intermediate clutch (C) to
apply the clutch.
Solenoid operation:
2nd Gear Solenoid Operation Chart

Shift Solenoid
PCM
D and 2 2 On On On On Off Off
CB = Clutch brake
NH = Normally high
NL = Normally low
3rd Gear
Apply components:

z Planetary carrier
z No. 3 sun gear

z No. 2 sun gear
z Planetary carrier
z None
3rd Gear Clutch Application Chart

Inter- Low/
Gear (1,2,3,4) (3,5,R) (2,6) (1,R) (4,5,6) Low-OWC
3rd Gear D and D D O/R
Manual 3
gear
z D = Drive Clutch
z O/R = Overrunning
Power Flow
Hydraulic Operation
manual valve.
regulator valves.
regulator valve.
valve.
z SSB supplies pressure to the clutch B regulator valve to position the valve for direct clutch (B)
application.
the clutch.
the clutch.
Solenoid operation:
3rd Gear Solenoid Operation Chart

Shift Solenoid
PCM
D and 3 3 On Off Off On Off Off
CB = Clutch brake
NH = Normally high
NL = Normally low
4th Gear
Apply components:

z Overdrive clutch (E) applied
z Planetary carrier
z No. 3 sun gear

z Planetary carrier
z None
4th Gear Clutch Application Chart

Inter- Low/
Gear (1,2,3,4) (3,5,R) (2,6) (1,R) (4,5,6) Low-OWC
4th Gear D D D O/R
gear
z D = Drive Clutch
z O/R = Overrunning
Power Flow
Hydraulic Operation
manual valve.
regulator valves.
regulator valve.
z The LPC applies varying pressure to the main regulator valve through the VFS5 hydraulic circuit. The
z SSE supplies pressure to the solenoid multiplex valve and the drive enable valve through the SS1
circuit to move the valves.
z The position of the solenoid multiplex valve and the drive enable valve allows pressure from the VFS4
circuit to be directed to the clutch E latch and regulator valves through the CLEC circuit to position the
valves for overdrive clutch (E) application.
the clutch.
z Regulated line pressure from the clutch E regulator valve is supplied to the overdrive clutch (E) to
apply the clutch.
Solenoid operation:
4th Gear Solenoid Operation Chart

Shift Solenoid
PCM
D 4 On On Off Off Off On/Off
CB = Clutch brake
NH = Normally high
NL = Normally low
5th Gear
Apply components:

z Planetary carrier
z No. 2 sun gear

z Planetary carrier
z None
5th Gear Clutch Application Chart

Inter- Low/
Gear (1,2,3,4) (3,5,R) (2,6) (1,R) (4,5,6) Low-OWC
5th Gear D D D O/R
gear
z D = Drive Clutch
z O/R = Overrunning
Power Flow
Hydraulic Operation
manual valve.
regulator valves.
regulator valve.
z The PCA applies varying pressure to the main regulator valve through the VFS5 hydraulic circuit.
z SSB supplies pressure to the clutch B regulator valve to position the valve for direct clutch (B)
application.
the clutch.
apply the clutch.
Solenoid operation:
5th Gear Solenoid Operation Chart

Shift Solenoid
PCM
D 5 Off Off Off Off Off On/Off
CB = Clutch brake
NH = Normally high
NL = Normally low
6th Gear Torque Converter Clutch (TCC) Applied
Apply components:

z Intermediate clutch (C) applied
z Planetary carrier (does not contribute to power flow)
z Planetary carrier
z No. 2 sun gear
6th Gear Torque Converter Clutch (TCC) Applied Clutch Application Chart
Inter- Low/
Gear (1,2,3,4) (3,5,R) (2,6) (1,R) (4,5,6) Low-OWC
6th Gear D H D O/R
gear
z D = Drive Clutch
z H = Hold Clutch
z O/R = Overrunning
Power Flow
Hydraulic Operation
manual valve.
regulator valves.
z When the TCC is applied, the bypass clutch control regulator valve applies pressure to the torque
converter through the CAPLY circuit to apply the TCC .
z CAPLY pressure exits the torque converter through the CREL circuit to the converter release
regulator valve.
solenoids through the SREG hydraulic circuit.
valve.
z The TCC solenoid supplies pressure to the converter release regulator valve and the bypass clutch
control regulator valve to move the position of the valves for TCC application.
z SSC supplies pressure to the clutch C regulator valve to position the valve for intermediate clutch (C)
application.
z Regulated line pressure from the clutch C regulator valve is supplied to the intermediate clutch (C) to
apply the clutch.
apply the clutch.
Solenoid operation:
6th Gear Torque Converter Clutch (TCC) Applied Solenoid Operation Chart
Shift Solenoid
PCM
6 Off On On Off Off On/Off
CB = Clutch brake
NH = Normally high
NL = Normally low
3rd Gear Fail Safe
Apply components:

z Planetary carrier
z No. 3 sun gear

z No. 2 sun gear
z Planetary carrier
z None
3rd Gear Fail Safe Clutch Application Chart

Inter- Low/
Gear (1,2,3,4) (3,5,R) (2,6) (1,R) (4,5,6) Low-OWC
3rd Gear D and D D O/R
Manual 3
gear
z D = Drive Clutch
z O/R = Overrunning
Power Flow
Hydraulic Operation
manual valve.
regulator valves.
regulator valve.
z The solenoid pressure regulator valve supplies line pressure to the shift, LPC and TCC solenoid
through the SREG hydraulic circuit.
z The LPC solenoid applies full solenoid output pressure to the main regulator valve through the VFS5
hydraulic circuit. With full solenoid output pressure, the main regulator valve provides maximum line
pressure during fail safe.
z SSB supplies maximum solenoid output pressure to the clutch B regulator valve to position the valve
for direct clutch (B) application.
z Regulated line pressure from the clutch B regulator valve is supplied to the direct clutch (B) to, apply
the clutch. Regulated line pressure from the clutch B regulator valve is also supplied to the clutch A
latch valve from the clutch B latch valve through the BREV 5F circuit.
z The clutch A latch valve directs the regulated line pressure to the drive enable valve through the
BREV5 circuit.
z The drive enable valve directs the BREV5 pressure to the BREVA circuit which supplies the clutch A
regulator valve to position the valve to apply the forward clutch (A) with 81% of line pressure.
Solenoid operation: In failsafe, voltage is removed from all solenoids and the solenoids default to their
normal position. If a solenoid is a normally low (NL) solenoid, the solenoid will not supply pressure to the
regulator valve, releasing the clutch that it controls. If a solenoid is a normally high (NH) solenoid, the
solenoid will provide high pressure to the regulator valve, applying the clutch that it controls.
3rd Gear Fail Safe Solenoid Operation Chart

SSA NL SSB NH SSC NL (CB SSD NH (CB L/R SSE LPC TCC
Gear (1,2,3,4) (3,5,R) 2,6) 4,5,6) NC NH NL
3rd — — — — — — —
Gear
CB = Clutch brake
NH = Normally high
NL = Normally low

Diagnosis By Symptom
The Diagnosis by Symptom gives the technician diagnostic information and direction, and suggests possible
components using a symptom as a starting point. All routines start out with any potential electrical
components that can cause or contribute to the symptom described. The routines then list all possible
hydraulic or mechanical components that can cause or contribute the symptom described.
Diagnosis by Symptom Chart Directions
1. Using the Diagnosis by Symptom, select the condition that best describes the condition.
2. Refer to the routine indicated in the Diagnosis by Symptom Index.
3. Always begin diagnosis of a symptom with:

1. preliminary inspections.
2. verifications of condition.
3. checking the fluid levels.
4. carrying out other test procedures as directed.
4. NOTE: Not all concerns and conditions with electrical components will set a DTC. Be aware that the
components listed may still be the cause. Verify correct function of these components prior to
proceeding to the Hydraulic/Mechanical Routine listed.
NOTE: When the battery is disconnected or a new battery is installed, certain transmission operating
parameters can be lost. The PCM must relearn these parameters. During this learning process, the
vehicle may exhibit slightly firm shifts, delayed or early shifts. This operation is considered normal and
will not affect the function of the transmission. Normal operation will return once these parameters are
stored by the PCM.
Begin Diagnosis by Symptoms with the Routines, if indicated. Follow the reference or action required
statements. Always perform the self-tests as required. Never skip steps. Repair as required. If the
concern is still present after electrical diagnosis, proceed to the Hydraulic/Mechanical Routine listed.
5. The list contains only possible hydraulic or mechanical components that may cause or contribute to
the concern. These components are listed in the removal sequence and by most probable cause. All
components listed must be inspected to make sure that repairs are complete.
Diagnosis by Symptom Index

Title Routines
Engagement Concerns
No Forward in D 201
No Reverse 202
Harsh Reverse 203
Harsh Forward 204
Delayed/Soft Reverse 205

Delayed/Soft Forward 206
No Forward and No Reverse 207
Harsh Forward and Harsh Reverse 208
Delayed Forward and Delayed Reverse 209
Shift Concerns
Some/All Shifts Missing 210
Timing — Early/Late 211
Timing — Erratic/Hunting 212
Feel Concerns
Soft/Slipping (some or all) 213
Harsh (some or all) 214
No 1st Gear, Engages in Higher Gear 215
No Manual 1st Gear 216
No Manual 2nd Gear 217
No Manual 3rd Gear 218
No 1-2 Shift (Automatic) 220
Torque Converter Operation Concerns
No Apply 240
Cycling/Chatter 241
Always Applied/Stalls Vehicle 242
Other Concerns
External Leaks 252
Noise/Vibration in Forward or Reverse 254
Engine Will Not Crank 255
No Park (P) Range 256
Transmission Overheating 257
Fluid Venting/Foaming 261
Diagnostic Routines
Engagement Concerns: No Forward in D

Possible Component Reference/Action
201 — ROUTINE
Transmission Fluid
z Incorrect level z CHECK the transmission fluid level. ADJUST transmission fluid to
correct level. REFER to Transmission Fluid Level Check in this
section.
z Fluid filter and seal z INSTALL a new filter assembly.
assembly — plugged,
damaged
Selector Lever Linkage
z Selector lever linkage z INSPECT and REPAIR as required. VERIFY transmission selector
— damage or lever cable adjustment. REFER to Section 307-05 . ADJUST
incorrectly adjusted transmission selector lever cable as necessary.
z PCM, external vehicle z If DTCs are set, CLEAR the DTCs. CARRY OUT the Key ON
harness, main control Engine OFF (KOEO) and Key ON Engine Running (KOER) self-test.
molded leadframe or ROAD TEST the vehicle and CHECK for DTCs. If the DTCs return,
Shift Solenoid A GO to Pinpoint Test A . INSPECT and CLEAN the SSA terminals on
(SSA). the molded leadframe for metallic contamination, REFER to Shift
Solenoids (SS) in this section.
Main Control
z Defective manual z INSPECT manual valve linkage.
valve
z Defective clutch (A) z INSPECT main control assembly for stuck valves or contamination.
regulator valve REFER to Main Control in this section.
z Front pump adapter z INSTALL a new front pump adapter seal.
seal — cracked,
leaking or damaged
Clutch Plates
z Forward clutch (A) z INSPECT the forward clutch assembly for damage. REPAIR as
friction and steel plate required. REFER to Forward Clutch Assembly in this section.
— failure
z Direct clutch (B) z INSPECT the direct clutch assembly for damage. REPAIR as
friction and steel plate required. REFER to Direct Clutch Assembly in this section.
— failure
z Low One-Way Clutch z INSPECT the OWC assembly for damage. The OWC must rotate
(OWC) assembly — counterclockwise and lock clockwise. REPLACE the OWC . REFER
failure to Transmission — Early Build or Transmission — Late Build in this
section.
Pump
z Pump gear — failure z INSTALL a new pump assembly. REFER to Pump Assembly in this
section.
Engagement Concerns: No Reverse

202 — ROUTINE
Transmission Fluid
section.
z PCM, external z If DTCs are set, CLEAR the DTCs. CARRY OUT the Key ON Engine
vehicle harness, OFF (KOEO) and Key ON Engine Running (KOER) self-test. ROAD
main control TEST the vehicle and CHECK for DTCs. If the DTCs return, GO to
leadframe or Shift Pinpoint Test A . INSPECT and CLEAN the shift solenoid terminals
Solenoid B (SSB). on the molded leadframe for metallic contamination, REFER to Shift
Main Control
z Defective clutch (B) z INSPECT main control assembly for stuck valves or contamination.
Clutch Plates
friction and steel required. REFER to Direct Clutch Assembly in this section.
plate — failure
Pump
z Pump gear — failure z INSTALL a new pump assembly. REFER to Pump Assembly in this
section.
Engagement Concerns: Harsh Reverse

203 — ROUTINE
Transmission Fluid
section.
Driveline
z Engine driveline z REPAIR as required.
looseness in the
driveshaft, U-joints
or the engine mounts
Main Control
Clutch Plates
plate — failure
Engagement Concerns: Harsh Forward

204 — ROUTINE
Transmission Fluid
section.
Driveline
z Engine driveline z REPAIR as required.
looseness in the
driveshaft, U-joints
or the engine mounts
Solenoid A (SSA). on the molded leadframe for metallic contamination, REFER to Shift
Main Control
latch valve REFER to Main Control in this section.
Engagement Concerns: Delayed/Soft Reverse

205 — ROUTINE
Transmission Fluid
section.
assembly —
plugged, damaged
Main Control
seal — cracked,
leaking or damaged
Clutch Plates
plate — failure
Engagement Concerns: Delayed/Soft Forward

206 — ROUTINE
Transmission Fluid
section.
damaged
harness, main control Engine OFF (KOEO) and Key ON Engine Running (KOER) self-
leadframe or a test. ROAD TEST the vehicle and CHECK for DTCs. If the DTCs
defective Shift return, GO to Pinpoint Test A . INSPECT and CLEAN the shift
Solenoid A (SSA). solenoid terminals on the mechatronic leadframe for metallic
contamination, REFER to Shift Solenoids (SS) in this section.
Main Control
seal — cracked,
leaking or damaged
Clutch Plates
— failure
Engagement Concerns: No Forward and No Reverse

207 — ROUTINE
Transmission Fluid
section.
(Internal/External)
z Damaged, out of z INSPECT for damage, repair as required.
aadjustment
Transmission Filter and Seal
Assembly
z Not seated, damaged z INSPECT for position, damage and restriction. INSTALL a new
or plugged filter and seal assembly. .
z Pump adapter Seal z INSPECT for crack or damage. INSTALL new as required.
Main Controls
z Manual Valve z INSPECT for damage. Replace as required.
z Mounting bolt torque z INSPECT for loose main control to transmission bolts. Tighten to
specification.
z Solenoid Pressure
Regulator Valve z INSPECT for valve stuck in spring compressed position or broken
spring. CLEAN or REPLACE main control as required. Main
Control
Pump Assembly
z Gear z INSPECT for damage. REPLACE as required.
z Sun gear hub/splines z INSPECT for damage. REPLACE as required.

Other Possible Components
z Turbine shaft z INSPECT for damage. REPAIR as required.
z Front planetary gear z INSPECT for damage. REPAIR as required.

set
z INSPECT for damage. REPAIR as required.
z Forward clutch drum
z INSPECT for damage. REPAIR as required.
z Output shaft/ring gear
Engagement Concerns: Harsh Forward and Harsh Reverse

208 — ROUTINE
Transmission Fluid
z Incorrect level z CHECK the transmission fluid level. ADJUST
transmission fluid to correct level. REFER to
Transmission Fluid Level Check in this section.
z Fluid filter and seal assembly — z INSTALL a new filter assembly.

plugged, damaged
z PCM electrical inputs/outputs, z If DTCs are set, CLEAR the DTCs. CARRY OUT the
external vehicle wiring harnesses, Key ON Engine OFF (KOEO) and Key ON Engine
main control molded leadframe, Running (KOER) self-test. ROAD TEST the vehicle
Transmission Range (TR) sensor, and CHECK for DTCs. If the DTCs return, GO to
Shift Solenoid A (SSA) or Line Pinpoint Test A . If engine control DTCs return,
Pressure Control (LPC) REFER to Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
z Multiple shift missing (more than z If some shifts are missing, DETERMINE which shifts
one gear) do not occur. REFER to Clutch and Solenoid
Application Charts in this section. MONITOR
appropriate PIDs as listed in Diagnostic Parameters
Identification (PID) Chart. REFER to Routine 210.
z Gears 4-6 default to 5th gear and z RETRIEVE DTCs.
gears 1-3 default to 3rd gear
Engagement Concerns: Delayed Forward and Delayed Reverse

209 — ROUTINE
Transmission Fluid
section.
z Transmission fluid z INSTALL a new transmission fluid filter assembly.
filter and seal
damaged
wiring harnesses or Engine OFF (KOEO) and Key ON Engine Running (KOER) self-
molded leadframe test. ROAD TEST the vehicle and CHECK for DTCs. INSPECT and
CLEAN the shift solenoid terminals on the molded leadframe for
metallic contamination, REFER to Shift Solenoids (SS) in this
section.
Main Control
seal — cracked,
leaking or damaged
Shift Concerns: Some/All Shifts Missing

210 — ROUTINE
Transmission Fluid

z Transmission fluid filter and seal z INSTALL a new transmission fluid filter assembly.
assembly — plugged, damaged REFER to Fluid Pan, Gasket and Filter in this section.
Selector Lever Linkage Damaged or
Incorrectly Adjusted
z Selector lever cable z INSPECT and REPAIR as required. VERIFY selector
lever cable adjustment. REFER to Section 307-05 .
ADJUST selector lever cable as necessary.
z PCM electrical inputs/outputs, z If DTCs are set, CLEAR the DTCs. CARRY OUT the Key
external vehicle wiring ON Engine OFF (KOEO) and Key ON Engine Running
harnesses, main control molded (KOER) self-test. ROAD TEST the vehicle and CHECK
leadframe, Transmission Range for DTCs. If the DTCs return, GO to Pinpoint Test A . If
(TR) sensor, Shift Solenoid A engine control DTCs return, REFER to Powertrain
(SSA) or Line Pressure Control Control/Emissions Diagnosis (PC/ED) manual.
(LPC)
z Multiple shift missing (more than z If some shifts are missing, DETERMINE which shifts do
one gear) not occur. REFER to clutch and solenoid application
charts in this section. MONITOR appropriate PIDs as
listed in Diagnostic Parameters Identification (PID)
Chart.
Main Control
z Leadframe — contamination z REMOVE the main control assembly, REFER to Main
Control in this section. INSPECT and CLEAN the shift
solenoid terminals on the main control molded leadframe
for metallic contamination, REFER to Shift Solenoids
(SS) in this section. CLEAR the DTCs. ROAD TEST the
vehicle. If the symptom returns, GO to Pinpoint Test A .
z Defective clutch (A) regulator z INSPECT main control assembly for stuck valves or
valve contamination. REFER to Main Control in this section.
z Defective clutch (A) latch valve z INSPECT main control assembly for stuck valves or
contamination. REFER to Main Control in this section.
z Defective clutch (B) regulator z INSPECT main control assembly for stuck valves or
z Defective clutch (B) latch valve z INSPECT main control assembly for stuck valves or
z Defective clutch (C) regulator z INSPECT main control assembly for stuck valves or
z Defective clutch (E) regulator z INSPECT main control assembly for stuck valves or
z Defective clutch (E) latch valve z INSPECT main control assembly for stuck valves or
Clutch Plates
z Forward clutch (A) friction and z For 1st, 2nd, 3rd or 4th gear concerns, INSPECT the
steel plate — failure or Low One- forward clutch assembly for damage. REPAIR as
Way Clutch (OWC) assembly — required. REFER to Forward Clutch Assembly in this
failure section. For the One-Way Clutch (OWC), INSPECT for
damage. One-Way Clutch (OWC) must rotate
counterclockwise and lock clockwise. REFER to
Transmission — Early Build or Transmission — Late

Build in this section.
z Direct clutch (B) friction and steel z For 3rd or 5th gear concerns, INSPECT the direct clutch
plate — failure assembly for damage. REPAIR as required. REFER to
Direct Clutch Assembly in this section.
z Intermediate clutch (C) friction z For 2nd or 6th gear concerns, INSPECT the intermediate
and steel plate — failure clutch assembly for damage. REPAIR as required.
REFER to Intermediate Clutch Assembly in this section.
z Overdrive clutch (E) assembly — z For 4th, 5th or 6th gear concerns, INSPECT the
failure overdrive clutch for damage. REPLACE the overdrive
clutch. REFER to Overdrive Clutch Assembly in this
section.
Shift Concerns: Timing — Early/Late

211 — ROUTINE
z PCM electrical z If DTCs are set, CLEAR the DTCs. CARRY OUT the Key ON
inputs/outputs, external Engine OFF (KOEO) and Key ON Engine Running (KOER)
vehicle wiring harnesses self-test. ROAD TEST the vehicle and CHECK for DTCs. If
or main control molded engine control DTCs return, REFER to Powertrain
leadframe Control/Emissions Diagnosis (PC/ED) manual. INSPECT and
CLEAN the shift solenoid terminals on the main control molded
leadframe for metallic contamination, REFER to Shift Solenoids
(SS) in this section.
z Engine driveability z REFER to Section 303-00 .
concerns
Main Control
z Bolts not tightened to z TIGHTEN to specification.
specification
z Main control unit z REFER to Main Control in this section.
contaminated, solenoid(s)
damaged, stuck or bore
damaged. Manual valve
damaged
Incorrect Pressures
z Application pressures are z Incorrect application pressures may be due to non-
incorrect transmission components, main control assembly or internal
transmission damage. REPAIR all non-transmission
components then continue with this routine.
Other
z Tire size change, axle z VERIFY the vehicle has the original equipment. REFER to the
ratio change certification label. Changes in tire size and axle ratio will affect
shift timing.
Shift Concerns: Timing — Erratic/Hunting

212 — ROUTINE
Transmission Fluid
z Incorrect level z CHECK the transmission fluid level. ADJUST transmission
fluid to correct level. REFER to Transmission Fluid Level
Check in this section.
z Condition z CARRY OUT the fluid level check in Transmission Fluid Level
z Transmission fluid over z REFER to Routine 257 Transmission Overheating.
temperature condition
vehicle wiring harnesses or self-test. ROAD TEST the vehicle and CHECK for DTCs. If
main control leadframe engine control DTCs return, REFER to Powertrain
Control/Emissions Diagnosis (PC/ED) manual.
Torque Converter Concerns
z Torque converter z REFER to torque converter operation concern:
Cycling/Chatter.
Feel Concerns: Soft/Slipping (Some or All)

213 — ROUTINE
Transmission Fluid
z Transmission fluid filter and seal z INSTALL a new transmission fluid filter assembly.
assembly — plugged, damaged REFER to Fluid Pan, Gasket and Filter in this section.
z PCM electrical inputs/outputs, z If DTCs are set, CLEAR the DTCs. CARRY OUT the Key
external vehicle wiring ON Engine OFF (KOEO) and Key ON Engine Running
harnesses, main control molded (KOER) self-test. ROAD TEST the vehicle and CHECK
leadframe or Transmission Fluid for DTCs. If the DTCs return, GO to Pinpoint Test B .
Temperature (TFT) sensor.
Main Control
z Main control molded leadframe z REMOVE the main control assembly, REFER to Main
Control in this section. INSPECT and CLEAN the shift
solenoid terminals on the main control molded leadframe
for metallic contamination, REFER to Shift Solenoids
(SS) in this section. CLEAR the DTCs. ROAD TEST the
z Front pump adapter seal — z INSTALL a new front pump adapter seal.
cracked, leaking or damaged
z Bolts not tightened to z TIGHTEN to specification.
specification
z Main control contaminated, z INSPECT for damage. If damaged, INSTALL a new main
solenoid(s) damaged, stuck or control assembly. REFER to Main Control in this section.
bore damaged. Manual valve
damaged, stick or bore
damaged
Feel Concerns: Harsh (Some or All)

214 — ROUTINE
Transmission Fluid
z Transmission fluid filter and z INSTALL a new transmission fluid filter assembly. REFER to
seal assembly — plugged, Fluid Pan, Gasket and Filter in this section.
damaged
vehicle wiring harnesses, self-test. ROAD TEST the vehicle and CHECK for DTCs. If
main control molded solenoid body and PCM information does not match,
leadframe or solenoid body REPROGRAM the PCM with the latest calibration.
information does not match PERFORM the Solenoid Body Strategy Data Download.
PCM information REFER to Solenoid Body Strategy in this section. PERFORM
Road Test — Adaptive Drive Cycle, REFER to Shift Point
Road Test in this section. ROAD TEST and CHECK for
DTCs.
Main Control
z Bolts not tightened to z TIGHTEN bolts to specification.
specification
z Main control contaminated, z INSPECT for damage. If damaged, INSTALL a new main
solenoid(s) damaged, control assembly. REFER to Main Control in this section.
solenoids stuck or bore
damaged
z Manual valve damaged, z INSPECT for damage. If damaged, INSTALL a new main
stuck or bore damaged control assembly. REFER to Main Control in this section.
Feel Concerns: No 1st Gear, Engages in a Higher Gear

215 — ROUTINE
wiring harnesses or main Engine OFF (KOEO) and Key ON Engine Running (KOER)
control molded leadframe self-test. ROAD TEST the vehicle and CHECK for DTCs.
Clutch Plates
z Low One-Way Clutch z INSPECT the OWC assembly for damage. The OWC must
(OWC) assembly — failure rotate counterclockwise and lock clockwise. REPLACE the
OWC . REFER to Transmission — Early Build or
Transmission — Late Build in this section.
Incorrect Gear
z Transmission failure z DETERMINE which gear the transmission is in. REFER to the
Clutch and Solenoid Application Charts in this section.
Feel Concerns: No Manual 1st Gear

216 — ROUTINE
Transmission Fluid
section.
z Transmission fluid filter z INSTALL a new transmission fluid filter assembly. REFER to
and seal assembly — Fluid Pan, Gasket and Filter in this section.
plugged, damaged
z Selector lever cable z INSPECT and REPAIR as necessary. VERIFY selector lever
system — damaged, cable adjustment. REFER to Section 307-05 .
misaligned
harness, main control Engine OFF (KOEO) and Key ON Engine Running (KOER) self-
molded leadframe or test. ROAD TEST the vehicle and Manual for DTCs. If the DTCs
Shift Solenoid A (SSA). return, GO to Pinpoint Test A .
Main Control
z Molded leadframe — z REMOVE the main control assembly, REFER to Main Control in
contamination this section. INSPECT and CLEAN the shift solenoid terminals on
the main control molded leadframe for metallic contamination.,
REFER to Shift Solenoids (SS) in this section. INSTALL the main
control assembly. CLEAR the DTCs. ROAD TEST the vehicle. If
the symptom returns, GO to Pinpoint Test A .
Clutch Plates
— failure
z Low/reverse clutch (D) z INSPECT the low/reverse clutch assembly for damage. REPAIR
friction and steel plate as required. REFER to Low/Reverse Clutch Assembly in this
— failure section.
z Low One-Way Clutch z If no 1st gear above 3 mph, INSPECT the OWC assembly for
(OWC) assembly — damage. The OWC must rotate counterclockwise and lock
failure clockwise. REPLACE the OWC . REFER to Transmission —
Early Build or Transmission — Late Build in this section.
Pump
z Pump gear — failure z INSTALL a new pump assembly. REFER to Pump Assembly in
this section.
Feel Concerns: No Manual 2nd Gear

217 — ROUTINE
Transmission Fluid
z Incorrect level z CHECK the transmission fluid level. ADJUST transmission fluid
to correct level. REFER to Transmission Fluid Level Check in
this section.
z Transmission fluid filter z INSTALL a new transmission fluid filter assembly.
and seal assembly —
plugged, damaged
misaligned
wiring harnesses, main Engine OFF (KOEO) and Key ON Engine Running (KOER) self-
control molded leadframe test. ROAD TEST the vehicle and CHECK for DTCs. If the
or Shift Solenoid A (SSA) DTCs return, GO to Pinpoint Test A .
Main Control
contamination this section. INSPECT and CLEAN the shift solenoid terminals
on the main control molded leadframe for metallic
INSTALL the main control assembly. CLEAR the DTCs. ROAD
TEST the vehicle. If the symptom returns, GO to Pinpoint Test
A.
Clutch Plates
z Forward clutch (A) friction z INSPECT the forward clutch assembly for damage. REPAIR as
and steel plate — failure required. REFER to Forward Clutch Assembly in this section.
z Intermediate clutch (C) z INSPECT the intermediate clutch assembly for damage.
friction and steel plate — REPAIR as required. REFER to Intermediate Clutch Assembly
failure in this section.
Pump
this section.
Feel Concerns: No Manual 3rd Gear

218 — ROUTINE

misaligned
control molded leadframe test. ROAD TEST the vehicle and CHECK for DTCs. If the
or Shift Solenoid B (SSB). DTCs return, GO to Pinpoint Test A .
Main Control
on the main control leadframe for metallic contamination,
REFER to Shift Solenoids (SS) in this section. INSTALL the
main control assembly. CLEAR the DTCs. ROAD TEST the
Clutch Plates
z Forward clutch (A) friction z INSPECT the forward clutch assembly for damage. REPAIR as
and steel plate — failure required. REFER to Forward Clutch Assembly in this section.
z Direct clutch (B) friction z INSPECT the direct clutch assembly for damage. REPAIR as
and steel plate — failure required. REFER to Direct Clutch Assembly in this section.
Pump
this section.
Feel Concerns: No 1-2 Shift

220 — ROUTINE
Transmission Fluid
damaged
wiring harnesses, main Engine OFF (KOEO) and Key ON Engine Running (KOER)
control molded leadframe, self-test. ROAD TEST the vehicle and CHECK for DTCs. If
Shift Solenoid C (SSC) or the DTCs return, GO to Pinpoint Test A .
Shift Solenoid D (SSD).
Main Control
z Molded leadframe — z REMOVE the main control assembly, REFER to Main Control
contamination in this section. INSPECT and CLEAN the shift solenoid
terminals on the main control molded leadframe for metallic
INSTALL the main control assembly. CLEAR the DTCs.
ROAD TEST the vehicle. If the symptom returns, GO to

Pinpoint Test A .
z Defective clutch (B) z INSPECT main control assembly for stuck valves or
regulator valve contamination. REFER to Main Control in this section.
z Defective clutch (B) latch z INSPECT main control assembly for stuck valves or
z Defective clutch (C) z INSPECT main control assembly for stuck valves or
Clutch Plates
friction and steel plate — REPAIR as required. REFER to Intermediate Clutch
failure Assembly in this section.
z Low/reverse clutch (D) z INSPECT the low/reverse clutch assembly for damage.
friction and steel plate — REPAIR as required. REFER to Low/Reverse Clutch
(OWC) assembly — failure rotate counterclockwise and lock clockwise. REPLACE the
OWC . REFER to Transmission — Early Build or
Transmission — Late Build in this section.

221 — ROUTINE
Transmission Fluid
damaged
z PCM, external vehicle wiring z If DTCs are set, CLEAR the DTCs. CARRY OUT the Key ON
harnesses, main control Engine OFF (KOEO) and Key ON Engine Running (KOER)
molded leadframe, Shift self-test. ROAD TEST the vehicle and CHECK for DTCs. If
Solenoid B (SSB) or Shift the DTCs return, GO to Pinpoint Test A .
Solenoid C (SSC).
Main Control
z Molded leadframe — z REMOVE the main control assembly, REFER to Main
contamination Control in this section. INSPECT and CLEAN the shift
solenoid terminals on the main control leadframe for metallic
Pinpoint Test A .

Clutch Plates
z Direct clutch (B) friction and z INSPECT the direct clutch assembly for damage. REPAIR as
steel plate — failure required. REFER to Direct Clutch Assembly in this section.

222 — ROUTINE
z PCM, external vehicle wiring z If DTCs are set, CLEAR the DTCs. CARRY OUT the Key
harnesses, main control ON Engine OFF (KOEO) and Key ON Engine Running
molded leadframe, Shift (KOER) self-test. ROAD TEST the vehicle and CHECK for
Solenoid B (SSB), Shift DTCs. If the DTCs return, GO to Pinpoint Test A .
Solenoid D (SSD) or Shift
Solenoid E (SSE).
Main Control
solenoid terminals on the main control leadframe for
metallic contamination, REFER to Shift Solenoids (SS) in
this section. INSTALL the main control assembly. CLEAR
the DTCs. ROAD TEST the vehicle. If the symptom
returns, GO to Pinpoint Test A .
z Defective clutch (B) latch valve z INSPECT main control assembly for stuck valves or
z Defective clutch (E) regulator z INSPECT main control assembly for stuck valves or
z Defective solenoid multiplex z INSPECT main control assembly for stuck valves or
Clutch Plates
z Direct clutch (B) friction and z INSPECT the direct clutch assembly for damage. REPAIR
steel plate — failure as required. REFER to Direct Clutch Assembly in this
section.
z Overdrive clutch (E) friction z INSPECT the overdrive clutch assembly for damage.
and steel plate — failure REPAIR as required. REFER to Overdrive Clutch
Assembly in this section.

223 — ROUTINE
Solenoid D (SSD).
Main Control
Pinpoint Test A .
z Defective clutch (E) z INSPECT main control assembly for stuck valves or
z Defective clutch (E) latch z INSPECT main control assembly for stuck valves or
z Solenoid multiplex valve z INSPECT main control assembly for stuck valves or
z Drive enable valve z INSPECT main control assembly for stuck valves or
Clutch Plates
z Overdrive clutch (E) friction z INSPECT the overdrive clutch assembly for damage.
and steel plate — failure REPAIR as required. REFER to Overdrive Clutch Assembly
in this section.

224 — ROUTINE
Solenoid C (SSC).
Main Control

Pinpoint Test A .
Clutch Plates

225 — ROUTINE
control molded leadframe test. ROAD TEST the vehicle and CHECK for DTCs. If the DTCs
or Shift Solenoid C return, GO to Pinpoint Test A .
(SSC).
Main Control
on the main control molded leadframe for metallic
INSTALL the main control assembly. CLEAR the DTCs. ROAD
TEST the vehicle. If the symptom returns, GO to Pinpoint Test
A.
Clutch Plates
z Direct clutch (C) friction z INSPECT the direct clutch assembly for damage. REPAIR as
z Low/reverse clutch (D) z INSPECT the low/reverse clutch assembly for damage. REPAIR
friction and steel plate — as required. REFER to Low/Reverse Clutch Assembly in this
failure section.
(OWC) assembly — rotate counterclockwise and lock clockwise. REPLACE the
failure OWC . REFER to Transmission — Early Build or Transmission
— Late Build in this section.
Torque Converter Operation Concerns: No Apply

240 — ROUTINE
Transmission Fluid
z Fluid condition z CHECK transmission fluid condition. REFER to Preliminary
z PCM, external vehicle wiring z If DTCs are set, CLEAR the DTCs. CARRY OUT the Key
harnesses, main control ON Engine OFF (KOEO) and Key ON Engine Running
molded leadframe or Torque (KOER) self-test. ROAD TEST the vehicle and CHECK for
Converter Clutch (TCC) DTCs. If the DTCs return, GO to Pinpoint Test A .
solenoid.
Main Control
contamination Control in this section. INSPECT and CLEAN the TCC
solenoid terminals on the main control molded leadframe for
the DTCs. ROAD TEST the vehicle. If the symptom returns,
GO to Pinpoint Test A .
z Main control assembly z INSPECT for damage. If damaged, install a new main
contaminated, solenoid(s) control assembly. REFER to Main Control in this section.
damaged
z Defective torque converter z INSPECT main control assembly for stuck valves or
apply regulator valve contamination. REFER to Main Control in this section.
release regulator valve contamination. REFER to Main Control in this section.
z Main control assembly bolts z TIGHTEN to specification.
— not tightened to
specification
Torque Converter
z Torque converter z REMOVE the transmission. INSPECT for damage. INSTALL
components a new or remanufactured torque converter. REFER to
Transmission — Four Wheel Drive (4WD) or Transmission
— Rear Wheel Drive (RWD) in this section.
Torque Converter Operation Concerns: Cycling/Chatter

241 — ROUTINE
Transmission Fluid
z PCM, vehicle wiring z If DTCs are set, CLEAR the DTCs. CARRY OUT the Key ON
molded leadframe, Torque self-test. ROAD TEST the vehicle and CHECK for DTCs. If the
Converter Clutch (TCC) DTCs return, GO to Pinpoint Test A for TCC solenoid
solenoid or Transmission diagnosis and GO to Pinpoint Test B for TFT sensor
Fluid Temperature (TFT) diagnosis.
sensor
Main Control
contamination in this section. INSPECT and CLEAN the TCC solenoid
Pinpoint Test A to diagnosis the Torque Converter Clutch
(TCC) or GO to Pinpoint Test B to diagnosis the Transmission
Fluid Temperature (TFT) sensor.
z Main control assembly z INSPECT for damage. If damaged, install a new main control
contaminated, solenoid(s) assembly. REFER to Main Control in this section.
damaged
apply regulator valve contamination. REFER to Main Control in this section.
z Main control assembly z TIGHTEN to specification.
bolts — not tightened to
specification
Torque Converter
z Torque converter z REMOVE the transmission. INSPECT for damage. INSTALL a
components new or remanufactured torque converter. REFER to
Transmission — Four Wheel Drive (4WD) or Transmission —
Rear Wheel Drive (RWD) in this section.
Torque Converter Operation Concerns: Always Applied/Stalls Vehicle

242 — ROUTINE
Transmission Fluid

molded leadframe, Torque self-test. ROAD TEST the vehicle and CHECK for DTCs. If the
Converter Clutch (TCC) DTCs return, GO to Pinpoint Test A for TCC solenoid
solenoid or Transmission diagnosis and GO to Pinpoint Test B for TFT sensor
Fluid Temperature (TFT) diagnosis.
sensor
Main Control
contamination in this section. INSPECT and CLEAN the TCC solenoid
Pinpoint Test A to diagnosis the Torque Converter Clutch
(TCC) or GO to Pinpoint Test B to diagnosis the Transmission
Fluid Temperature (TFT) sensor.
z Main control assembly z INSPECT for damage. If damaged, install a new main control
contaminated, solenoid(s) assembly. REFER to Main Control in this section.
damaged
z Main control assembly z TIGHTEN to specification.
bolts — not tightened to
specification
Torque Converter
z Torque converter z REMOVE the transmission. INSPECT for damage. INSTALL a
components new or remanufactured torque converter. REFER to
Transmission — Four Wheel Drive (4WD) or Transmission —
Rear Wheel Drive (RWD) in this section.
Other Concerns: External Leaks

252 — ROUTINE
Transmission Fluid
section.
z Transmission case z REPAIR as necessary.
vent — damaged,
case porosity
z Leakage at gaskets, z REFER to Leakage Inspection , Fluid Leakage in Torque Converter
seals, electrical Area and Leak Check Test with A Black Light in this section.
connector REMOVE all traces of lubricant on exposed surface of the
transmission. REPAIR as necessary.
Fluid Cooler Tubes

z Cooler tube fittings z LOCATE leak source. REPAIR as required. REFER to Section
307-02 .
z Cooler tube O-rings, z LOCATE leak source. REPAIR as required. REFER to Section
cooler tubes 307-02 .
Torque Converter
z Torque converter z INSTALL a new torque converter. If a new or remanufactured
studs torque converter is installed, use the scan tool and follow the on-
screen instructions and perform the Misfire Monitor Neutral Profile
Correction procedure.
z Torque converter hub z INSTALL a new torque converter hub seal.
seal
z Torque converter weld z INSTALL a new torque converter. If a new or remanufactured
torque converter is installed, use the scan tool and follow the on-
screen instructions and perform the Misfire Monitor Neutral Profile
Correction procedure.
Transmission Case
z Case — leaking z INSTALL a new transmission case. REFER to Transmission —
Early Build or Transmission — Late Build in this section.
z Transmission vehicle z INSTALL a new transmission vehicle harness connector O-ring.
harness connector
z Transmission fluid fill z INSTALL a new transmission fluid fill plug.
plug
z Output shaft seal z INSTALL a new seal. REFER to Output Shaft Seal in this section.
z Manual control lever z INSTALL a new seal.
seal
z Transmission fluid pan z INSTALL a new gasket.
gasket
Fluid Pump
z Fluid pump O-ring z INSTALL a new O-ring. REFER to Pump Assembly in this section.
z Fluid pump seal ring z INSTALL a new seal ring. REFER to Pump Assembly in this
section.
Other Concerns: Noise/Vibration in Forward or Reverse
NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For a list of these
tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 . Since it is
possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process
of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system
for the symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.

254 — ROUTINE
Transmission Fluid
z Incorrect level (low) pump z CHECK the transmission fluid level. ADJUST transmission
cavitation fluid to correct level. REFER to Transmission Fluid Level

Fluid Cooler Tubes
z Cooler tubes grounding out z ADJUST or REPOSITION cooler tubes.
Torque Converter
z Check the torque converter z LOCATE source of disturbance. REPAIR as required. If a
components/balance weight new or remanufactured torque converter is installed, use the
scan tool and follow the on-screen instructions and perform
the Misfire Monitor Neutral Profile Correction procedure.
Engine Driveline
z Engine drive accessories z REFER to Section 303-00 .
Other Concerns: Engine Will Not Crank

255 — ROUTINE
Selector Lever Cable System
z Selector lever cable system — z INSPECT and REPAIR as necessary. REFER to
damaged, misaligned Section 307-05 .
z PCM, vehicle wiring harnesses, z If DTCs are set, CLEAR the DTCs. CARRY OUT the
engine starting and charging system, Key ON Engine OFF (KOEO) and Key ON Engine
main control molded leadframe or Running (KOER) self-test. ROAD TEST the vehicle
Transmission Range (TR) sensor and CHECK for DTCs. If the DTCs return, GO to
Pinpoint Test C .
Torque Converter
z Flexplate — damaged z REPAIR as necessary.
Vehicle Starter
z Starter system concerns z INSPECT and REPAIR as necessary. REFER to
Section 303-06 .
Transmission Range (TR) Sensor
Assembly
z TR sensor assembly — damaged z INSPECT and REPAIR as necessary.
Fluid Pump Assembly
z Internal parts seized z REPAIR as necessary.
Other Concerns: No Park (P) Range

256 — ROUTINE
Selector Lever Cable
z Selector lever cable system — damaged, z INSPECT and REPAIR as necessary.
misaligned REFER to Section 307-05 for additional
information.
z Manual control lever assembly damaged, z INSPECT for damage. REPAIR as

manual valve inner lever pin bent, manual necessary.
valve inner lever damaged, spring rod
damaged, park pawl pin loose or damaged,
park rod actuating plate loose, damaged or
missing
z Transmission case z INSPECT for damage. If damaged,
REPAIR as necessary.
z Park gear, park pawl, park pawl return spring, z INSPECT for damage. If damaged,
part or guide, park actuating rod, park pawl REPAIR as necessary.
shaft, manual lever
z External linkages/brackets — damaged z INSPECT for damage. REPAIR as
necessary.
z PCM, vehicle wiring harnesses, main control z If DTCs are set, CLEAR the DTCs.
molded leadframe or Transmission Range (TR) CARRY OUT the Key ON Engine OFF
sensor (KOEO) and Key ON Engine Running
(KOER) self-test. ROAD TEST the vehicle
and CHECK for DTCs. If the DTCs return,
GO to Pinpoint Test C .
Transmission Range (TR) Sensor Assembly
Damaged
z Manual lever detent spring INSPECT for damage. REPAIR as necessary.
z TR sensor assembly z INSTALL a new main control assembly.
REFER to Main Control in this section.
Other Concerns: Transmission Overheating

257 — ROUTINE
Transmission Fluid
z Incorrect level z CHECK transmission fluid level. ADJUST transmission
z Fluid condition z CHECK transmission fluid condition. REFER to
Preliminary Inspection in this section.
z PCM, vehicle wiring harnesses, z If DTCs are set, CLEAR the DTCs. CARRY OUT the
main control molded leadframe, Key ON Engine OFF (KOEO) and Key ON Engine
Torque Converter Clutch (TCC) Running (KOER) self-test. ROAD TEST the vehicle and
solenoid or Transmission Fluid CHECK for DTCs. If the DTCs return, GO to Pinpoint
Temperature (TFT) sensor Test A for TCC solenoid diagnosis and GO to Pinpoint
Test B for TFT sensor diagnosis.
Torque Converter Not Engaging
z Torque converter z INSTALL a new torque converter. If a new or
remanufactured torque converter is installed, use the
scan tool and follow the on-screen instructions and
perform the Misfire Monitor Neutral Profile Correction
procedure.
Case Vent Damaged

z Transmission case z INSPECT for damage. If damaged, REPAIR as
necessary.
Other
z Restriction in transmission z CHECK transmission cooling system efficiency. REFER
cooling system to Section 307-02 for automatic transmission cooling
system diagnostic procedures.
z Excessive trailer tow load z REFER to the Owner's Literature for specifications on
trailer towing.
z Vehicle heat shield — missing or z INSPECT for damage. REPAIR as necessary.
damaged
z Vehicle airflow is restricted z INSPECT for damage. REPAIR as necessary.
z Thermal bypass valve — missing z INSPECT for damage. REPAIR as necessary. REFER
or damaged to Main Control in this section.
Other Concerns: Fluid Venting/Foaming

261 — ROUTINE
Transmission Fluid
z Incorrect level z CHECK the transmission fluid level. ADJUST transmission fluid to correct
level. REFER to Transmission Fluid Level Check in this section.
Case Vent Damaged
z Transmission z INSPECT for damage. If damaged, REPAIR as necessary.
case
Feel Concerns: Shift Concerns: No 4-5 Shift

270 — ROUTINE
Solenoid A (SSA) solenoid the DTCs return, GO to Pinpoint Test A .
or Shift Solenoid B (SSB)
sensor
Main Control
solenoid terminals on the main control molded leadframe for
the DTCs. ROAD TEST the vehicle. If the symptom returns,
z Defective clutch (A) regulator z INSPECT main control assembly for stuck valves or
z Defective clutch (A) latch z INSPECT main control assembly for stuck valves or
Clutch Plates
z Forward clutch (A) friction z INSPECT the forward clutch assembly for damage. REPAIR
and steel plate — failure as required. REFER to Forward Clutch Assembly in this
section.
z Direct clutch (B) friction and z INSPECT the direct clutch assembly for damage. REPAIR
steel plate — failure as required. REFER to Direct Clutch Assembly in this
section.
Feel Concerns: No 5-4 Shift (Automatic)

271 — ROUTINE
harnesses, main control Engine OFF (KOEO) and Key ON Engine Running (KOER) self-
molded leadframe or test. ROAD TEST the vehicle and CHECK for DTCs. If the DTCs
Shift Solenoid B (SSB) return, GO to Pinpoint Test A .
Main Control
on the main control molded leadframe for metallic contamination,
latch valve contamination. REFER to Main Control in this section.
z Defective clutch (A) z INSPECT main control assembly for stuck valves or
Clutch Plates
— failure

272 — ROUTINE
molded leadframe, Shift self-test. ROAD TEST the vehicle and CHECK for DTCs. If the
Solenoid B (SSB) or Shift DTCs return, GO to Pinpoint Test A .
Solenoid C (SSC)
Main Control
Pinpoint Test A .
Clutch Plates
friction and steel plate — REPAIR as required. REFER to Intermediate Clutch Assembly
failure in this section.

273 — ROUTINE
harnesses, main Engine OFF (KOEO) and Key ON Engine Running (KOER) self-
control leadframe or test. ROAD TEST the vehicle and CHECK for DTCs. If the DTCs
Shift Solenoid C (SSC) return, GO to Pinpoint Test A .
Main Control
contamination this section. INSPECT and CLEAN the shift solenoid terminals on
the main control molded leadframe for metallic contamination,
latch valve contamination. REFER to Main Control in this section.
Clutch Plates
and steel plate — required. REFER to Direct Clutch Assembly in this section.
failure
z Intermediate clutch (C) z INSPECT the intermediate clutch assembly for damage. REPAIR
friction and steel plate as required. REFER to Intermediate Clutch Assembly in this
— failure section.

Diagnostic Parameters Identification (PID) Chart
The following is a list of output state control parameters and their corresponding PIDs:
Diagnostic PID Chart

PID Name PID Description Units
AXLE Axle Ratio Ratio
BOO1 Brake ON/OFF Switch On/Off
BOO2 Brake ON/OFF Switch On/Off
CHT Cylinder Head Temperature Temperature
DTCCNT Continuous Codes Number
GEAR Gear Commanded by Module Mode
GEAR_OSC# Gear Commanded by Output State Control Mode
GEAR_RAT Gear Ratio Commanded Ratio
HRSH_SHFT# Firm Shift On/Off
IN_GEAR In Gear-Transmission is Applying a Load to Engine In Gear
ISS_F Input Shaft Speed Sensor Fault No Fault/Yes Fault
ISS_SRC Input Shaft Speed Sensor rpm
LINEDSD# Line Pressure Control Desired Pressure
LOAD Engine Load Percentage
OSS_F Output Shaft Speed Reliable No Fault/Yes Fault
OSS_SRC Unfiltered Output Shaft Speed rpm
PARK_BRK Park Brake Switch On/Off
LPC Line Pressure Control (LPC) solenoid Pressure
LPC_AMP# LPC solenoid current Current
LPC_F LPC solenoid fault status No Fault/Yes Fault
RLC_F Reverse Control Lamp Status No Fault/Yes Fault
RPM# Engine Revolutions Per Minute rpm
SHIFT_DROP Shift rpm Drop in Input Shaft Speed Below Expected rpm
SHIFT_FLRE Shift rpm Rise in Input Shaft Speed Above Expected rpm
SHIFT_ID Shift Identification of Shift PIDs Lag, Time, Flair and Drop rpm
SHIFT_LAG Shift Time Elapsed From 1% to 9% Complete Time
SHIFT_TIME Shift Time From Commanded to 10% Complete Time
SHIFT_TYPE Shift Type Type
SSA_AMP# Shift Solenoid Pressure Control A (SSPCA) Current
SSB_AMP# Shift Solenoid Pressure Control B (SSPCB) Current

SSC_AMP# Shift Solenoid Pressure Control C (SSPCC) Current
SSD_AMP# Shift Solenoid Pressure Control D (SSPCD) Current
SSE_AMP# Shift Solenoid Pressure Control E (SSPCE) Current
SSPCA SSPCA Pressure
SSPCA_F SSPCA Status No Fault/Yes Fault
SSPCB SSPCB Pressure
SSPCB_F SSPCB Status No Fault/Yes Fault
SSPCC SSPCC Pressure
SSPCC_F SSPCC Status No Fault/Yes Fault
SSPCD SSPCD Pressure
SSPCD_F SSPCD Status No Fault/Yes Fault
SSPCE_F SSPCE Status No Fault/Yes Fault
TCC Torque Converter Clutch (TCC) Solenoid Pressure
TCC AMP# Converter Pressure Control Current
TCC_F TCC Fault No Fault/Yes Fault
TCC_OSC# Output State Control of Torque Converter Locked/Unlocked
TCC_RAT Transmission Slip Ratio Ratio
TCIL Transmission Control Indicator Lamp (TCIL) On/Off
TCS_DEPRES Transmission Control Switch (TCS) Pressed Yes/No
TCS_STATE TCS Requested State On/Off
TC_SLIPACT Torque Converter Slip Actual rpm
TC_SLIPDSD Torque Converter Slip Desired rpm
TFT Transmission Fluid Temperature (TFT) Temperature
TFTV TFT Volts Volts
TFT_F TFT Status No Fault/Yes Fault
TIRESIZE Tire Size Rev Per Mile
TP Throttle Position (TP) Sensor Percentage
TP1 TP Sensor 1 Volts
TP2 TP Sensor 2 Volts
TR Transmission Range (TR) Mode
TRANS_VOLT_A Transmission Supply Voltage Control State On/Off
TRAN_RAT Transmission Gear ratio Ratio
TRN_N_F Neutral Output Status On/Off
TRN_P_F Park Output Status On/Off
TR_CRANK TR Input Allowing Input Start Yes/No
TR_DC TR Duty Cycle Percentage
TR_F TR Status No Fault/Yes Fault
TR_FREQ TR Frequency Frequency
Turbine Shaft Speed (TSS) Reliable No Fault/Yes Fault

TSS_SRC Unfiltered Turbine Shaft Speed rpm
VPWR Module Supply Voltage Volts
VREF Reference Voltage Volts
VSOUT_F Vehicle Speed Output Status No Fault/Yes Fault
VSS Vehicle Speed Sensor (VSS) Speed

Diagnostic Strategy
Troubleshooting an electronically controlled automatic transmission is simplified by using the proven method
of diagnosis. One of the most important things to remember is that there is a definite procedure to follow.
NOTE: Do not take short cuts or assume that critical checks or adjustments have already been made.
Follow the procedures as written to avoid missing critical components or steps.
To correctly diagnose a concern, have the following publications available:
z Powertrain Control/Emissions Diagnosis (PC/ED) manual

z On-Line Automotive Service Information System (OASIS)
z TSBs
z Wiring Diagrams manual
These publications provide the information required when diagnosing transmission concerns.
Use the Diagnostic Flow Chart as a guide and follow the steps as indicated.
Preliminary Inspection
z Know and understand the customer concern.

z Verify the concern by operating the vehicle.
z Check the transmission fluid level and condition.
z Check for non-factory add-on items.
z Check selector lever cable for correct adjustment.
z Check TSBs regarding the concern.
Diagnostics
z Carry out On-Board Diagnostic (OBD) procedures, Key ON Engine OFF (KOEO) and Key ON Engine
Running (KOER).
z Record all DTCs.
z Repair all non-transmission codes first.
z Repair all transmission codes second.
z Clear all continuous codes and attempt to repeat them.
z Repair all continuous codes.
z If only codes that have passed are obtained, refer to Diagnosis By Symptom in this section for
additional information and diagnosis.
Follow the diagnostic sequence to diagnose and repair the concern the first time.

Diagnostic Trouble Code (DTC) Charts
Special Tool(s)
Using a scan tool to retrieve DTCs, begin with and repair all non-transmission related DTCs. Start with the
U-DTCs (communication link codes) then repair transmission related DTCs.
The PCM will command a default gear to protect the engine and transmission when certain faults occur.
Default or (limp-home mode) depends on the actual gear the vehicle was in when the fault occurred.
z For gears 1-3, the default will be 3rd gear.

z For gears 4-6, the default will be 5th gear.
The default gear is held until the vehicle is placed in reverse, park or the vehicle is restarted. After these
action(s) the vehicle will default to 3rd gear.
DTC Chart
DTC Component Description Condition Symptom Action
B2572 Brake Shift BSIA open or The BSIA system z BSIA REFER to Section
Interlock shorted circuit a malfunction. inoperative 307-05 .
Actuator
(BSIA)
P0657 PCM Actuator supply The Transmission z Malfunction Power is routed
voltage A circuit Solenoid Power Indicator through the
open Control (TSPC) Lamp (MIL) transmission
relay failed open. ON solenoid power
z Maximum line control (TSPC) relay
pressure (inside the PCM) to
z Default to 5th all solenoids. If the
gear power circuit to the
transmission
solenoids or the
TSPC relay fails
open, then all
solenoids are failed
electrically off.
CHECK for open,
short to ground or
the transmission
connector
disconnected. The
TSPC relay also
disables power to
the transmission
solenoids when
certain transmission
DTCs are set.
REPAIR as
required. CLEAR
the DTC. GO to
Pinpoint Test A .
P0701 PCM Transmission The PCM z Vehicle CLEAR the DTCs.
control system detected an decelerates TEST the system for
range/performance intermittent clutch during upshift normal operation. If
ON fault. or hangs in the DTCs return,
gear REPAIR the more
z DTCs P2700 specific DTC first.
(A) clutch, REFER to Diagnosis
P2701 (B) By Symptom in this
clutch, P2702 section.
(C) clutch,
P2703 (D)
clutch and/or
P2704 (E)
clutch may
set
P0702 Battery Battery voltage out The PCM z Wrench light REPAIR the more
of range detected a illuminated specific DTC first.
voltage level z Maximum line CLEAR the DTCs.
above or below pressure TEST the system for
the accepted z DTCs P0882 normal operation.
voltage range. and/or P0883 REFER to Section
may set 414-00 .
P0705 Transmission TR sensor failure The PCM z MIL ON REPAIR the more
Range (TR) detected a TR z Engine will specific DTC first.
sensor sensor signal duty not crank CLEAR the DTCs.
cycle is within z Default to 3rd GO to Pinpoint Test
range but does or 5th gear if C.
not match the DTC sets
calibrated bit after engine
pattern. running
z Maximum line
pressure
z DTC P1702
may set
P0706 TR sensor TR sensor A circuit The PCM z MIL ON The TR sensor
range/performance detected a TR z Engine will outputs a duty cycle
sensor signal duty not crank indicating manual
cycle is out of z Default to 3rd lever position. This
range. or 5th gear if DTC sets when the
DTC sets duty cycle is greater
after engine or less than
running commanded by
z Maximum line 50Hz. GO to
pressure Pinpoint Test C .
z DTC P1705
may set
low detected a TR z Engine will outputs a duty cycle
cycle is out of z Default to 5th lever position. This
range. gear if DTC DTC sets when the
sets after duty cycle is 8%
engine is less than
running commanded. GO to
z Maximum line Pinpoint Test C .
pressure
z DTC P1702
may set
high detected a TR z Engine will outputs a duty cycle
cycle is out of z Default to 5th lever position. This
range. gear if DTC DTC sets when the
sets after duty cycle is 92%
engine greater than
running commanded. GO to
z Maximum line Pinpoint Test C .
pressure
z DTC P1702
may set
P0709 TR sensor TR sensor A circuit The PCM z Wrench light The TR sensor
intermittent detected a TR illuminated outputs a duty cycle
sensor signal duty z Engine may indicating manual
cycle is not out of not crank lever position. This
range but is z Default to 5th DTC sets when the
invalid. gear if DTC duty cycle is within
sets after range but is in the
engine dead band between
running the design position,
z Maximum line an in-range but
pressure invalid duty cycle.
z DTC P1702 GO to Pinpoint Test
may set C.
P0710 Transmission TFT sensor A The PCM z Wrench light REPAIR the more
Fluid circuit detected a illuminated specific DTC first.
Temperature voltage drop z DTC P0712 GO to Pinpoint Test
(TFT) sensor across the TFT and/or P0713 B.
sensor exceeds may set
scale.
P0711 TFT sensor TFT sensor A The PCM z MIL ON CLEAR the DTC. If
circuit detected no TFT z Default to 1st the DTC returns,
range/performance sensor change or 3rd gear GO to Pinpoint Test
during operation. B.
The TFT sensor
is stuck below 21°
C (70°F) or above
107°C (225°F) or
the temperature
did not change by
8°F during a drive
cycle.
P0712 TFT sensor TFT sensor A The PCM z MIL ON REPAIR the more
circuit low detected a z Default to 1st specific DTC first.
temperature gear CLEAR the DTCs. If
greater than 171° z DTC P0710 the DTC returns,
C (340°F) for at may set GO to Pinpoint Test
least 2.5 seconds B.
(grounded circuit).
P0713 TFT sensor TFT sensor A The PCM z MIL ON REPAIR the more
circuit high detected a z Default to 1st specific DTC first.
temperature less gear CLEAR the DTCs. If
than -45°C (-50° z DTC P0710 the DTC returns,
F) for at least 2.5 may set GO to Pinpoint Test
seconds (open B.
circuit).
P0715 Turbine Shaft TSS sensor A The PCM z MIL ON REPAIR the more
Speed (TSS) circuit indicated no rpm z Default to 5th specific DTC first.
sensor input from the gear CLEAR the DTCs. If
TSS sensor when z Maximum line the DTC returns,
the Output Shaft pressure GO to Pinpoint Test
Speed (OSS) z DTC P0717 D.
sensor indicated may set
rpm greater than
0.
P0717 TSS sensor TSS sensor A The PCM has not z Wrench light This DTC sets when
circuit no signal detected a TSS illuminated DTC P0715 is set.
sensor signal z Default to 5th REFER to DTC
during operation. gear P0715.
z Maximum line
pressure
z DTC P0715
may set
P0718 TSS sensor TSS sensor A The PCM has z Wrench light CLEAR the DTC. If
circuit intermittent detected an illuminated the DTC returns,
intermittent z Poor shift GO to Pinpoint Test
(noise) in the TSS quality D.
sensor signal
during operation.
P0720 OSS sensor OSS sensor circuit The PCM z MIL ON REPAIR the more
indicated no rpm z Default to 5th specific DTC first.
input from the gear CLEAR the DTCs. If
OSS sensor when z Maximum line the DTC returns,
the TSS sensor pressure GO to Pinpoint Test
indicated rpm z DTC P0722 E.
greater than 0. may set
P0721 OSS sensor OSS sensor circuit The PCM has z Wrench light CLEAR the DTC. If
intermittent detected and illuminated the DTC returns,
unrealistic rpm z Poor shift GO to Pinpoint Test
change in the quality E.
OSS sensor.
P0722 OSS sensor OSS sensor no The PCM z Wrench light This DTC sets when
signal indicated no rpm illuminated DTC P0720 is set.
input from the z Default to 5th REFER to DTC
OSS sensor when gear P0720.
the TSS sensor z Maximum line
indicated rpm pressure
greater than 0. z DTC P0720

may set
P0729 Transmission Gear 6 incorrect The PCM did not z Wrench light Intermediate clutch
ratio detect a 6th gear illuminated (C) or overdrive
ratio when z No 6th gear clutch (E) failed to
commanded. z Flair or apply. REFER to the
neutral Clutch Application
condition Chart located in
z Hangs in gear Specifications in this
section. CLEAR the
DTCs. TEST the
system for normal
operation. If the
DTC returns,
REFER to Diagnosis
By Symptom in this
section.
P0731 Transmission Gear 1 incorrect The PCM did not z Wrench light Forward clutch (A)
ratio detect a 1st gear illuminated or low/reverse clutch
ratio when z No 1st gear (D) slip of clutch (D)
commanded. z Flair or failed to apply or
neutral OWC failed to hold.
condition REFER to the
z Hangs in gear Clutch Application
Chart located in
Specifications in this
section. CLEAR the
DTCs. TEST the
system for normal
operation. If the
DTC returns,
REFER to Diagnosis
By Symptom in this
section.
ratio detect a 2nd gear illuminated or intermediate
ratio when z No 2nd gear clutch (C) slip or
commanded. z Flair or clutch (C) failed to
neutral apply. REFER to the
condition Clutch Application
z Hangs in gear Chart located in
section. CLEAR the
DTCs. TEST the
system for normal
operation. If the
DTC returns,
REFER to Diagnosis
By Symptom in this
section.
ratio detect a 3rd gear illuminated or direct clutch (B)
ratio when z No 3rd gear slip or clutch (B)
commanded. z Flair or failed to apply.
neutral REFER to the
section. CLEAR the
DTCs. TEST the
system for normal
operation. If the
DTC returns,
REFER to Diagnosis
By Symptom in this
section.
ratio detect a 4th gear illuminated or overdrive clutch
ratio when z No 4th gear (E) slip or clutch (A)
commanded. z Flair or or (E) failed to
neutral apply. REFER to the
section. CLEAR the
DTCs. TEST the
system for normal
operation. If the
DTC returns,
REFER to Diagnosis
By Symptom in this
section.
P0735 Transmission Gear 5 incorrect The PCM did not z Wrench light Direct clutch (B) or
ratio detect a 5th gear illuminated overdrive clutch (E)
ratio when z No 5th gear slip or clutch (B) or
commanded. z Flair or (E) failed to apply.
neutral REFER to the
section. CLEAR the
DTCs. TEST the
system for normal
operation. If the
DTC returns,
REFER to Diagnosis
By Symptom in this
section.
P0740 Torque TCC solenoid The PCM z MIL ON GO to Pinpoint Test
Converter circuit/open detected that the z TCC is A.
Clutch (TCC) TCC solenoid disabled
solenoid control circuit z DTC P0743
failed open. may set
P0741 TCC TCC solenoid The TCC failed to z MIL ON DTC P0741 is a
solenoid circuit apply after 3 z TCC is non-electrical DTC.
performance/stuck consecutive disabled CLEAR the DTCs.
OFF commands from z TCC regulator TEST the system for
the PCM. apply valve normal operation. If
stuck in the the DTC returns,
release REFER to Torque
position Converter Operation
z TCC control Concerns, No Apply
valve stuck in in Diagnosis By
the release Symptom in this
position section.
z DTC P0751
may set
P0742 TCC TCC solenoid The PCM z MIL ON GO to Pinpoint Test
solenoid circuit stuck ON detected the TCC z TCC is A.
solenoid control disabled
circuit is shorted z Poor launch
to ground. performance
z Default to 3rd
or 5th gear
z DTC P0743
may set
P0743 TCC TCC solenoid The PCM z Wrench light REPAIR the more
solenoid circuit electrical detected that the illuminated specific DTC first.
TCC solenoid z TCC is GO to Pinpoint Test
circuit is open, disabled A.
shorted to ground z Poor launch
or an intermittent. performance
z Default to 5th
gear
z DTCs P0740,
P0742 and/or
P0744 may
set
P0744 TCC TCC solenoid The PCM z MIL ON GO to Pinpoint Test
solenoid circuit intermittent detected that the z TCC is A.
TCC solenoid disabled
control circuit is z DTC P0743
shorted to power. may set
P0748 Line LPC electrical The PCM sets z Wrench light REPAIR the more
Pressure this DTC along illuminated specific DTC first.
Control with one or more z Maximum line GO to Pinpoint Test
(LPC) specific electrical pressure A.
DTCs. z May default to
5th gear
z DTCs P0960,
P0962 and/or
P0963 may
set
P0750 Shift SSA The PCM z MIL ON GO to Pinpoint Test
Solenoid A detected that the z 5th and 6th A.
(SSA) SSA circuit failed gear only
open or shorted z DTC P0753
to power. may set
P0751 SSA SSA The PCM z MIL ON DTC P0751 is a
performance/stuck commanded SSA z 5th and 6th non-electrical DTC.
OFF ON but detected gear only CLEAR the DTCs.
a ratio error. z Harsh reverse TEST the system for
Forward clutch engagement normal operation. If
(A) failed OFF. z Neutral or flair the DTC returns,
condition REFER to Hydraulic
z Clutch A Circuits in this
regulator section.
valve stuck in
default
position
z Clutch A latch
valve stuck in
default
position
z DTC P2700
may set
P0752 SSA SSA stuck ON The PCM z MIL ON DTC P0752 is a
commanded SSA z Disable 5th non-electrical DTC.
OFF but detected and 6th gear CLEAR the DTCs.
a ratio error. z Erratic shifts TEST the system for
Forward clutch z Stuck in 4th normal operation. If
(A) stuck ON. gear the DTC returns,
z Clutch A REFER to Forward
regulator Clutch Assembly in
valve stuck in this section.
spring
compressed
position
z DTC P2700
may set
P0753 SSA SSA electrical The PCM sets z Wrench light REPAIR the more
this DTC along illuminated specific DTC first.
with one or more z 5th and 6th GO to Pinpoint Test
specific electrical gear only A.
DTCs. z DTCs P0750,
P0973 and/or
P0974 may
set
P0754 SSA SSA intermittent The PCM sets z Unexpected CLEAR the DTC.
this DTC when an upshifts, TEST the system for
intermittent downshifts, normal operation. If
condition (open, flairs or the DTC returns,
short to power or neutral GO to Pinpoint Test
ground) occurs 3 conditions A.
times for less
than 5 seconds
with each
occurrence.
P0755 Shift SSB The PCM z MIL ON GO to Pinpoint Test
Solenoid B detected that the z Default to 3rd A .
(SSB) SSB circuit failed or 5th gear
open or shorted z Harsh 1-3
to power. shift
z DTC P0756
may set
P0756 SSB SSB The PCM z MIL ON DTC P0756 is a
performance/stuck commanded SSB z Default to 3rd non-electrical DTC.
OFF ON but detected or 5th gear CLEAR the DTCs.
a ratio error. z Neutral or flair TEST the system for
Direct clutch (B) condition normal operation. If
failed OFF. z Transmission the DTC returns,
hangs in 2nd REFER to Hydraulic
gear on Circuits in this
acceleration section.
z Clutch B
regulator
valve stuck in
default
position
z Clutch B latch
valve stuck in
default
position
z DTC P0757
may set
P0757 SSB SSB stuck ON The PCM z MIL ON DTC P0757 is a
commanded SSB z Default to 3rd non-electrical DTC.
OFF but detected or 5th gear CLEAR the DTCs.
a ratio error. z Harsh 1-3 TEST the system for
Direct clutch (B) shift normal operation. If
stuck ON. z Erratic shifts the DTC returns,
z Clutch B REFER to Direct
regulator Clutch Assembly in
valve stuck in this section.
spring
compressed
position
z DTC P0758
may set
P0758 SSB SSB electrical The PCM sets z Wrench light REPAIR the more
with one or more z Default to 3rd GO to Pinpoint Test
specific electrical or 5th gear A.
DTCs. z Maximum line
pressure
z DTCs P0755,
P0976 and/or
P0977 may
set
P0759 SSB SSB intermittent The PCM sets z Unexpected CLEAR the DTCs.
times for less
than 5 seconds
with each
occurrence.
P0760 Shift SSC The PCM z MIL ON GO to Pinpoint Test
Solenoid C detected the SSC z Disable 2nd A.
(SSC) circuit has failed and 6th gear
open. z Erratic or
harsh 1-3
shift
z DTC P0763
may set
P0761 SSC SSC The PCM z MIL ON DTC P0761 is a
performance/stuck commanded SSC z Disable 2nd non-electrical DTC.
OFF ON but detected and 6th gear CLEAR the DTCs.
a ratio error. z Neutral or flair TEST the system for
Intermediate condition normal operation. If
clutch (C) failed z Clutch C the DTC returns,

OFF. regulator REFER to
valve stuck in Intermediate Clutch
default Assembly in this
position section.
z DTC P2702
may set
P0762 SSC SSC stuck ON The PCM z MIL ON DTC P0762 is a
commanded SSC z 2nd and 6th non-electrical DTC.
OFF but detected upshift only CLEAR the DTCs.
a ratio error. z Harsh reverse TEST the system for
Intermediate engagement normal operation. If
clutch (C) stuck z Erratic shift or the DTC returns,
ON. stuck in 6th REFER to
z Clutch C Intermediate Clutch
regulator Assembly in this
valve stuck in section.
spring
compressed
position
z DTC P2702
may set
P0763 SSC SSC electrical The PCM sets z Wrench light REPAIR the more
with one or more z Disable 2nd GO to Pinpoint Test
specific electrical and 6th gear A.
DTCs. z DTCs P0760,
P0979 and/or
P0980 may
set
P0764 SSC SSC intermittent The PCM sets z Unexpected CLEAR the DTCs.
times for less
than 5 seconds
with each
occurrence.
P0765 Shift SSD The PCM z MIL ON GO to Pinpoint Test
Solenoid D detected that z Disable 1st, A.
(SSD) SSD circuit has 2nd and 3rd
failed open. gears
z Poor launch
performance
z DTC P0768
may set
P0766 SSD SSD The PCM z MIL ON REPAIR the more
performance/stuck commanded SSD z 3rd gear only specific DTC first.
OFF ON but detected z Delayed or no DTC P0766 is a
a ratio error. The reverse non-electrical DTC.
low/reverse clutch engagement CLEAR the DTCs.
(D) and overdrive z Neutral or flair TEST the system for
clutch (E) have condition normal operation. If
both failed OFF. z DTCs P2703 the DTC returns,
and/or P2704 REFER to Hydraulic

may set Circuits in this
section.
P0767 SSD SSD stuck ON The PCM z MIL ON DTC P0767 is a
commanded SSD z 4th, 5th and non-electrical DTC.
OFF but detected 6th gear only CLEAR the DTCs.
a ratio error. z Early upshifts TEST the system for
Overdrive clutch z Stuck in 4th normal operation. If
(E) failed to z DTC P2704 the DTC returns,
release. may set REFER to Diagnosis
By Symptom in this
section.
P0768 SSD SSD electrical The PCM sets z Wrench light REPAIR the more
with one or more z Default to 3rd GO to Pinpoint Test
specific electrical gear A.
DTCs. z DTCs P0765,
P0982 and/or
P0983 may
set
P0769 SSD SSD intermittent The PCM sets z Unexpected CLEAR the DTCs.
times for less
than 5 seconds
with each
occurrence.
P0770 Shift SSE The PCM z MIL ON GO to Pinpoint Test
Solenoid E detected that the z No TCC A.
(SSE) SSE circuit failed z If 1st, 2nd
open, shorted to and 3rd gears
ground or shorted are achieved
to power. than circuit is
open or
shorted to
power (no
pressure)
z If 5th gear
launch than
circuit is
shorted to
ground
(pressure)
z DTC P0773
may set
P0771 SSE SSE The PCM z MIL ON DTC P0771 is a
performance/stuck commanded SSE z 1st, 2nd and non-electrical DTC.
OFF ON but detected 3rd gear only CLEAR the DTCs.
a ratio error z Solenoid TEST the system for
(mechanical multiplex normal operation. If
failure). valve stuck in the DTC returns,
default REFER to Diagnosis
position By Symptom in this
z DTC P0984 section.

may set
P0772 SSE SSE stuck ON The PCM z MIL ON DTC P0772 is a
commanded SSE z No 1st gear non-electrical DTC.
OFF but detected z 4th gear CLEAR the DTCs.
a ratio error launch TEST the system for
(mechanical z Solenoid normal operation. If
failure). multiplex the DTC returns,
valve stuck in REFER to Diagnosis
spring By Symptom in this
compressed section.
position
z DTC P0984
may set
P0773 SSE SSE electrical The PCM sets z Wrench light REFER to DTC
this DTC along illuminated P0770.
with one other z If 1st, 2nd
specific electrical and 3rd gears
DTC. SSE circuit are achieved
may be open, than circuit is
short to power or open or
ground. shorted to
power (no
pressure)
z If 5th gear
launch than
circuit is
shorted to
ground
(pressure)
z DTC P0770
may set
P0774 SSE SSE intermittent The PCM sets z Wrench light CLEAR the DTCs.
this DTC when an illuminated TEST the system for
intermittent z Transmission normal operation. If
condition (open, hangs in 1st the DTC returns,
short to power or gear or may GO to Pinpoint Test
ground) occurs be stuck in A.
but does not set 3rd gear
DTC P0770.
P07A8 Transmission Transmission The low/reverse z Wrench light DTC P07A8 is a
friction element D clutch failed OFF. illuminated non-electrical DTC.
performance/stuck z Delay or no CLEAR the DTC.
OFF reverse TEST the system for
engagement normal operation. If
z Disable 1st the DTC returns,
gear REFER to
z Erratic shifts Low/Reverse Clutch
Assembly in this
section.
P07A9 Transmission Transmission The low/reverse z Wrench light DTC P07A9 is a
friction element D One-Way Clutch illuminated non-electrical DTC.
stuck ON (OWC) is failed z No TCC CLEAR the DTC.
ON. z 1st gear only TEST the system for
z High engine normal operation. If
rpm the DTC returns,
REFER to
Low/Reverse Clutch
Assembly in this
section.
P07AA Transmission Transmission The PCM z Wrench light DTC P07AA is a
friction element E detected a ratio illuminated non-electrical DTC.
performance/stuck error. Overdrive z 1st, 2nd and CLEAR the DTC.
off clutch (E) failed 3rd gears TEST the system for
OFF. only normal operation. If
z Neutral or flair the DTC returns,
condition REFER to Overdrive
z High engine Clutch Assembly in
rpm this section.
z Erratic shifts
P0815 SelectShift™ Upshift switch The upshift and z Wrench light REFER to Section
switch circuit downshift illuminated 307-05 .
switches are open z Disable
in PARK, SelectShift™
REVERSE and scheduling to
NEUTRAL. The automatic
PCM sets this shift
DTC when it scheduling
detects an upshift z Upshifts
switch is closed request
(short to ground). ignored
z Unexpected
upshifts
P0816 SelectShift™ Downshift switch The upshift and z Wrench light REFER to Section
switch circuit downshift illuminated 307-05 .
switches are open z Disable
in PARK, SelectShift™
REVERSE and scheduling to
NEUTRAL. The automatic
PCM sets this shift
DTC when it scheduling
detects a z Upshifts
downshift switch request
is closed (short to ignored
ground). z Unexpected
downshifts
P0826 SelectShift™ Up and Down The upshift and z Wrench light REFER to Section
switch switch circuit downshift illuminated 307-05 .
switches are open z Default to
in PARK, automatic
REVERSE and shift
NEUTRAL. The scheduling
PCM sets this z Upshifts and
DTC when it downshift
detects the select request
switch inputs do ignored
not match the
selector lever
position.
P0882 Battery PCM power input The battery z MIL ON CLEAR the DTC.
signal low voltage is out of z Default to 3rd TEST the system for
range low. At low or 5th gear normal operation. If
volts the solenoid depending the DTC returns,

drivers may no vehicle speed REFER to Section
longer be able to and gear 414-00 .
achieve desired z Battery
current so the voltage below
transmission 9 volts
solenoid power z Maximum line
control relay will pressure
be turned OFF.
P0883 Battery PCM power input The battery z MIL ON CLEAR the DTC.
signal high voltage is out of z Default to 3rd TEST the system for
range high. or 5th gear normal operation. If
Greater than 21 depending the DTC returns,
volts. vehicle speed REFER to Section
and gear 414-00 .
z Battery
voltage above
21 volts
z Maximum line
pressure
z May set DTC
P0702
P0960 LPC LPC control The PCM z MIL ON GO to Pinpoint Test
circuit/open detected 0 volts z Maximum line A .
on the LPC pressure
circuit. z May default to
5th gear
z DTC P0748
may set
P0961 LPC LPC control circuit The PCM z Intermittent GO to Pinpoint Test
range/performance detected that the condition A.
LPC control z Minimum line
circuit is shorted pressure
to ground but not
long enough to
set DTC P0962.
P0962 LPC LPC control circuit The PCM z MIL ON GO to Pinpoint Test
low detected 0 volts z Default to 5th A .
on the LPC gear
circuit. Short to z Maximum line
ground detected. pressure
z DTC P0748
may set
P0963 LPC LPC control circuit The PCM z MIL ON GO to Pinpoint Test
high detected voltage z Maximum line A .
on the LPC pressure
circuit. Short to z DTC P0748
power detected. may set
P0973 SSA SSA control circuit The PCM z MIL ON GO to Pinpoint Test
on the SSA gear
circuit. Short to z Default to 3rd
ground detected. only, when
the selector
lever is
shifted into
Reverse then
back into
Drive
z Maximum line
pressure
z DTC P0753
may set
P0974 SSA SSA control circuit The PCM z MIL ON GO to Pinpoint Test
high detected voltage z 5th and 6th A.
on the SSA gear only
circuit. Short to z DTC P0753
power or open may set
circuit detected.
P0976 SSB SSB control circuit The PCM z MIL ON GO to Pinpoint Test
on the SSB gear
the selector
lever is
shifted into
REVERSE
then back into
DRIVE
z Maximum line
pressure
z DTC P0753
may set
P0977 SSB SSB control circuit The PCM z MIL ON GO to Pinpoint Test
high detected voltage z Default to 3rd A .
on the SSB and 5th gear
circuit. Short to z Harsh 1st to
power or open 3rd shift
circuit. z Maximum line
pressure
z DTC P0758
may set
P0979 SSC SSC control circuit The PCM z MIL ON GO to Pinpoint Test
on the SSC gear
circuit. Short to z Maximum line
ground detected. pressure
z DTC P0763
may set
P0980 SSC SSC control circuit The PCM z MIL ON GO to Pinpoint Test
high detected voltage z 2nd and 6th A.
on the SSC gears
circuit. Short to disabled
power detected. z Harsh 1st to
3rd shift
z Maximum line
pressure
z DTC P0763
may set
P0982 SSD SSD control circuit The PCM z MIL ON GO to Pinpoint Test
on the SSD gear

the selector
lever is
shifted into
REVERSE
then back into
DRIVE
z Maximum line
pressure
z DTC P0768
may set
P0983 SSD SSD control circuit The PCM z MIL ON GO to Pinpoint Test
high detected voltage z Disable 1st, A.
on the SSD 2nd and 3rd
circuit. Short to gear
power detected. z Poor launch
performance
z Maximum line
pressure
z DTC P0768
may set
P0984 SSE SSE control circuit The PCM z Wrench light DTC P0984 is a
range/performance commanded SSE illuminated non-electrical DTC.
ON or OFF but z DTC P0771 CLEAR the DTCs.
detected a ratio and/or P0772 REPAIR the more
error (mechanical will set specific DTC first.
failure). TEST the system for
normal operation. If
the DTC returns,
REFER to Diagnosis
By Symptom in this
section.
P1001 PCM Key ON Engine The KOER self- z — REFER to,
Running (KOER) test was unable to Powertrain
not able to complete and Control/Emissions
complete, KOER aborted. Diagnosis (PC/ED)
aborted manual.
P1397 PCM System voltage out The PCM z — CLEAR the DTC.
of self-test range detected that RERUN the KOEO
system voltage is and KOER self test.
out of self-test If the DTC returns,
range of 11 to 18 REFER to Section
volts, during the 414-00 .
Key ON Engine
OFF (KOEO) or
KOER .
P1501 PCM Vehicle Speed The PCM z Self-test CLEAR the DTC.
Sensor (VSS) out detected a VSS aborted With the selector
of self-test range signal during the lever in the Park
self-test. position, RERUN
the self-test. If the
DTC returns,
REFER to
Powertrain
Control/Emissions
Diagnosis (PC/ED)
manual.
P1502 PCM VSS intermittent Intermittent VSS z Can not REFER to,
fault keeps complete Powertrain
disabling engine engine Control/Emissions
monitors. monitors Diagnosis (PC/ED)
manual.
P1635 PCM Tire/Axle out of The tire, axle or z MIL ON REFER to,
acceptable range the combination z PCM will use Powertrain
of tire and axle a default tire Control/Emissions
are out of the and axle Diagnosis (PC/ED)
certified range. calibration manual.
Calibration was
not updated.
P1636 PCM Inductive signature The PCM lost z MIL ON REPLACE the PCM,
chip communication z Default to 3rd REFER to Section
communication with an internal or 5th gear 303-14 . After
error chip that controls z Maximum line installing the new
the solenoid pressure PCM, PROGRAM it
states and fault z Poor launch with the latest
reporting. performance calibration and
PERFORM the
Solenoid Body
Strategy Data
Download. REFER
to Solenoid Body
Strategy in this
section. ROAD
TEST the vehicle
and PERFORM the
Adaptive Drive
Cycle, REFER to
Shift Point Road
P163E PCM PCM programming The PCM has z MIL ON REPROGRAM the
error detected an z Default to 1st original PCM with
invalid checksum. or 3rd gear the latest calibration.
z Maximum line CLEAR the DTC.
pressure TEST the system for
the DTC returns,
REPLACE the PCM.
REFER to Section
303-14 . After
installing the new
PCM, PROGRAM it
with the latest
calibration and
PERFORM the
Solenoid Body
Strategy Data
Download. REFER
to Solenoid Body
Strategy in this
section. ROAD
TEST the vehicle
and PERFORM the

Adaptive Drive
Cycle, REFER to
Shift Point Road
P163F PCM Transmission ID The PCM has z MIL ON REPROGRAM the
block corrupted, detected an z Default to 1st original PCM with
not programmed invalid or 3rd gear the latest calibration.
transmission z Maximum line CLEAR the DTC.
identification. pressure TEST the system for
the DTC returns,
REPLACE the PCM.
REFER to Section
303-14 . After
installing the new
PCM, PROGRAM it
with the latest
calibration and
PERFORM the
Solenoid Body
Strategy Data
Download. REFER
to Solenoid Body
Strategy in this
section. ROAD
TEST the vehicle
and PERFORM the
Adaptive Drive
Cycle, REFER to
Shift Point Road
P1700 Transmission Transmission Main control body z Wrench light DTC P1700 is a
intermittent failure issue where the illuminated non-electrical DTC.
(failed to neutral) multiplex valve z Neutral CLEAR the DTC.
reverse pressure condition TEST the system for
bleeds off to slow when 1st gear normal operation. If
and causes the commanded the DTC returns,
multiplex valve to REFER to Diagnosis
get stuck in the By Symptom in this
wrong state. section.
P1702 TR sensor TR sensor circuit The PCM z Wrench light REPAIR the more
intermittent detected a TR illuminated specific DTC first.
sensor signal duty z DTC P0705, GO to Pinpoint Test
cycle is not out of P0706, C.
range but is P0707,
invalid. P0708 and/or
P0709 may
set
P1705 TR sensor TR sensor circuit The TR sensor z — CLEAR the DTC.
did not indicate circuit did not RERUN the KOEO
PARK/NEUTRAL indicate and KOER self test.
during the self-test. PARK/NEUTRAL If DTC returns. GO
during KOEO or to Pinpoint Test C .
KOER self-test.
P1711 TFT sensor TFT sensor out of The PCM did not z — CLEAR the DTC.
self-test range receive a TFT RERUN the KOEO

sensor input and KOER self-test.
during the KOEO If DTC returns GO
or KOER self-test to Pinpoint Test B .
that was within -
1.11°C to 104°C
(30°F to 220°F)
during the self-
test.
P1744 TCC TCC solenoid The PCM z Wrench light DTC P1744 is a
circuit detected that the illuminated non-electrical DTC.
TCC solenoid is z DTC P0741 REPAIR the more
stuck ON or stuck and/or P2758 specific DTC first.
OFF. may set CLEAR the DTCs.
TEST the system for
the DTCs return,
REFER to Diagnosis
By Symptom in this
section.
P1780 Transmission TCS (Tow/Haul) The PCM did not z Disable CLEAR the DTC.
Control circuit out of self- receive a TCS Tow/Haul RERUN KOER self-
Switch (TCS) test range input during the function test. If DTC returns,
KOER self-test. REFER to Section
307-05 .
P1783 Transmission Transmission The PCM z Wrench light CLEAR the DTC.
overtemperature detected a illuminated TEST the system for
condition transmission z TCC normal operation. If
temperature commanded the DTC returns,
greater than 135° on early REFER to Diagnosis
C (275°F) for By Symptom in this
more than 5 section.
seconds.
P1921 TR sensor TR signal The PCM z Engine will REPAIR the more
detected a TR not crank specific DTC first.
sensor signal duty z DTCs P1705, GO to Pinpoint Test
cycle out of P0706, C.
range. P0707,
P0708 and/or
P0709 may
set
P2700 Transmission Transmission The PCM z Wrench light DTC P2700 is a
friction element A commanded SSA illuminated non-electrical DTC.
apply time ON or OFF but z DTC P0751 REPAIR the more
range/performance detected a ratio and/or P0752 specific DTC first.
error (mechanical will set REFER to Diagnosis
failure). By Symptom in this
section.
friction element B commanded SSB illuminated non-electrical DTC.
section.

friction element C commanded SSC illuminated non-electrical DTC.
section.
friction element D commanded SSD illuminated non-electrical DTC.
section.
friction element E commanded SSE illuminated non-electrical DTC.
section.
P2705 Transmission Transmission The One-Way z Wrench light DTC P2704 is a
friction element F Clutch (OWC) illuminated non-electrical DTC.
apply time failed OFF ( OWC z Neutral REPAIR the more
range/performance failure). condition specific DTC first.
when 1st gear REFER to Diagnosis
is By Symptom in this
commanded section.
z Poor launch
performance
z Harsh
engagements
P2758 TCC TCC pressure The PCM z Wrench light DTC P2758 is a
control solenoid commanded the illuminated non-electrical DTC.
stuck ON TCC solenoid z Engine stalls REPAIR the more
OFF but the TCC or is lugging specific DTC first.
did not release z DTC P1744 REFER to Diagnosis
(mechanical may set By Symptom in this
error). section.
P2760 TCC TCC pressure The TCC solenoid z TCC disabled CLEAR the DTC.
control solenoid control circuit z Poor launch TEST the system for
intermittent shorted to ground performance normal operation. If
3 times without z Default to 5th the DTC returns,
setting DTC gear GO to Pinpoint Test
P0742. A.

Diagnostics
Special Tool(s)

Diagnosing an electronically controlled automatic transmission is simplified by using the following

procedures. The most important things to remember is there is a definite procedure to follow. Do not take
shortcuts or assume that critical checks or adjustments have already been made. Follow the procedures as
written to avoid missing critical components or steps. By following the diagnostic sequence, the technician
will be able to diagnose and repair the concern the first time.
On-Board Diagnostic (OBD) with Scan Tool
These self-tests should be used to diagnose the PCM and should be carried out in order.
NOTE: Make sure the latest software version is loaded on the scan tool.
1. If the cause is not visually evident, connect the scan tool to the Data Link Connector (DLC).
NOTE: The Vehicle Communication Module (VCM) LED prove-out confirms power and ground from the DLC
to the VCM .
2. If the scan tool does not communicate with the VCM :

z refer to Section 418-00 , No power to the scan tool.

z verify the ignition is in the RUN position.
z verify scan tool operation with a known good vehicle.
z refer to Section 418-00 , The PCM does not respond to the scan tool.
4. Carry out the network test:
z If the scan tool responds with no communication from one or more modules, refer to Section
418-00 , No High Speed Controller Area Network (CAN) communication, all modules are not
responding.
z If the network test passes, retrieve and record the continuous memory DTCs.
5. Clear the continuous DTCs and carry out the PCM self-test.
6. If DTCs retrieved are related to the concern, GO to the DTC Chart.
7. If no DTCs related to the concern are retrieved, REFER to Diagnosis By Symptom in this section.

Leakage Inspection
Special Tool(s)
Leak Tester, Torque Converter
307-691
Material
Item Specification
Dye-Lite® ATF/Power Steering Fluid —
Leak Detection Dye
164-R3701 (Rotunda)
Leak Check Test
NOTE: When diagnosing transmission leaks, the source of the leak must be positively identified prior to
repair. If the vehicle is driven extensively between adding the fluorescent additive and performing the leak
test, the leaking oil can spread and make identifying the location of the leak difficult.
1. Clean off any transmission fluid from the top and bottom of the torque converter housing, the front of
the case and rear face of the engine and oil pan. Clean the torque converter area by washing with a
nonflammable solvent and blow dry with compressed air.
2. Add Dye-Lite® ATF Power Steering Fluid Leak Detection Dye to the transmission fluid. Use one 30
ml (1 fl. oz) of dye solution for every 3.8 L (4 qt) of transmission fluid.
3. Start and run the engine until the transmission reaches its normal operating temperature. Raise the
vehicle on a hoist and run the engine occasionally shifting to the DRIVE and REVERSE ranges to
increase pressure within the transmission. Using a black light, observe the back of the cylinder block
and top of the torque converter housing for evidence of fluid leakage. Run the engine until
transmission fluid leakage is evident and the probable source of leakage can be determined.
4. If the source of the leak is obvious, repair as required. Leaks from the torque converter housing can
originate from several locations. The paths which the fluid takes to reach the bottom of the torque
converter housing are shown in the illustration. The 5 steps following correspond with the numbers in
the illustration.
1. Transmission fluid leaking by the converter hub seal lip will tend to move along the drive hub
and onto the back of the torque converter. Except in the case of a total seal failure,
transmission fluid leakage by the lip of the seal will be deposited on the inside of the torque
converter housing only, near the outside diameter of the housing.
2. Transmission fluid leakage by the outside diameter of the converter impeller hub seal and the
case will follow the same path that leaks by the ID of the converter hub seal follow.
3. Transmission fluid leakage from the converter cover weld or the converter-to-flexplate stud
weld will appear at outside diameter of torque converter on the back face of the flexplate and in
the converter housing only near the flexplate. If a converter-to-flexplate lug, lug weld or
converter cover weld leak is suspected, remove the converter and pressure check.
4. Transmission fluid leakage from the bolts inside the converter housing will flow down the back
of the torque converter housing. Leakage may be from loose or missing bolts.
5. Engine oil leaks from the rear main oil.
5. Remove the torque converter.
6. Using a black light, observe the torque converter housing. Inspect for evidence of dye from the pump
bolts, pump seal, and torque converter hub seal. Repair as required.
7. If the source of the leak is not evident, continue with this procedure to leak test the torque converter.
8. Install the torque converter in the arbor press. Support the torque converter on the mounting pads.
9. Install the Leak Tester, Torque Converter 307-691 into the torque converter hub. Tighten to 25 Nm.
10. Secure the press. Only apply enough force from the press to seal the Leak Tester, Torque Converter
307-691 into the torque converter hub.
11. Connect a compressed air supply to the Leak Tester, Torque Converter 307-691.
12. With air pressure applied to valve, inspect for leaks at the converter hub weld and seams. A soap
bubble solution can be applied around those areas to aid in the diagnosis. If any leaks are present,
install a new torque converter.
13. With air pressure applied to valve, inspect for leaks at the stud or mounting pad and balance weight
welds. A soap bubble solution can be applied around those areas to aid in the diagnosis. If any leaks
are present, install a new torque converter.
14. After leaks are repaired, clean the remaining transmission fluid dye from serviced areas.

Output State Control (OSC) Mode
On-Board Diagnostic (OBD)
Output state control allows the technician to take control of certain parameters to function the transmission.
Output state control allows the technician to shift the transmission when commanding a gear change.
Another example of the output state control features is, the technician can command the torque converter
ON or OFF to check operation.
This transmission output state control has one mode of operation; DRIVE. This mode has a unique set of
operating requirements that the technician must meet before allowed to operate the torque converter or
select gears.

Pinpoint Tests — OSC Equipped Vehicle
Special Tool(s)

When the electrical connector or solenoid body is disconnected, inspect the connector for terminal condition,
corrosion and contamination. Also inspect the connector seal for damage. Clean, repair or install new
components as required.
Power is routed through the Transmission Solenoid Power Control (TSPC) relay (inside the PCM) to all
transmission solenoids. If the power circuit to the transmission solenoids or the TSPC relay fails open, then
all solenoids are failed electrically OFF. CHECK for open, short to ground or the transmission connector
disconnected. The TSPC relay will disable power to the transmission solenoids when certain transmission
DTCs are set.
Shift Solenoid Pre-Diagnosis

Shift Solenoid
PCM

Mc — — — — — — —
2 2 On On On On Off Off
a Solenoid state will change if vehicle is moving forward with the selector lever in the NEUTRAL position.
c
All gears available upon driver request.
CB = Clutch brake
NH = Normally high
NL = Normally low
Pinpoint Tests
Refer to Wiring Diagrams Cell 30 for schematic and connector information.
NOTE: Refer to all TSBs and On-Line Automotive Service Information System (OASIS) messages that
pertain to the transmission concern and follow the procedure as described.
NOTE: Vehicles equipped with a 3.7L engine use PCM C175T.
NOTE: Vehicles equipped with a 5.0L or 6.2L engine use PCM C1381T.
NOTE: Vehicles equipped with a 3.5L engine use PCM C1551E.
PINPOINT TEST A: TRANSMISSION CONTROL SOLENOIDS
NOTE: Refer to the Transmission Vehicle Harness Connector illustration within the Transmission Connector
Layouts procedure in this section.
NOTE: Refer to the Transmission Leadframe Connector illustration within the Transmission Connector
NOTE: If the scan tool is unable to access the transmission PIDs, refer to Powertrain Control/Emissions
NOTE: Read and record all DTCs.
NOTE: Without a voltage signal return to the PCM, the Transmission Solenoid Power Control (TSPC) relay
is commanded OFF. By using a fused jumper between a transmission solenoid control circuit and the signal
return circuit, the TSPC relay circuit will supply power to the transmission solenoids when the ignition is
cycled from OFF to ON. Do not use a solenoid control circuit that may be at fault, refer to Diagnostic Trouble
Code (DTC) Charts in this section for a fault listing.

A1 CHECK THE SOLENOID POWER CIRCUIT FOR VOLTAGE
z Ignition OFF. Yes
z Disconnect: Transmission C1575 . GO to A4 .
z Inspect the connector for damaged or pushed out terminals,
corrosion, loose wires and missing or damaged seals. No
z NOTICE: Do not use a solenoid control circuit that may be GO to A2 .
at fault. Failure to jump pin 5 to a known good solenoid
control circuit can cause incorrect diagnostic results. For
additional information, refer to Diagnostic Trouble Code
(DTC) Charts in this section for a fault listing.
z Using the chart, connect a fused jumper between one of the 7
solenoid control circuit pins on transmission vehicle harness
C1575 and C1575-5.
Transmission Vehicle
Harness C1575 Solenoid Control Circuit
C1575-9 Shift Solenoid A (SSA) CET05
(BU/GN)
C1575-14 Shift Solenoid B (SSB) CET06
(GN/BN)
C1575-13 Shift Solenoid C (SSC) CET07
(GY/OG)
C1575-10 Shift Solenoid D (SSD) CET08
(BN/WH)
C1575-8 Shift Solenoid E (SSE) CET18
(GY/YE)
C1575-16 Line Pressure Control (LPC)
solenoid CET09 (YE/VT)
C1575-3 Torque Converter Clutch (TCC)
solenoid CET10 (BU/GY)
z Ignition ON.
z Measure the voltage from the transmission vehicle harness
C1575-7 circuit CET25 (BU/GN) harness side to ground.

A2 CHECK THE SOLENOID POWER CIRCUIT FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: PCM C175T (3.7L Engine) . GO to A3 .
z Disconnect: PCM C1381T (5.0L and 6.2L Engines) .
z Disconnect: PCM C1551E (3.5L Gasoline Turbocharged No

Direct Injection (GTDI) Engine) . REPAIR transmission vehicle
z Inspect the connector for damaged or pushed out terminals, harness circuit CET25 (BU/GN)
corrosion, loose wires and missing or damaged seals. for an open. CLEAR the DTC's.
z Vehicle equipped with 3.7L engine, measure the resistance TEST the system for normal
from the PCM C175T-50 to the transmission vehicle harness operation. If DTC P0657
C1575-7, circuit CET25 (BU/GN). returns, REPLACE the PCM.
PROGRAM the PCM with the
latest calibration level.
PERFORM the Solenoid Body
Strategy Data Download
procedure. REFER to Solenoid
Body Strategy in this section.
operation.
z Vehicle equipped with 5.0L or 6.2L engine, measure the

resistance from the PCM C1381T-50 to the transmission
vehicle harness C1575-7, circuit CET25 (BU/GN).
z Vehicle equipped with 3.5L engine, measure the resistance

from the PCM C1551E-80 to the transmission vehicle harness
C1575-7, circuit CET25 (BU/GN).

A3 CHECK THE SOLENOID POWER CIRCUIT FOR A SHORT
TO GROUND
z Vehicle equipped with 3.7L engine, measure the resistance Yes
from the PCM C175T-50, circuit CET25 (BU/GN) of the GO to A4 .
transmission vehicle harness to ground.
No
REPAIR transmission vehicle
harness circuit CET25 (BU/GN)
for a short to ground. CLEAR

the DTC's. TEST the system for
normal operation. If DTC
P0657 returns, REPLACE the
PCM, REFER to Section 303-
14 . PROGRAM the PCM with
the latest calibration level.
Strategy Data Download
procedure. REFER to Solenoid
Body Strategy in this section.
z Vehicle equipped with 5.0L or 6.2L engine, measure the TEST the system for moral
resistance from the PCM C1381T-50, circuit CET25 (BU/GN) operation.
of the transmission vehicle harness to ground.
z Vehicle equipped with 3.5L engine, measure the resistance

from the PCM C1551E-80, circuit CET25 (BU/GN) of the
transmission vehicle harness to ground.

A4 CHECK SOLENOID CONTROL CIRCUITS FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: PCM C175T (3.7L Engine) . GO to A5 .
z Disconnect: PCM C1381T (5.0L and 6.2L Engines) .
z Disconnect: PCM C1551E (3.5L GTDI Engine) . No
z Inspect the connector for damaged or pushed out terminals, REPAIR the transmission
corrosion, loose wires and missing or damaged seals. vehicle harness circuit which
z Vehicles equipped with a 3.7L engine, measure the resistance measured greater than 5 ohms.
of the solenoid control circuits using the following chart. CLEAR the DTCs. TEST the
PCM Circuit Transmission
C175T-45 SSA CET05 (BU/GN) C1575-9
C175T-43 SSB CET06 (GN/BN) C1575-14
C175T-44 SSC CET07 (GY/OG) C1575-13

C175T-10 SSD CET08 (BN/WH) C1575-10
C175T-11 SSE CET18 (GY/YE) C1575-8
C175T-34 LPC solenoid CET09 (YE/VT) C1575-16
C175T-46 TCC solenoid CET10 (BU/GY) C1575-3
z Vehicles equipped with a 5.0L or 6.2L engine, measure the

resistance of the solenoid control circuits using the following
chart.

C1381T-43 SSA CET05 (BU/GN) C1575-9
C1381T-44 SSB CET06 (GN/BN) C1575-14
C1381T-45 SSC CET07 (GY/OG) C1575-13
C1381T-10 SSD CET08 (BN/WH) C1575-10
C1381T-11 SSE CET18 (GY/YE) C1575-8
C1381T-34 LPC CET09 (YE/VT) C1575-16
C1381T-46 TCC CET10 (BU/GY) C1575-3
z Vehicles equipped with a 3.5L engine, measure the resistance

of the solenoid control circuits using the following chart.

C1551E-60 SSA CET05 (BU/GN) C1575-9
C1551E-45 SSB CET06 (GN/BN) C1575-14
C1551E-75 SSC CET07 (GY/OG) C1575-13
C1551E-30 SSD CET08 (BN/WH) C1575-10
C1551E-2 SSE CET16 (WH/BU) C1575-8
C1551E-59 LPC solenoid CET09 (YE/VT) C1575-16
C1551E-44 TCC solenoid CET10 (BU/GY) C1575-3
z Is the resistance less than 5 ohms on each circuit?

A5 CHECK SOLENOID CONTROL CIRCUITS FOR A SHORT TO
GROUND
z Measure the resistance between the transmission vehicle Yes
harness C1575, harness side and ground using the following GO to A6 .
chart.
No
Transmission Control Circuit Ground REPAIR the transmission
vehicle harness circuit which
C1575-7 Solenoid Power CET25 (BU/GN) Ground measured less than 10,000
ohms. CLEAR the DTCs. TEST
C1575-9 SSA CET05 (BU/GN) Ground
C1575-14 SSB CET06 (GN/BN) Ground operation.
C1575-13 SSC CET07 (GY/OG) Ground
C1575-10 SSD CET08 (BN/WH) Ground

C1575-8 SSE CET18 (GY/YE) (CET16 Ground
(WH/BU) 3.5L only)
C1575-16 LPC solenoid CET09 (YE/VT) Ground
C1575-3 TCC solenoid CET10 (BU/GY) Ground

A6 CHECK SOLENOID CONTROL CIRCUITS FOR A SHORT TO
POWER
z Connect: PCM C175T (3.7L Engine) . Yes
z Connect: PCM C1381T (5.0L and 6.2L Engines) . REPAIR the transmission
z Connect: PCM C1551E (3.5L GTDI Engine) . vehicle harness circuit shorted
z Ignition ON. to power. CLEAR the DTCs.
z Measure for voltage between the transmission vehicle TEST the system for normal
harness C1575, harness side and ground using the following operation.
chart.
No
Transmission Control Circuit Ground GO to A7 .
C1575-9 SSA CET05 (BU/GN) Ground
C1575-14 SSB CET06 (GN/BN) Ground
C1575-13 SSC CET07 (GY/OG) Ground
C1575-10 SSD CET08 (BN/WH) Ground
C1575-8 SSE CET18 (GY/YE) (CET16 Ground
(WH/BU) 3.5L only)
C1575-16 LPC solenoid CET09 (YE/VT) Ground
C1575-3 TCC solenoid CET10 (BU/GY) Ground
z Is voltage greater that 4 volts?

A7 CHECK COMPONENT RESISTANCE
z Measure resistance of the solenoid between the transmission Yes
molded leadframe C1575, component side using the following REFER to Main Control to
chart. inspect for stuck valves or
debris. If no problems are
Transmission Solenoid Transmission Ohms found, INSTALL suspected
solonoid. REFER to Shift
C1575-7 SSA C1575-9 4.8 to 5.6 Solenoids (SS) . CLEAR the
C1575-7 SSB C1575-14 4.8 to 5.6
normal operation.
C1575-7 SSC C1575-13 4.8 to 5.6
No
C1575-7 SSD C1575-10 4.8 to 5.6
REPLACE the suspected
C1575-7 SSE C1575-8 17.5 to 18.6 solenoid which failed the
resistance check. REFER to
C1575-7 LPC solenoid C1575-16 4.8 to 5.6 Shift Solenoids (SS) in this
C1575-7 TCC solenoid C1575-3 4.8 to 5.6 section. CLEAR the
transmission adaptive tables
and perform the adaptive drive
z Is the resistance within specifications?
cycle. REFER to Shift Point
Road Test in this section. TEST
operation.
A8 CHECK SOLENOID RESISTANCE
z Remove the molded leadframe from the main control. Refer to Yes
Shift Solenoids (SS) in this section. Inspect for metallic INSTALL a new molded
contamination and clean the solenoid and molded leadframe leadframe, REFER to Shift
terminals. Solenoids (SS) in this section.
z Measure and record the resistance of the suspected solenoid. CLEAR the DTCs. TEST the
For solenoid location, refer to Shift Solenoids (SS) in this system for normal operation.
section. Compare the recorded value with the chart below.
No
Solenoid Ohms REPLACE the suspected
solenoid which failed the
SSA 4.8 to 5.6 resistance check. REFER to
Shift Solenoids (SS) in this
SSB 4.8 to 5.6
section. CLEAR the
SSC 4.8 to 5.6 transmission adaptive tables
and perform the adaptive drive
SSD 4.8 to 5.6 cycle. REFER to Shift Point
SSE 17.5 to 18.6 Road Test in this section. TEST
LPC solenoid 4.8 to 5.6 operation.
TCC solenoid 4.8 to 5.6
z Is the solenoid resistance within specification?
PINPOINT TEST B: TFT SENSOR

B1 CHECK TFT INPUT SIGNAL
z Ignition OFF. Yes
z Disconnect: Transmission Vehicle Harness GO to B2 .
C1575 .
z Inspect the connector for damaged or pushed out No
terminals, corrosion, loose wires and missing or REPAIR vehicle harness circuit VET27
damaged seals. (BN/YE) for a short to ground. CLEAR the
z Connect the scan tool. DTCs. TEST the system for normal
tool: TFT PIDs: TFT and TFTV .
z Does the TFT PID display -40°C (-40°F) and
the TFTV PID display 4.96 to 5.10 volts?
B2 CHECK TFT SIGNAL INPUT CIRCUIT FOR
VOLTAGE
z Measure the voltage between the transmission Yes
vehicle harness C1575-6, circuit VET27 (BN/YE), GO to B3 .
No
INSPECT and REPAIR transmission vehicle
harness circuit VET27 (BN/YE) for an open.
If an open circuit is not found, REPLACE
the PCM, REFER to Section 303-14 .
PROGRAM the PCM with the latest
calibration level. PERFORM the Solenoid
Body Strategy Data Download procedure.
REFER to Solenoid Body Strategy in this
operation.
z Is the voltage between 4.8 and 5.1 volts?

B3 CHECK TFT SIGNAL RETURN CIRCUIT
z Connect a fused jumper between the Yes
transmission vehicle harness C1575-5 and GO to B4 .
C1575-6, harness side.
No
INSPECT and REPAIR the transmission
vehicle harness signal return circuit for an
open. If an open circuit is not found,
REPLACE the PCM, REFER to Section
303-14 . PROGRAM the PCM with the
latest calibration level. PERFORM the
Solenoid Body Strategy Data Download
procedure. REFER to Solenoid Body
Strategy in this section. TEST the system
z Does the TFT PID display 190°-195°C (374°-

383°F) and the TFTV PID display 0 volts?
B4 CHECK TFT SENSOR RESISTANCE
z Measure the resistance between the transmission Yes
molded leadframe C1575-5 and C1575-6, REFER to Diagnosis By Symptom in this
component side using the following chart. section to diagnose an overheating concern.
TRANSMISSION FLUID TEMPERATURE (TFT)

No
°C °F Resistance INSPECT and CLEAN the TFT sensor on
-40 to -20 -40 to -4 967K-284K the molded leadframe for metallic
contamination. INSTALL a new molded
-19 to -1 -3 to 31 284K-100K leadframe if no debris was found, REFER to
0-20 32-68 100K-37K Shift Solenoids (SS) in this section. CLEAR
the DTCs. TEST the system for normal
21-40 69-104 37K-16K operation.
41-70 105-158 16K-5K
71-90 159-194 5K-2.7K
91-110 195-230 2.7K-1.5K
111-130 231-266 1.5K-0.8K
131-150 267-302 0.8K-0.54K
z Does the temperature to resistance

specifications match?
PINPOINT TEST C: TR SENSOR

C1 VERIFY DTCs
z Ignition OFF. Yes
z Select PARK. GO to C3 .
z Connect the scan tool.
z Carry out the Key ON Engine OFF (KOEO) then the No
Key ON Engine Running (KOER) test. DTCs P0705, GO to C2 .
P0706, P0707, P0708, P0709, P1702, P1705 and
P1921 cannot be set by an incorrectly adjusted selector
lever cable.
z Are Transmission Range (TR) sensor DTCs
present?
C2 VERIFY SELECTOR LEVER CABLE/LINKAGE
ADJUSTMENT
z Verify the selector lever cable is correctly adjusted. Yes
Refer to Section 307-05 . GO to C3 .
z Is the selector lever cable correctly adjusted?
No
ADJUST the selector lever cable.
C3 CHECK TR SENSOR ELECTRICAL OPERATION
z Ignition ON. Yes

z Enter the following diagnostic mode on the scan tool: The problem is not in the TR sensor
TR PIDs: TR_DC and TR_FREQ . system. REFER to Diagnosis By
z Move the selector lever into each range and stop. Symptom in this section for further
z Observe the following PIDs: TR_DC and TR_FREQ diagnosis.
while wiggling the harness or driving the vehicle.
z Compare the PID: TR_DC to the selector lever position No
duty cycle, using the following chart. GO to C4 .
Selector Lever Position Range (% Duty Cycle)

P 8.0 — 25.8
R 30.50 — 39.31
N 40.54 — 52.49
D 54.35 — 71.15
M 65.15 — 82
2 70.55 — 85.61
1 75.25 — 88.91
z Is the TR_FREQ between 100 to 150 Hz?
Is the TR_DC within range?
Does the TR_DC and TR_FREQ remain steady when

the harness is wiggled or the vehicle driven?
C4 CHECK TR SENSOR VPWR CIRCUIT FOR POWER
z Ignition OFF. Yes
z Disconnect: Transmission Vehicle Harness C1575 . INSPECT and REPAIR the
z Inspect the connector for damaged or pushed out transmission vehicle harness circuit
terminals, corrosion, loose wires and missing or LE111 (VT/GN) for an open. If an
damaged seals. open circuit is not found, REPLACE
z Ignition ON. the PCM, REFER to Section 303-14 .
z Measure the voltage between the transmission vehicle PERFORM the Solenoid Body
harness C1575-12, circuit LE111 (VT/GN) harness side Strategy Data Download procedure.
and ground. REFER to Solenoid Body Strategy in
this section. CLEAR the DTCs. TEST
No
GO to C5 .
z Is the voltage less than 9.5 volts?

C5 CHECK TR SENSOR SIGNAL CIRCUIT
z Measure the voltage between the transmission vehicle Yes
harness C1575-4, circuit VET32 (VT) harness side and GO to C6 .
ground.
No
INSPECT and REPAIR vehicle

harness circuit VET32 (VT) for an
open. If an open circuit is not found,
REPLACE the PCM, REFER to
Section 303-14 . PERFORM the
Solenoid Body Strategy Data
Download procedure. REFER to
Solenoid Body Strategy in this
section. CLEAR the DTCs. TEST the
z Is the voltage greater than 4.8 volts?

C6 CHECK TR SENSOR GROUND CIRCUIT
z Measure the voltage between the transmission vehicle Yes
harness C1575-4 circuit VET32 (VT) and C1575-11 GO to C7 .
circuit RET24 (BN/BU).
No
INSPECT and REPAIR transmission
vehicle harness circuit RET24
(BN/BU) for an open. If an open circuit
is not found, REPLACE the PCM,
Strategy Data Download procedure.
REFER to Solenoid Body Strategy in
this section. CLEAR the DTCs. TEST
z Is the voltage greater than 4.8 volts?

C7 CHECK TR SENSOR POWER CIRCUIT FOR A SHORT
TO GROUND
z Ignition OFF. Yes
z Disconnect: PCM C175T . GO to C8 .
z Disconnect: PCM C1381T .
z Disconnect: PCM C1551E . No
z Inspect the connector for damaged or pushed out REPAIR transmission vehicle harness
terminals, corrosion, loose wires and missing or circuit VET32 (VT) for a short to
damaged seals. ground. CLEAR the DTCs. TEST the
z Measure the resistance between the transmission system for normal operation.
vehicle harness C1575-4 circuit VET32 (VT) and
ground.

C8 CHECK TR SENSOR CIRCUITS FOR A SHORT TO
POWER
z Connect: PCM C175T . Yes

z Connect: PCM C1381T . REPAIR the transmission vehicle
z Connect: PCM C1551E . harness circuit which measured
z Ignition ON. greater than 9.8 volts. CLEAR the
z Measure the voltage between the transmission vehicle DTCs. TEST the system for normal
harness C1575-4, circuit VET32 (VT) and C1575-11, operation.
circuit RET24 (BN/BU) to ground.
No
GO to C9 .
z Is voltage greater than 9.8 volts?

C9 CHECK TR SENSOR TO MANUAL VALVE
z Drain the transmission fluid and remove the Yes
transmission fluid pan. Refer to Fluid Pan, Gasket and REPLACE molded leadframe. REFER
Filter in this section. to Shift Solenoids in this section.
z Check the connection between the TR sensor and the
manual control valve. Refer to Transmission — Early No
Build or Transmission — Late Build in this section. CONNECT the TR sensor to the
z Inspect the molded leadframe for metallic manual control valve, REFER to
contamination, refer to Shift Solenoids (SS) . Transmission — Early Build or
z Is the TR sensor connected to the manual control Transmission — Late Build in this
valve shaft? section. CLEAN any debris from the
molded leadframe. RUN the Key ON
Engine OFF (KOEO) self-test. If DTCs
return, REPLACE the molded
leadframe, REFER to Shift Solenoids
(SS) in this section.
PINPOINT TEST D: TSS SENSOR
NOTE: Always drive the vehicle in a safe manner according to driving conditions and obey all traffic laws.
NOTE: If DTCs P0705, P0706, P0707, P0708, P0709, P1702, P1705 and/or P1921 are set, diagnose those
DTCs first.

D1 DRIVE CYCLE TEST
z Enter the following diagnostic mode on the scan REFER to Shift Point Road Test in this
tool: TSS PID: TSS_SRC . section for further diagnosis.
z Monitor the TSS_SRC PID while road testing the
vehicle. Drive the vehicle so the transmission No
upshifts and downshifts through all the gears. GO to D2 .
z Does the TSS sensor rpm increase and decrease
with engine rpm and vehicle speed?
D2 CHECK TSS SENSOR SIGNAL CIRCUIT FOR
POWER
z Ignition OFF. Yes
z Disconnect: Transmission Vehicle Harness C1575 . GO to D3 .
z Ignition ON.
z Measure the voltage between the transmission No
vehicle harness C1575-1 and ground. GO to D6 .

D3 CHECK THE TSS SENSOR SIGNAL CIRCUIT FOR
AN OPEN
z Ignition OFF. Yes
z Disconnect: PCM C175T . GO to D4 .
z Inspect the connector for damaged or pushed out
terminals, corrosion, loose wires and missing or No
damaged seals. INSPECT and REPAIR transmission
z Vehicles equipped with a 3.7L engine, measure the vehicle harness TSS signal circuit for an
resistance between the transmission vehicle open. If an open circuit is not found,
harness C1575-1 circuit VET33 (WH/OG) and PCM REPLACE the PCM, REFER to Section
C175T-16. 303-14 . PERFORM the Solenoid Body
operation.

terminals, corrosion, loose wires and missing or
damaged seals.
z Vehicles equipped with a 5.0L or 6.2L engine,
measure the resistance between the transmission
vehicle harness C1575-1 circuit VET33 (WH/OG)
and PCM C1381T-1.
z Disconnect: PCM C1551E .

damaged seals.
z Vehicles equipped with a 3.5L engine, measure the
resistance between the transmission vehicle
harness C1575-1 circuit RET33 (WH/VT) and PCM
C1551E-27.

A SHORT TO GROUND
vehicle harness C1575-1 and ground. GO to D5 .
No
vehicle harness TSS signal circuit for a
short to ground. If a short to ground is not
found, REPLACE the PCM, REFER to
Section 303-14 . PERFORM the

A SHORT TO POWER

z Connect: PCM C1381T . INSPECT and REPAIR transmission
z Connect: PCM C1551E . vehicle harness TSS signal circuit for a
z Ignition ON. short to power. If a short to power is not
z Measure for voltage between the transmission found, REPLACE the PCM, REFER to
vehicle harness C1575-1, and ground. Section 303-14 . PERFORM the
No
GO to D6 .

D6 CHECK THE TSS SENSOR GROUND CIRCUIT
vehicle harness C1575-1 and C1575-5. REPAIR the transmission vehicle
harness signal return circuit for an open.
If an open is not found, REPLACE the
PCM, REFER to Section 303-14 .
Body Strategy Data Download
No
REPLACE the molded leadframe,
z Is voltage less than 4.8 volts? REFER to Shift Solenoids (SS) in this
section. CLEAR the DTCs. TEST the
PINPOINT TEST E: OSS SENSOR
NOTE: If DTCs P0705, P0706, P0707, P0708, P0709, P1702, P1705 and/or P1921 are set, diagnose those
DTCs first.

E1 DRIVE CYCLE TEST
z Enter the following diagnostic mode on the scan tool: REFER to Shift Point Road Test in this
OSS PID: OSS_SRC . section for further diagnosis.
z Monitor the Output Shaft Speed (OSS) sensor PID
while road testing the vehicle. Drive the vehicle so No
the transmission upshifts and downshifts through all GO to E2 .
the gears.
z Does the OSS sensor rpm increase and decrease
with engine rpm and vehicle speed?
E2 CHECK OSS SENSOR SIGNAL CIRCUIT FOR
POWER
z Ignition OFF. Yes
z Disconnect: Transmission Vehicle Harness C1575 . GO to E3 .
z Ignition ON.
z Measure the voltage between the transmission No
vehicle harness C1575-15 and ground. GO to E6 .

E3 CHECK THE OSS SENSOR SIGNAL CIRCUIT FOR
AN OPEN
z Ignition OFF. Yes
z Disconnect: PCM C175T . GO to E4 .
terminals, corrosion, loose wires and missing or No
damaged seals. INSPECT and REPAIR transmission
z Vehicles equipped with a 3.7L engine, measure the vehicle harness OSS signal circuit for an
resistance between the transmission vehicle harness open. If an open circuit is not found,
C1575-15 circuit VET26 (BN/GN) and PCM C175T- REPLACE the PCM, REFER to Section
25. 303-14 . PERFORM the Solenoid Body
operation.


damaged seals.
z Vehicles equipped with a 5.0L or 6.2L engine,
measure the resistance between the transmission
vehicle harness C1575-15 circuit VET26 (BN/GN)
and PCM C1381T-14.
z Disconnect: PCM C1551E .

damaged seals.
z Vehicles equipped with a 3.5L engine, measure the
resistance between the transmission vehicle harness
C1575-15 circuit RET04 (YE/OG) and PCM
C1551E-12.

A SHORT TO GROUND
vehicle harness C1575-15 and ground. GO to E5 .
No
vehicle harness OSS signal circuit for a
short to ground. If a short to ground is
not found, REPLACE the PCM, REFER
to Section 303-14 . PERFORM the
A SHORT TO POWER
z Connect: PCM C1381T . INSPECT and REPAIR transmission
z Connect: PCM C1551E . vehicle harness OSS signal circuit for a
z Ignition ON. short to power. If a short to power is not
z Measure for voltage between the transmission found, REPLACE the PCM, REFER to
vehicle harness C1575-15, and ground. Section 303-14 . PERFORM the
No
GO to E6 .

E6 CHECK THE OSS SENSOR GROUND CIRCUIT
vehicle harness C1575-15 and C1575-5. REPAIR the transmission vehicle
harness signal return circuit for an open.
If an open is not found, REPLACE the
PCM, REFER to Section 303-14 .
Body Strategy Data Download
No
REPLACE the molded leadframe,
z Is voltage less than 4.8 volts? REFER to Main Control in this section.
CLEAR the DTCs. TEST the system for
normal operation.

Preliminary Inspection
Special Tool(s)
Material
Item Specification
(Canada)
Check the following items prior to beginning the diagnostic procedures:
Know and Understand the Concern
To correctly diagnose a concern, first understand the customer concern or condition. Customer contact may
be required to understand the conditions, including when the concern occurs. For example:
z Hot or cold vehicle temperature

z Hot or cold ambient temperature
z Vehicle driving conditions
z Vehicle loaded/unloaded
After understanding when and how the concern occurs, proceed to Verification of Condition.
Verification of Condition
This section provides information that must be used in determining the actual cause of customer concerns
and carrying out the appropriate procedures.
Use the following procedures when verifying customer concerns for the transmission.
Determine Customer Concern
Determine customer concerns relative to vehicle use and dependent driving conditions, paying attention to
the following items:
z Hot or cold vehicle operating temperature

z Hot or cold ambient temperature
z Type of terrain
z Vehicle loaded/unloaded
z City/highway driving
z Upshifting
z Downshifting
z Coasting
z Engagement
z Noise/vibration — check for engine rpm, vehicle speed, shift, gear, range or temperature
dependencies.
Check Transmission Fluid Level and Condition
Transmission Fluid Level Check
NOTICE: The vehicle should not be driven if the transmission fluid level is low. Internal transmission
failure could result.
NOTICE: The transmission fluid fill plug is located near the exhaust system. The exhaust will be
extremely hot during this procedure.
NOTE: If the vehicle is operated for an extended period at high highway speeds, in city traffic, during hot
weather, or while pulling a trailer, allow the transmission fluid to cool down to obtain an accurate reading.
NOTE: If the transmission starts to slip, shifts slowly, or shows signs of transmission fluid leaking, check the
transmission fluid level.
This transmission is equipped with an internal thermal bypass located in the case. This internal thermal
bypass valve shuts off transmission fluid flowing to the transmission fluid cooler if the transmission fluid
temperature falls below normal operating temperature. Refer to Transmission Fluid Level Check in this
section.
The transmission fluid level indicator has 2 areas for the fluid level, a crosshatched area (labeled A) and a
dotted area (labeled B). Use the dotted (labeled B) area when checking the transmission fluid level. The
correct transmission fluid level is at the upper level of the dotted marks on the transmission fluid level
indicator.
High Transmission Fluid Level
NOTICE: Transmission fluid level that is too high can cause the transmission fluid to become
aerated due to the churning action of the rotating internal parts. This may cause erratic control
pressure, foaming, loss of transmission fluid through the vent tube, and possible transmission
failure.
If an overfill reading is indicated on the transmission fluid level indicator, remove the excess transmission
fluid. Refer to Transmission Fluid Level Check in this section.
Low Transmission Fluid Level
Low transmission fluid level can result in poor transmission engagement, slipping, or failure. This may also
indicate a leak in one of the transmission seals or gaskets.
Adding Transmission Fluid
NOTICE: The use of any type of transmission fluid other than specified can result in transmission
failure.
NOTICE: The vehicle should not be driven if the transmission fluid level is low. Internal failure could
result.
Add transmission fluid using the refill procedure. Refer to Transmission Fluid Drain and Refill in this section.
Transmission Fluid Condition Check
1. Check the transmission fluid level.
2. Remove the transmission fluid fill plug and transmission fluid level indicator, allowing the transmission
fluid to drip onto a facial tissue. Examine the stain.
3. Observe the color and the odor.
4. If evidence of solid material is found, remove the transmission fluid pan for further inspection.
5. If the stain is a foamy pink color, this may indicate coolant in the transmission. Inspect the engine
cooling system at this time.
6. If transmission fluid contamination or transmission failure is confirmed by the sediment in the bottom
of the transmission fluid pan, disassemble and completely clean the transmission. This includes the
torque converter and transmission fluid cooler tubes. Refer to Transmission Fluid Cooler Backflushing
and Cleaning in this section.
Water in Transmission Fluid
To correctly repair an automatic transmission that has had water or coolant introduced into the system,
completely disassemble, clean, and replace the following parts:
z All internal and external seals

z All friction material
z Torque converter
z All parts with bonded seals
z All solenoids
z All transmission fluid filters
Prior to installing the transmission, flush and clean the transmission fluid cooler(s) and the transmission fluid
cooler tubes and hoses. For additional information, refer to Transmission Fluid Cooler Backflushing and
Cleaning in this section.

Shift Point Road Test
Special Tool(s)
This test verifies the shift control system is operating correctly.
1. Bring engine and transmission up to normal operating temperature.
2. Operate vehicle with the selector lever in the D position.
3. Apply minimum throttle and observe speeds when an upshift occurs. Refer to the Shift Speeds chart
in this section.
4. With the selector lever in the D position and speed above 80 km/h (50 mph) and less than half
throttle, move the selector lever from the D position to manual 2 position and release the accelerator
pedal. The transmission should downshift into 2nd gear. With the transmission remaining in the
manual 2 position, move the selector lever into the manual 1 position and release the accelerator
pedal. The transmission should downshift into 1st gear at speeds below approximately 45-56 km/h
(28-35 mph).
5. If the transmission fails to upshift/downshift, refer to Diagnosis By Symptom in this section.
Shift Speeds
Throttle Position Shift Km/H MPH
Light Throttle 1-2 13-21 8-13
Throttle Position (TP) Sensor 2-3 26-34 16-21
Voltage @ 1.25 Volts 3-4 35-43 22-27
4-5 56-64 35-40
5-6 71-79 44-49
Closed Throttle 6-5 56-64 35-40
5-4 40-48 25-30
4-3 13-21 8-13
3-2 3-11 2-7
2-1 2-6 1-4
Wide Open Throttle (WOT) 1-2 45-53 28-33
2-3 87-95 54-59

3-4 140-148 87-92
Road Test — Adaptive Drive Cycle
1. Connect the scan tool to the Data Link Connector (DLC).
2. NOTE: Disconnecting the battery will not clear the Keep Alive Memory (KAM).
NOTE: Do not clear the PCM KAM .
Using the scan tool, clear the adaptive table before conducting an adaptive drive cycle test.
3. Verify the transmission fluid is at normal operating temperature, between 91°-102°C (195°-215°F). If
the transmission fluid is not at operating temperature, drive the vehicle until the operating temperature
is reached.
4. NOTE: The transmission fluid must be at operating temperature before proceeding to this step.
Drive the vehicle on a level road surface performing the adaptive drive cycle.
1. Accelerate from a stop with light throttle to 24 km/h (15 mph) then release the accelerator
pedal.
2. Gently brake and bring the vehicle to a stop and hold the brake for 6 seconds.
3. Repeat substeps 1 and 2 an additional 5 times.
4. Accelerate from a stop with light throttle so the 1-2, 2-3 and 3-4 shifts occur with engine rpm
between 1,700-2,000.
5. Continue accelerating until the vehicle speed reaches 80 km/h (50 mph) or the 5-6 upshift is
reached.
6. Gently brake and bring the vehicle to a stop and hold the brake for 10 seconds.
7. Repeat substeps 4, 5 and 6 an additional 3 times.

Solenoid Body Strategy
Special Tool(s)
Solenoid Body Identification Procedure
1. Using the scan tool, select Powertrain, Transmission and Transmission Solenoid Body Identification
from the toolbox icon and follow the instructions displayed on the scan tool.
The solenoid body identification screen displays solenoid body identification information:
z Solenoid body strategy 13-digits
z Solenoid body identification 12-digits
The next screen displays the current solenoid body identification and strategy data file stored
in the PCM. If the solenoid body strategy field is blank, the module contains a partial
transmission solenoid body strategy. This is due to a corrupt or missing file at the time the
programmable parameters were completed.
NOTE: The 13-digit solenoid body strategy number consists of only numbers. Letters are not used.
2. Compare the solenoid body identification and strategy to the solenoid body identification tag located
on the left side of the transmission case.
Solenoid Strategy Identification Tag
Item Description
1 13-digit solenoid body strategy
2 12-digit solenoid body identification
3. If the solenoid body identification and strategy displayed on the scan tool match the solenoid body
identification tag or replacement tag, then the solenoid body identification and strategy are correct for
this transmission and a solenoid body strategy data download is not required. If the solenoid body
identification tag or replacement tag is missing or damaged so it is not readable or does not match
the identification or strategy displayed on the scan tool, remove the transmission fluid pan and filter
and locate the 13-digit solenoid body strategy etched on the main control casting. For additional
information, refer to Fluid Pan, Gasket and Filter in this section.
Replacement Solenoid Strategy Identification Tag
Item Description
1 13-digit solenoid body strategy
2 12-digit solenoid body identification
4. NOTICE: The 13-digit solenoid body strategy number displayed on the scan tool must match
the solenoid body strategy number etched on the main control. If the numbers do not match,
damage to the transmission or driveability concerns can occur.
NOTICE: If the new main control was not supplied with a replacement solenoid strategy
identification tag, DO NOT INSTALL the main control as all required programming information
will be missing.
Compare the solenoid body strategy identification etched on the main control to the solenoid strategy
identification tag on the transmission case. If the solenoid body strategy identification etched on the
main control does not match the solenoid strategy identification tag then a solenoid body strategy
data download is required. If the solenoid body strategy etched on the main control does match the
solenoid strategy identification tag on the transmission case but does not match the solenoid body
identification and strategy displayed on the scan tool, then a solenoid body strategy data download is
also required.
Main Control Solenoid Body Strategy
1. Using the scan tool, select Module Programming and Programmable Parameters under the toolbox
icon then select transmission. Follow the instructions displayed on the scan tool.
There are fields to enter the 12-digit solenoid body identification and 13-digit solenoid body strategy
recorded from the solenoid body.
2. NOTICE: If the solenoid body information is not correct, transmission damage or driveability
concerns can occur.
Enter the solenoid body identification and strategy.

The scan tool verifies the numbers entered are valid and displays a message if the information is not
valid.
The scan tool checks to see if the file is present on the scan tool. If the file is present, the technician
may proceed with downloading the file to the PCM. If the file is not present, the scan tool will need to
be connected to the Professional Technician Society (PTS) server to download the file onto the scan
tool.
3. Verify the file is present on the scan tool. If the file is present, go to Step 8. If the file is not present,
continue with this procedure.
4. Connect the scan tool to the PTS server.
5. Follow the instructions on the network to download the strategy file to the scan tool.
6. If the scan tool cannot connect to the PTS server, download the file from www.motorcraft.com.
If the scan tool cannot download a strategy from the web site, a partial strategy will automatically be
downloaded.
7. Reconnect the scan tool to the vehicle.
8. Follow the instructions displayed on the scan tool.
9. If a new solenoid body was installed, compare the 12-digit identification and the 13-digit strategy
fields from the solenoid body to the replacement solenoid body tag provided with the solenoid body
service kit and place it over the existing identification tag.
The scan tool automatically downloads the strategy file or partial strategy file to the PCM. The scan
tool displays a message when it is finished downloading the data that states that the file was
downloaded successfully.
10. NOTICE: The customer may feel erratic shifts and driveability concerns if the adaptive drive
cycle has not been performed.
Road test the vehicle following the Adaptive Drive Cycle. For additional information, refer to Shift
Point Road Test in this section.

Special Testing Procedures
The special tests are designed to aid the technician in diagnosing the hydraulic and mechanical portions of
the transmission.
Air Pressure Test
Item Description
1 Intermediate clutch (C) port
2 Low/reverse clutch (D1) port
3 Not used
4 Direct clutch (B) port
5 Overdrive clutch (E) port
6 Forward clutch (A) port
7 Thermal bypass valve
A no-drive condition can exist with correct transmission fluid pressure because of inoperative clutches. Refer
to the Clutch Application Chart to determine the appropriate elements. A clutch concern can be located
through a series of checks by substituting air pressure for fluid pressure to determine the location of the
concern.
Example: When the selector lever is in a forward gear range, a no-drive condition may be caused by an
inoperative clutch.
1. Drain the transmission fluid. Remove the transmission fluid pan.
2. Remove the transmission fluid filter, seal assembly and mechatronic unit.
3. Locate the inoperative clutches by applying air pressure into the appropriate clutch port.
4. Apply air pressure to the appropriate clutch port. A dull thud may be heard or movement felt when a
clutch piston is applied. If the clutch seals or check ball are leaking, a hissing sound may be heard.
5. If the clutches fail to operate during the air check:

z the piston seals are not seated, damaged or installed incorrectly.
z plugged feed holes for clutch apply in the case and/or clutch cylinder.
z damaged piston and/or clutch cylinder.
6. Service as required and recheck.

Torque Converter Diagnosis
Special Tool(s)
NOTE: If the torque converter is replaced, use the scan tool and follow the on-screen instructions and
perform the Misfire Monitor Neutral Profile Correction procedure.
Perform all diagnostic procedures prior to torque converter installation. This prevents the unnecessary
installation of new or remanufactured torque converters. Only after a complete diagnostic evaluation can the
decision be made to install a new torque converter.
Torque Converter Operation Test
The Torque Converter Operation Test verifies the Torque Converter Clutch (TCC) control system and the
torque converter are operating correctly.
1. Connect a scan tool to the vehicle.
2. Perform a self-test and check for DTCs.
3. Bring the engine to normal operating temperature by driving the vehicle at highway speeds in the D
position.
4. After normal operating temperature is reached, maintain a constant speed of about 56 km/h (35 mph)
in 5th gear for 10 seconds.
5. Release the accelerator pedal and monitor the scan tool TP1 PID voltage to approximately 1.25 volts
or 25% throttle.
6. Monitor the TCC_OSC# and RPM# PID. The torque converter should release and engine rpm should
increase before the 5-4 shift occurs.

Transmission Connector Layouts
Transmission Vehicle Harness
Item Description
1 Turbine Shaft Speed (TSS) sensor
2 NOT USED
3 TCC control
4 Transmission Range (TR) sensor
5 Signal return
6 Transmission Fluid Temperature (TFT) sensor power
7 Ignition voltage
8 Shift Solenoid E (SSE) control
9 Shift Solenoid A (SSA) control
10 Shift Solenoid D (SSD) control
11 TR sensor signal return
12 Battery voltage
13 Shift Solenoid C (SSC) control
14 Shift Solenoid B (SSB) control
15 Output Shaft Speed (OSS) sensor
16 LPC solenoid control
Transmission Leadframe Connector
Item Description
1 Turbine Shaft Speed (TSS) sensor
2 NOT USED
3 TCC control
4 Transmission Range (TR) sensor
5 Signal return
6 Transmission Fluid Temperature (TFT) sensor power
7 Ignition voltage
11 TR sensor signal return
12 Battery voltage
15 Output Shaft Speed (OSS) sensor
Molded Leadframe
NOTE: Terminal 7 of the transmission leadframe connector is the common power feed to the solenoids
listed in the following chart.
Item Description
3 Torque Converter Clutch (TCC) control

Transmission Drive Cycle Test
Special Tool(s)
Material
Item Specification
(Canada)
NOTE: The Transmission Drive Cycle Test must be followed exactly. Malfunctions must occur 4 times
consecutively for a shift error DTC to set, and 5 times consecutively for continuous Torque Converter Clutch
(TCC) DTCs to set.
NOTE: Refer to the Solenoid Application Chart for solenoid operation while performing the Transmission
Drive Cycle Test.
After performing the self-test, follow the transmission drive cycle test for checking codes.
1. Record then clear the DTCs.
2. Warm the engine to normal operating temperature.
3. Make sure the transmission fluid level is correct.
4. With the selector lever in Overdrive (O/D), moderately accelerate from stop to 80 km/h (50 mph)
allowing the transmission to shift into 6th gear. Keep vehicle speed and throttle steady for a minimum
of 15 seconds.
5. With the transmission in 6th gear and maintaining steady speed and throttle, lightly apply and release
the brake pedal to operate the stop lamps. Then, hold vehicle speed and throttle steady for a
minimum of 5 seconds.
6. Brake to a stop and remain stopped for a minimum of 20 seconds.
7. Repeat steps 4 through 6 at least 5 times.
8. Perform a self-test and record DTCs.
z If DTCs are present, refer to the DTC Chart. Repair all non-transmission DTCs first as they can
directly affect the operation of the transmission. Repeat the self-test and the road test to verify
the correction. Clear the DTCs. Perform the transmission drive cycle test and repeat the self-
test after completing the repair.
z If the tests pass and a concern is present, refer to Diagnosis By Symptom in this section,
OASIS messages and TSBs for concerns.
After On-Board Diagnostic (OBD)
NOTE: The vehicle wiring harness, PCM and non-transmission sensors may affect transmission operations.
Repair these concerns first.
Repair all DTCs after the On-Board Diagnostic (OBD) test procedures are completed.
Begin with non-transmission related DTCs, then repair transmission related DTCs. Use the DTC Chart for
information on condition and symptoms. This chart will be helpful in referring to the correct manual(s) and
aids in diagnosing internal transmission concerns and external non-transmission inputs. The pinpoint tests
are used in diagnosing transmission electrical concerns. Diagnosis the vehicle wiring harness and the PCM
as well. The Powertrain Control/Emissions Diagnosis (PC/ED) manual aids in diagnosing non-transmission
electronic components.

Visual Inspection
A visual inspection identifies modifications or additions to the vehicle operating system that may affect
diagnosis. Inspect the vehicle for non-Ford factory add-on devices such as:
z Electronic add-on items

z Vehicle modification
PCM or transmission function is affected if add on devices, wiring splices, abnormal tire size or axle ratio
changes are made.
z If leaks are present; refer to Leakage Inspection in this section.

z Correct selector lever adjustments; refer to Section 307-05 .
Selector Lever Check
Check for misadjustment in the selector lever by matching the detents in the selector lever with those of the
manual control lever in the transmission. Refer to Section 307-05 for selector lever cable adjustment.
Hydraulic leakage at the manual control valve can cause delay in engagements and/or slipping while
operating if the linkage is not correctly adjusted. Refer to Section 307-05 for selector lever cable adjustment.
Check TSBs and On-Line Automotive Service Information System (OASIS)
Refer to all TSB and On-Line Automotive Service Information System (OASIS) messages that pertain to the
transmission concern and follow the procedure as described.
Carry Out On-Board Diagnostic (OBD) Key ON Engine OFF (KOEO), Key ON Engine Running (KOER)
After a road test, with the engine and transmission warm and before disconnecting any connectors, use the
scan tool and perform a self-test.

Torque Converter Contamination Inspection
Material
Item Specification
(Canada)
1. A new or remanufactured torque converter must be installed if one or more of the following
statements is true:
z A torque converter malfunction has been determined based on complete diagnostic
procedures.
z The torque converter stud or studs, impeller hub or bushing are damaged.
z The torque converter exhibits external discoloration (due to overheating).
z There is evidence of transmission assembly or fluid contamination due to the following
transmission or converter failure modes.
Major metallic failure
Multiple clutch plates or band failures
Sufficient component wear which results in metallic contamination
Water or antifreeze contamination
2. If none of the above conditions are present, continue with the following fluid inspection.
3. Pour a small amount of transmission fluid from the torque converter onto an absorbent white tissue or
through a paper filter.
4. Examine the fluid for contaminants. The fluid must be free of metallic contaminants.
5. NOTICE: Do not use water-based cleaners or mineral spirits to clean or flush the torque
converter or transmission damage will occur.
If the fluid passed inspection:

z drain the remaining fluid from the torque converter.
z using only the recommended transmission fluid, add 1.9L (2 qt) of clean fluid into the converter
and agitate by hand.
z thoroughly drain the fluid.

Transmission Fluid Cooler Backflushing and Cleaning
Special Tool(s)
Transmission Heated Cooler Line
Flusher
222-00007, 222-00004 or
equivalent
NOTICE: Do not use any supplemental transmission fluid additives or cleaning agents. The use of
these products could cause internal transmission components to fail; this will affect the operation of
the transmission.
NOTE: Transmission fluid cooler backflushing and cleaning will be performed using the Transmission
Heated Cooler Line Flusher or equivalent. Follow the manufacturer's instructions included with the machine.
Test the equipment to make sure that a vigorous fluid flow is present before proceeding.
NOTE: If the Transmission Heated Cooler Line Flusher or equivalent is not available, install a new
transmission fluid cooler and/or an auxiliary transmission fluid cooler.
1. Check and top off the fluid level of the cooler line flusher with transmission fluid.
2. Allow the transmission fluid in the cooler line flusher 15-30 minutes to heat up to 60°C (140°F) before
using.
3. Install the line adapters into the transmission fluid cooler tubes.
4. Attach the cooler line flusher red line to the transmission fluid cooler pressure tube quick connect
fitting.
5. Attach the cooler line flusher blue line to the transmission fluid cooler return tube quick connect fitting.
6. Follow the equipment instructions to purge the transmission fluid cooler tubes and cooler prior to
starting the flushing procedure.
7. Allow the transmission fluid cooling system to backflush for 10-15 minutes, then flush the
transmission fluid cooler in a normal flow direction for an additional 10-15 minutes.

Transmission Fluid Drain and Refill
Special Tool(s)
Rubber Tip Air Nozzle
100-D009 (D93L-7000-A)
Transmission Fluid Fill Tube

307-570
Transporter Fluid
Evacuator/Injector
Vacuum Pump Kit

416-D002 (D95L-7559-A) or
equivalent

Material
Item Specification
(Canada)
Drain
2. Remove the transmission fluid pan and allow the transmission fluid to drain.
3. NOTE: The transmission fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket, if required.
4. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
Refill
NOTICE: This procedure contains the air purge steps required to purge air from the transmission
fluid cooling system. This procedure is NOT intended for use with the Transmission Fluid Level
Check.
NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal failure
could result.
NOTICE: The use of any other transmission fluid than specified can result in the transmission failing
to operate in a normal manner or transmission failure.
NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the
transmission fluid level should be checked.
NOTE: Here is an overview of the Transmission Fluid Drain and Refill procedure.
z Adding 3.3L (3.5 qt) of transmission fluid to the transmission is an initial fill enabling the engine to be
started.
z The cold level range shown in the procedure allows the vehicle to be driven.
z The vehicle should be driven to allow the TFT to reach 91ºC-102ºC (195ºF-215ºF) in order to purge
the air from the transmission fluid cooling system.
z Fill the transmission fluid to the fill range on the transmission fluid level indicator at the normal
operating range 91ºC-102ºC (195ºF-215ºF).
1. NOTE: The transmission will need 3.3L (3.5 qt) of transmission fluid added to the transmission as an
initial fill if:
z a new mechatronic assembly has been installed.
z the transmission fluid pan or transmission fluid filter have been removed.
NOTE: The transmission will need 11.35L (12 qt) of transmission fluid added to the transmission as
an initial fill if the transmission has been overhauled.
Using the Transmission Fluid Fill Tube, add the transmission fluid to the transmission through the
transmission fluid fill hole. For additional information, refer to Adding Additional Transmission Fluid in
this procedure.
2. Check the transmission fluid level cold.

z The vehicle is safe to drive if the transmission fluid is in the cold level range 32°C-43°C (90°F-
110°F).
z Using the scan tool and with the engine running, place the selector lever in each gear position
and hold approximately 5 seconds. Place the selector lever in PARK, with the engine at idle
(600-750 rpm).
3. Separate the transmission fluid level indicator from the transmission fluid fill plug.
4. Wipe the transmission fluid level indicator clean. Reinstall the transmission fluid level indicator only
back into the transmission fluid fill plug hole to check the transmission fluid level. Repeat this until a
consistent reading is established.
5. NOTE: The transmission fluid level indicator has 2 areas for the fluid level, a crosshatched (labeled
A) area and a dotted (labeled B) area. Use the dotted area to check the transmission fluid level.
Using the scan tool, verify that the TFT is between 91ºC-102ºC (195ºF-215ºF). Do not overfill the
transmission. The transmission fluid level must be at the upper level of the dotted (B) marked area on
the transmission fluid level indicator.
6. Install the transmission fluid fill plug.

7. While driving the vehicle, use the scan tool to verify that the TFT has reached a temperature of 91°C
(195°F). This will circulate the transmission fluid through the torque converter and the transmission
fluid cooling system, eliminating any trapped air in the transmission fluid cooling system.
z With the engine idling (600-750 rpm) in PARK, verify that the TFT is between 91ºC-102ºC
(195ºF-215ºF).
8. Remove the transmission fluid fill plug transmission fluid level indicator assembly located on the
passenger side front portion of the transmission case.
A) area and a dotted (labeled B) area. Use the dotted (labeled B) area when checking the
transmission fluid level. The correct transmission fluid level is at the upper level of the dotted marks
on the transmission fluid level indicator.
Using the scan tool verify that the TFT is between 91ºC-102ºC (195ºF-215ºF). The transmission fluid
level must be at the upper level of the dotted (B) mark.
12. NOTE: If the transmission fluid is not at the correct level, follow the steps for Adding Additional
Transmission Fluid or Removing Transmission Fluid in this procedure.
Install the transmission fluid fill plug.

Adding Additional Transmission Fluid
NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in
PARK.
1. Install the Transmission Fluid Fill Tube into the transmission fluid fill hole.
2. Fill the Transporter Fluid Evacuator/Injector with approximately 0.47L (1 pt) of transmission fluid.
3. Hang the Transporter Fluid Evacuator/Injector under the vehicle, upright and close to the
transmission.
4. Connect the Transporter Fluid Evacuator/Injector and Transmission Fluid Fill Tube.
z Connect the open end of the fluid hose from the Transporter Fluid Evacuator/Injector onto the
Transmission Fluid Fill Tube from the transmission case.
5. Use a Rubber Tip Air Nozzle to apply a maximum of 206.85 kPa (30 psi) to the open end of the
vacuum/pressure hose from the Transporter Fluid Evacuator/Injector. Transmission fluid will
immediately start flowing out of the Transporter Fluid Evacuator/Injector into the transmission.
6. NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the
dotted mark.
Reinstall the transmission fluid level indicator only back into the transmission fluid fill plug hole to
check the transmission fluid level. Repeat this until a consistent reading is established.
Using the scan tool, verify that the TFT is between 91ºC-102ºC (195ºF-215ºF). The transmission fluid
8. NOTE: If the transmission fluid is over full, follow the steps for Removing Transmission Fluid in this
procedure.

Removing Transmission Fluid
NOTE: To get an accurate transmission fluid level reading the engine should be idling (600-750 rpm) in
PARK.
1. If the transmission is overfilled, transmission fluid must be removed to the correct level. Use the
Transporter Fluid Evacuator/Injector and the Vacuum Pump Kit to extract any excessive transmission
fluid.
Using the scan tool, verify that the TFT is between 91ºC-102ºC (195ºF-215ºF). The transmission fluid
3. Install the transmission fluid fill plug.


Transmission Fluid Exchange
Special Tool(s)
ATF Fluid Exchanger W/Power
Steering Fluid Exchanger

Material
Item Specification
(Canada)
NOTICE: Use transmission fluid specific for this transmission. Do not use any supplemental
transmission fluid additives or cleaning agents. The use of these products can cause internal
transmission components to fail, which will affect the operation of the transmission.
NOTE: For best results, perform the transmission cooler backflush and cleaning procedure before
exchanging the fluid.
02 .
2. Connect the ATF Fluid Exchanger W/Power Steering Fluid Exchanger to the transmission fluid cooler
tube after the transmission fluid cooler on the return tube. This will help remove any foreign material
trapped in the transmission fluid coolers.
3. Perform the transmission fluid exchange using the ATF Fluid Exchanger W/Power Steering Fluid
Exchanger. Follow the manufacturer's instructions included with the machine.
4. Once the transmission fluid exchange is completed, disconnect the ATF Fluid Exchanger W/Power
Steering Fluid Exchanger. Reconnect any disconnected transmission fluid cooler tubes.
5. Using the scan tool with the engine running, check and make sure that the transmission is at normal
operating temperature 91ºC-102ºC (195ºF-215ºF). Check and adjust the transmission fluid level and
check for any leaks. If transmission fluid is needed, add transmission fluid in increments of 0.24L (0.5
pt) until the correct level is achieved.

Transmission Fluid Level Check
Special Tool(s)
Material
Item Specification
(Canada)
NOTICE: The vehicle should not be driven if the transmission fluid level is low as internal failure
could result.
NOTE: If the vehicle has been operated for an extended period at high highway speeds, in city traffic, during
hot weather or while pulling a trailer, the transmission fluid must cool down to obtain an accurate reading.
NOTE: If the transmission starts to slip, shifts slowly or shows signs of transmission fluid leaking, the
transmission fluid level should be checked.
NOTE: Do not overfill the transmission. The transmission fluid level must be at the upper level of the
crosshatch mark.
NOTE: If the installation of a new transmission fluid cooler or transmission fluid cooler tubes has been
carried out, the vehicle must be driven to get the transmission fluid to a temperature of 89°C (193°F) in order
to purge the air from the transmission fluid cooling system.
1. With the engine running, place the transmission selector lever in each gear position and hold
approximately 5 seconds. Place the transmission selector lever in PARK.
2. With the engine idling (600-750 rpm) in PARK, position it on a hoist. For additional information, refer
to Section 100-02 .
3. Remove the transmission fluid fill plug transmission fluid level indicator assembly, located on the
back into the transmission fluid fill plug hole to check the transmission fluid level.
Using the scan tool verify that the TFT is between 89ºC-102ºC (193ºF-215ºF). The transmission fluid
Transmission Fluid or Removing Transmission Fluid. For additional information, refer to Transmission
Fluid Drain and Refill in this section.


Transmission — Early Build
Special Tool(s)
Fixture
100-002 (TOOL-4201-C)
Drawbar (Heavy Duty Threaded)

204-029 (T77F-1176)
End Play Gauge, Transmission

307-534
Handle, Torque Converter

307-091 (T81P-7902-C)
Installer, 6R80 Rear Seal 4X4

307-637

307-638
Installer, Fluid Pump Seal

307-556
Installer, Front Wheel Hub Oil

Seal
205-276 (T88T-1175-AH)
Installer, Shifter Fluid Seal

307-559
Output Shaft Bearing Installer

307-647
Remover/Installer, 6R80 Rear

Bearing
307-639

Pump
307-553
Retaining Ring Pliers

307-343 (T95P-77001-AHR)
Material
Item Specification
(Canada)
Motorcraft® 6R ATF Additive Kit —

XL-16
Disassembled Views
Part
1 N800750- Flexplate-to-torque converter nut (4 required)
S437
2 7902 Torque converter
3 7A103 Pump assembly
4 7A248 Front pump oil seal
5 — Pump body (part of 7A103)
6 7A248 Front pump inner oil seal
7 7N134 Front pump-to-case bolt (13 required)
8 7A103 Front pump assembly
9 W707871- Bolt — attaches pump to pump adapter assembly (11
S300 required)
10 7A248 Front pump outer oil seal
11 7D019 Clutch support fluid seal
12 7L323 Front pump support seal
13 — Forward (A) clutch assembly
14 7D014 Front pump selective washer
15 7A360 Forward (A) clutch cylinder and hub assembly
16 7A548 Forward (A) clutch inner piston seal
17 7A548 Forward (A) clutch outer piston seal
18 7A262 Forward (A) clutch piston
19 7A480 Forward (A) clutch piston retaining spring
20 7H360 Forward (A) clutch balance piston assembly
21 7A548 Forward (A) clutch balance piston outer seal
22 7H365 Forward (A) clutch balance piston snap ring
23 7E085 Forward (A) clutch cushion spring
24 7E314 Forward (A) clutch steel plates (externally splined)
(quantity model dependent)
25 7B164 Forward (A) clutch friction plates (internally splined)
26 7B066 Forward (A) clutch pressure plate
27 7D483 Pressure plate retaining snap ring
28 7D063 Front planetary sun gear (No. 1)
29 7H375 Bearing (T1)
30 — Front planetary carrier assembly snap ring (part of
7A398)
31 7A398 Front planetary carrier assembly
32 7L339 Plate transmission fluid collector
33 7L495 Bearing (T2)
34 — Overdrive (E) clutch assembly
35 7G091 Turbine shaft seals (3 required)
36 7F207 Input shaft
37 7A548 Overdrive (E) clutch piston outer seal

38 7A548 Overdrive (E) clutch piston inner seal
39 7A262 Overdrive (E) clutch piston
40 7B070 Overdrive clutch piston spring
41 7A548 Balance piston outer seal
42 7H360 Overdrive (E) balance piston
43 7C122 Balance piston snap ring
44 7B442 Overdrive (E) clutch steel plates (externally splined)
45 7B164 Overdrive (E) clutch friction plates (internally splined)
46 7B066 Overdrive (E) pressure plate
47 7D483 Overdrive (E) clutch retaining ring
48 7C096 Bearing (T3)
49 7F351 Intermediate (C) clutch shaft
51 7B067 Sun gear hub and shaft assembly
52 7F236 Direct (B) clutch hub
53 7C122 Direct (B) clutch cylinder retaining ring
54 7D483 Direct (B) clutch pressure plate retaining ring
55 — Direct (B) clutch assembly (clutch B)
56 7B066 Direct (B) clutch pressure plate
57 7B164 Direct (B) clutch friction plates (internally splined)
58 7B442 Direct (B) clutch steel plates (externally splined)
59 7E085 Direct (B) clutch cushion plate
60 7C096 Roller bearing (T5)
61 7A577 Direct (B) clutch piston retaining ring
62 7A262 Direct (B) clutch balance piston
63 7A548 Direct (B) clutch balance seal
64 7B488 Direct (B) clutch piston return spring
65 — Direct (B) clutch piston
66 7A548 Direct (B) clutch piston outer seal
67 7C099 Direct (B) clutch piston inner seal
68 7F283 Direct (B) clutch cylinder
69 7D020 Shell cylinder seals (2 required)
70 7D483 Center support retaining ring
71 — Intermediate (C) clutch assembly
72 7D483 Intermediate (C) clutch pressure plate retaining ring
73 7B066 Intermediate (C) clutch pressure plate
74 7B442 Intermediate (C) clutch steel plates (externally

splined) (quantity model dependent)
75 7B164 Intermediate (C) clutch friction plates (internally
76 7E085 Intermediate (C) clutch pressure plate spring
77 7A577 Intermediate (C) clutch retaining ring
78 7B043 Intermediate (C) clutch ring
79 7A480 Intermediate (C) clutch piston spring
80 7E005 Intermediate (C) clutch piston
81 7F225 Intermediate (C) clutch piston inner seal
82 7F224 Intermediate (C) clutch piston outer seal
83 7F373 Bearing (T6)
84 7B220 Center support keys (2 required)
85 7G199 Center support feed tube seal (black)
86 7G087 Center support feed tube seal (green)
87 7G084 Center support feed tube seal (blue)
88 7G033 Center support assembly
89 7D404 Low/reverse clutch piston center seal
90 7D403 Low/reverse clutch piston outer seal
91 7A262 Low/reverse clutch piston
92 7B070 Low/reverse clutch piston return spring
93 7H318 Low/reverse clutch piston retainer
94 7D483 Retainer transmission-snap ring
95 7E085 Clutch disc cushion plate
96 7B442 Low/reverse clutch steel plates (externally splined)
97 7B164 Low/reverse clutch friction plates (internally splined)
98 7B066 Low/reverse clutch pressure plate (select fit)
99 7A089 OWC
100 7F405 Thrust gear shim (select fit)
101 7C041 Thrust bearing (T7)
102 7D063 Sun gear No. 2
103 7D235 Thrust bearing outer race
104 7D234 Roller bearing (T8)
107 — Roller bearing race (T9)
108 7D006 Rear planetary carrier assembly
109 — Fluid collar rear planetary plate (part of 7D006)
110 7A153 Output shaft ring gear assembly
111 7G178 Thrust Bearing (T10)

112 7060 Output shaft park gear assembly
113 7N194 Output shaft retaining ring
114 7B368 Bearing (T11)
115 7005 Transmission case assembly (model dependent)
116 7A010 Transmission case fluid fill plug assembly
117 7H398 Transmission case fluid fill plug
118 7A010 Transmission case fluid fill seal
119 7A010 Transmission oil level indicator
120 7034 Transmission case vent assembly (model
dependent)
121 7A415 Output shaft bearing assembly ( RWD )
122 7A415 Output shaft bearing assembly ( 4WD )
123 7A433 Washer ( RWD )
124 7B368 Thrust bearing (T12) ( RWD )
125 7030 Output shaft bearing snap ring ( 4WD )
126 7N357 Slip plane washer ( RWD )
127 7052 Output shaft seal ( RWD )
128 7052 Output shaft seal ( 4WD )
129 7089 Output shaft flange ( RWD )
130 7052 Output shaft flange seal ( RWD )
131 7045 Output shaft flange retaining nut ( RWD )
132 7E332 Manual valve detent spring
133 W711235- Manual valve detent spring retaining screw and
S300 washer
134 7A232 Park pawl actuator rod
135 7A441 Park pawl
136 7D070 Park pawl return spring
137 7D071 Park pawl shaft
138 7H398 Plug assembly transmission case housing
139 7G101 Park rod actuating plate
140 W711235- Park pawl abutment retaining screw and washer
S300
141 W708455- Manual control lever nut
S441
142 7A256 Manual control lever
143 7B498 Manual control lever shaft seal
144 7C493 Manual control lever shaft
145 7A209 Manual control lever shaft spacer
146 7A115 Manual valve detent lever assembly
147 7G100 Manual valve detent lever retaining pin

148 7F277 OWC bias spring
149 7H322 Thermal bypass valve
150 7F401 Front pump adapter seal
151 7A100 Main control assembly
152 — Main control valve body assembly (part of 7A100)
153 7Z490 Main control valve body separator plate
154 — Lower main control valve body (part of 7A100)
156 7G276 Bulkhead connector sleeve
157 7A248 Bulkhead connector sleeve seals
160 — Transmission fluid pan magnet
161 7A191 Transmission fluid pan gasket
162 7A194 Transmission fluid pan
163 W500214- Transmission fluid pan bolt
S437
NOTE: Clutch plate quantity is model dependant based on engine displacement. Refer to Clutch Plate
Quantity chart in the Specifications portion of this section.
All vehicles
1. Install the park detent spring and the 2 bolts.

2. Position the park pawl and spring into the case and install the park pawl pin.
1. Park pawl
2. Park pawl return spring
3. Park pawl pin
3. Install the park pawl pin bolt.

4. Install a new manual control lever shaft seal on the Shifter Fluid Seal Installer.
5. Using the Shifter Fluid Seal Installer, install the manual control lever shaft seal.
6. Assemble the manual control lever detent plate assembly and park pawl actuator rod.
7. Position the manual valve detent lever and park pawl actuator rod assembly in the transmission case.
8. Position the manual control lever spacer in place and slide the manual control lever shaft into the
case and the manual lever detent plate.
1. Manual control lever spacer
2. Manual control lever shaft
3. Manual control lever detent plate
9. Align the roll pin hole in the manual control lever detent plate with the roll pin hole in the manual
control lever shaft and install a new roll pin.
10. Install the park rod actuating plate and the 4 bolts.
11. If removed, position a new bearing on the Output Shaft Bearing Installer. Install the bearing with the
flat bearing surface facing down and the rounded bearing surface facing up so that when installed,
the flat surface is on the snap ring side and the rounded surface is on the transmission case side.
1. Rounded bearing surface facing up
2. Flat bearing surface facing down
12. Using the Output Shaft Bearing Installer, the Drawbar and the Front Wheel Hub Oil Seal Installer,
install the bearing in the transmission case.
14. Install the bearing on the 6R80 Rear Bearing Remover/Installer.
15. Assemble the Front Wheel Hub Oil Seal Installer and the 6R80 Rear Bearing Remover/Installer on
the Drawbar and install the bearing in the transmission case.
16. Position the thrust bearing spacer.
17. Using the 6R80 Rear Bearing Remover/Installer and a press, press the thrust bearing spacer in
place.
18. Install the T12 thrust bearing.
All vehicles
19. Install the T11 bearing, on the planetary ring gear and output shaft assembly.
20. Install the rear planetary ring gear and output shaft assembly.
21. Install the T10 thrust bearing on the output shaft assembly.
22. Install the T9 roller bearing race into the bottom of the carrier.
23. Install the top T8 and the bottom T9 roller bearings onto the sun gear.
24. NOTE: When installing the sun gear, make sure that the TAPERED EDGE is facing UP toward the
torque converter housing.
Install the sun gear into the planetary assembly.
25. NOTE: Be sure the bearing race is installed in the sun gear.
Install the low/reverse sun gear and bearing race into the planetary carrier with the race side facing
down.
1. Low/reverse sun gear
2. Bearing race
26. NOTE: Place the manual control lever in PARK when installing the rear planetary gearset to hold the
rear ring gear stationary.
Install the planetary carrier.
27. NOTE: Friction and steel plate quantity are model dependent and vary based on engine
displacement. For additional information, refer to the Clutch Plate Quantity Chart in the Specifications
portion of this section.
Soak the low/reverse clutch plates in clean automatic transmission fluid.
28. Install the low/reverse clutch plates, starting with the pressure plate and alternating between the
friction and steel plates and ending with the wave spring plate on the top.
29. NOTE: Inspect the T7 thrust bearing and selective shim for damage or scoring.
Install the T7 thrust bearing and the selective shim.
30. NOTE: Align the OWC in the transmission case so the bias spring fits into the transmission case.
Install the OWC as shown so the bias spring can be installed as shown.
31. Install the bias spring.
32. NOTE: Make sure that when installing the center support the feed holes on the center support are
lined up with the feed holes in the case.
Install the center support into the case.
33. NOTICE: Install the snap ring with the beveled surface facing up and the snap ring gap in the 3
o'clock or the 9 o'clock position.
NOTE: Rotate the case to a horizontal position.
Using the Retaining Ring Pliers, install the center support snap ring. Make sure the snap ring is fully
seated.
34. Install the seal protector provided with the new output shaft seal on the output shaft.
35. Slide the output shaft seal over the output shaft seal protector onto the output shaft. Remove the
output shaft seal protector.
36. Using the 6R80 Rear Seal 4X4 Installer, install the output shaft seal.
37. Rotate the transmission to the vertical position and install the slip plane washer.
38. Position a new output shaft seal on the 6R80 4X2 Rear Seal Installer.
40. Install the output shaft flange and the output shaft flange seal.
41. Loosely install a new output shaft flange retaining nut.
42. Install the Dial Indicator Gauge with Holding Fixture on the transmission case and position the
plunger on the output shaft flange.
43. NOTE: Loosely install the flange nut or an inaccurate reading may be recorded.
Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft flange and record the
reading. The reading should be within 0.6-0.9 mm (0.024-0.035 in).
z If the reading is not within specification, install a different (either thinner or thicker) selective
shim.
44. Tighten the output shaft flange retaining nut.

z After installing the new output shaft flange retaining nut, stake the slots to prevent it from
coming loose.
plunger on the output shaft.
46. Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft and record the reading.
The reading should be within 0.15-0.35 mm (0.005-0.013 in).
z If the reading is not within the specification, install a different (either thinner or thicker) select fit
thrust gear shim.
All vehicles
47. Rotate the transmission in the vertical position with the torque converter housing facing up and install
the T6 bearing.
48. Install the direct (B) clutch assembly.
49. Install the T5 roller bearing on the direct (B) clutch assembly.
50. Install the forward (A)/overdrive (E) clutch assembly.
51. Install the selective shim.
52. If the front pump was not disassembled and assembled, install a new front pump O-ring seal and
lubricate it with petroleum jelly.
53. Install a new front pump seal on the Fluid Pump Seal Installer.
54. Using the Fluid Pump Seal Installer, install the front pump seal.
55. Install the Transmission Fluid Pump Remover on the front pump.
56. Lubricate the transmission case pump bore with petroleum jelly. Using the Transmission Fluid Pump
Remover, position the pump assembly in the case and rotate the pump to insert the pump splines into
the front planetary sun gear. Rotate the pump to align the pump-to-case bolts and push the pump into
the case.
57. NOTE: Failure to replace the fasteners will result in transmission fluid leakage.
Install 13 new front pump-to-case bolts and washers. Tighten in a crisscross pattern.
z Tighten pump fasteners with washers to 10 Nm (89 lb-in).
z Tighten fasteners without washers to 10 Nm (89 lb-in).
58. Install the Transmission End Play Gauge on the input shaft to measure the end play.
z Tighten the wing nut.
59. Install the Dial Indicator Gauge with Holding Fixture on the Transmission End Play Gauge.
z Push down on the Transmission End Play Gauge and zero the Dial Indicator Gauge.
z Lift up on the Transmission End Play Gauge and record the measurement on the Dial Indicator
Gauge. The measurement should be between 0.2-0.4 mm (0.008-0.015 in). If the
measurement is not within specification, install a new selective front pump shim.
z Measure the original shim, install a thinner or a thicker shim to achieve the correct
measurement.
60. Rotate the transmission in the horizontal position with the main control area facing up and install 3
new center support feed tube seals.
1. Center support feed tube seal (7G199 Black)
2. Center support feed tube seal (7G087 Green)
3. Center support feed tube seal (7G084 Blue)
61. NOTE: Make sure the transmission fluid filter seal has been removed. If it has not, use a suitable pick
and remove the seal.
NOTE: Add 0.118L (4 oz) of clean transmission fluid to prime the pump.
Install the front pump adapter seal and prime the fluid pump.
62. Install the thermal bypass valve into the case.
63. Align the guide pins in the alignment holes in the transmission case and position the mechatronic
assembly in place.
1. Alignment holes
2. Guide pins
64. NOTE: The mechatronic assembly will not lay flush on the case, this is a normal condition with the
rubber feed tubes, the bolts will pull the mechatronic assembly down.
Slightly lift the mechatronic assembly and align the manual valve in the manual valve linkage and
position the mechatronic in place.
65. Install the 11 mechatronic assembly bolts and tighten in the sequence shown.
66. If removed, install the bulkhead connector sleeve seals.
67. With the release tab up and unlocked, push the outer shell of the bulkhead connector sleeve into the
transmission. Make sure the bulkhead connector sleeve is fully seated into the molded leadframe.
68. Press down on the tab and lock the outer shell of the bulkhead connector sleeve in place. Make sure
the locking tab is securely locked.
69. Install a new transmission fluid filter.
70. NOTE: The fluid pan gasket can be reused if not damaged.
Install a new transmission fluid pan gasket if required.
71. Install the transmission fluid pan and transmission fluid pan bolts. Tighten in a crisscross pattern.
72. Using the Torque Converter Handle, install the torque converter.
73. If the Overdrive clutch FRICTIONS were replaced, install 1 6R ATF Additive Kit XL-16.

Transmission — Late Build
Special Tool(s)
Fixture
100-002 (TOOL-4201-C)
Drawbar (Heavy Duty Threaded)

204-029 (T77F-1176)
End Play Gauge, Transmission

307-534

307-091 (T81P-7902-C)

307-556

Seal
205-276 (T88T-1175-AH)
Installer, Needle Bearing

307-714
Installer, Output Seal (4X2)

307-715

307-637
Installer, Roller Bearing

307-713

307-559
Installer, Spindle/Axle Shaft

205-199 (T83T-3132-A1)

Pump
307-553

307-343 (T95P-77001-AHR)
Material
Item Specification
(Canada)
Motorcraft® 6R ATF Additive Kit —
XL-16
Disassembled Views
Part
1 N800750- Flexplate-to-torque converter nut (4 required)
S437
2 7902 Torque converter
3 7A103 Pump assembly
6 7A248 Front pump inner oil seal
7 7N134 Front pump-to-case bolt (13 required)
8 7A103 Front pump assembly
9 W707871- Bolt — attaches pump to pump adapter assembly (11
S300 required)
10 7A248 Front pump outer oil seal
13 — Forward (A) clutch assembly
14 7D014 Front pump selective washer
15 7A360 Forward (A) clutch cylinder and hub assembly
16 7A548 Forward (A) clutch inner piston seal
17 7A548 Forward (A) clutch outer piston seal
18 7A262 Forward (A) clutch piston
19 7A480 Forward (A) clutch piston retaining spring
20 7H360 Forward (A) clutch balance piston assembly
21 7A548 Forward (A) clutch balance piston outer seal
22 7H365 Forward (A) clutch balance piston snap ring
23 7E085 Forward (A) clutch cushion spring
24 7E314 Forward (A) clutch steel plates (externally splined)
25 7B164 Forward (A) clutch friction plates (internally splined)
26 7B066 Forward (A) clutch pressure plate
27 7D483 Pressure plate retaining snap ring
28 7D063 Front planetary sun gear (No. 1)
30 — Front planetary carrier assembly snap ring (part of
7A398)
31 7A398 Front planetary carrier assembly
32 7L339 Plate transmission fluid collector
33 7L495 Bearing (T2)
34 — Overdrive (E) clutch assembly
35 7G091 Turbine shaft seals (3 required)
36 7F207 Input shaft
37 7A548 Overdrive (E) clutch piston outer seal

38 7A548 Overdrive (E) clutch piston inner seal
39 7A262 Overdrive (E) clutch piston
40 7B070 Overdrive clutch piston spring
41 7A548 Balance piston outer seal
42 7H360 Overdrive (E) balance piston
43 7C122 Balance piston snap ring
44 7B442 Overdrive (E) clutch steel plates (externally splined)
45 7B164 Overdrive (E) clutch friction plates (internally splined)
46 7B066 Overdrive (E) pressure plate
47 7D483 Overdrive (E) clutch retaining ring
49 7F351 Intermediate (C) clutch shaft
51 7B067 Sun gear hub and shaft assembly
52 7F236 Direct (B) clutch hub
53 7C122 Direct (B) clutch cylinder retaining ring
54 7D483 Direct (B) clutch pressure plate retaining ring
55 — Direct (B) clutch assembly (clutch B)
56 7B066 Direct (B) clutch pressure plate
57 7B164 Direct (B) clutch friction plates (internally splined)
58 7B442 Direct (B) clutch steel plates (externally splined)
59 7E085 Direct (B) clutch cushion plate
60 7C096 Roller bearing (T5)
61 7A577 Direct (B) clutch piston retaining ring
62 7A262 Direct (B) clutch balance piston
63 7A548 Direct (B) clutch balance seal
64 7B488 Direct (B) clutch piston return spring
65 — Direct (B) clutch piston
66 7A548 Direct (B) clutch piston outer seal
67 7C099 Direct (B) clutch piston inner seal
68 7F283 Direct (B) clutch cylinder
69 7D020 Shell cylinder seals (2 required)
71 — Intermediate (C) clutch assembly
72 7D483 Intermediate (C) clutch pressure plate retaining ring
73 7B066 Intermediate (C) clutch pressure plate
74 7B442 Intermediate (C) clutch steel plates (externally

75 7B164 Intermediate (C) clutch friction plates (internally
76 7E085 Intermediate (C) clutch pressure plate spring
77 7A577 Intermediate (C) clutch retaining ring
78 7B043 Intermediate (C) clutch ring
79 7A480 Intermediate (C) clutch piston spring
80 7E005 Intermediate (C) clutch piston
81 7F225 Intermediate (C) clutch piston inner seal
82 7F224 Intermediate (C) clutch piston outer seal
85 7G199 Center support feed tube seal (black)
86 7G087 Center support feed tube seal (green)
87 7G084 Center support feed tube seal (blue)
88 7G033 Center support assembly
89 7D404 Low/reverse clutch piston center seal
90 7D403 Low/reverse clutch piston outer seal
92 7B070 Low/reverse clutch piston return spring
93 7H318 Low/reverse clutch piston retainer
94 7D483 Retainer transmission-snap ring
95 7E085 Clutch disc cushion plate
96 7B442 Low/reverse clutch steel plates (externally splined)
97 7B164 Low/reverse clutch friction plates (internally splined)
98 7B066 Low/reverse clutch pressure plate (select fit)
99 7A089 OWC
100 7F405 Thrust gear shim (select fit)
101 7C041 Thrust bearing (T7)
103 7D235 Thrust bearing outer race
107 — Roller bearing race (T9)
108 7D006 Rear planetary carrier assembly
109 — Fluid collar rear planetary plate (part of 7D006)
110 7A153 Output shaft ring gear assembly
111 7G178 Thrust Bearing (T10)

112 7060 Output shaft park gear assembly
113 7N194 Output shaft retaining ring
114 7B368 Bearing (T11)
115 7005 Transmission case assembly (model dependent)
116 7A010 Transmission case fluid fill plug assembly
117 7H398 Transmission case fluid fill plug
118 7A010 Transmission case fluid fill seal
119 7A010 Transmission oil level indicator
120 7034 Transmission case vent assembly (model
dependent)
121 7A415 Output shaft bearing assembly (all models)
122 7030 Output shaft bearing snap ring (all models)
123 7052 Output shaft seal ( 4WD )
124 7R205 Output shaft ball bearing ( RWD )
125 7030 Output shaft ball bearing snap ring ( RWD )
126 7N135 Slip plane washer ( RWD )
127 7052 Output shaft seal ( RWD )
128 7A021 Output shaft flange ( RWD )
129 7052 Output shaft flange seal ( RWD )
130 7045 Output shaft flange retaining nut ( RWD )
131 7E332 Manual valve detent spring
132 W711235- Manual valve detent spring retaining screw and
S300 washer
133 7A232 Park pawl actuator rod
134 7A441 Park pawl
135 7D070 Park pawl return spring
136 7D071 Park pawl shaft
137 7H398 Plug assembly transmission case housing
138 7G101 Park rod actuating plate
139 W711235- Park pawl abutment retaining screw and washer
S300
140 W708455- Manual control lever nut
S441
141 7A256 Manual control lever
142 7B498 Manual control lever shaft seal
143 7C493 Manual control lever shaft
144 7A209 Manual control lever shaft spacer
145 7A115 Manual valve detent lever assembly
146 7G100 Manual valve detent lever retaining pin
147 7F277 OWC bias spring

148 7H322 Thermal bypass valve
149 7F401 Front pump adapter seal
150 7A100 Main control assembly
151 — Main control valve body assembly (part of 7A100)
153 — Lower main control valve body (part of 7A100)
155 7G276 Bulkhead connector sleeve
156 7A248 Bulkhead connector sleeve seals
159 — Transmission fluid pan magnet
160 7A191 Transmission fluid pan gasket
161 7A194 Transmission fluid pan
162 W500214- Transmission fluid pan bolt
S437
NOTE: Clutch plate quantity is model dependant based on engine displacement. Refer to Clutch Plate
Quantity chart in the Specifications portion of this section.
All vehicles
1. Install the park detent spring and the 2 bolts.

2. Position the park pawl and spring into the case and install the park pawl pin.
1. Park pawl
3. Park pawl pin
3. Install the park pawl pin bolt.

4. Install a new manual control lever shaft seal on the Shifter Fluid Seal Installer.
5. Using the Shifter Fluid Seal Installer, install the manual control lever shaft seal.
6. Assemble the manual control lever detent plate assembly and park pawl actuator rod.
7. Position the manual valve detent lever and park pawl actuator rod assembly in the transmission case.
8. Position the manual control lever spacer in place and slide the manual control lever shaft into the
case and the manual lever detent plate.
1. Manual control lever spacer
2. Manual control lever shaft
3. Manual control lever detent plate
9. Align the roll pin hole in the manual control lever detent plate with the roll pin hole in the manual
control lever shaft and install a new roll pin.
10. Install the park rod actuating plate and the 4 bolts.
11. If removed, position a new bearing on the Needle Bearing Installer. Install the bearing with the flat
bearing surface facing down and the rounded bearing surface facing up so that when installed, the
flat surface is on the snap ring side and the rounded surface is on the transmission case side.
1. Rounded bearing surface facing up
2. Flat bearing surface facing down
12. NOTE: RWD case shown, 4WD case similar.
Assemble the Front Wheel Hub Oil Seal Installer and the Needle Bearing Installer on the Drawbar
and install the bearing in the transmission case.
Install the snap ring.
14. Install the bearing on the Roller Bearing Installer.
15. Assemble the Front Wheel Hub Oil Seal Installer and the Roller Bearing Installer on the Drawbar and
install the bearing in the transmission case.
All vehicles
17. Install the T11 bearing, on the planetary ring gear and output shaft assembly.
18. Install the rear planetary ring gear and output shaft assembly.
19. Install the T10 thrust bearing on the output shaft assembly.
20. Install the T9 roller bearing race into the bottom of the carrier.
21. Install the top T8 and the bottom T9 roller bearings onto the sun gear.
22. NOTE: When installing the sun gear, make sure that the TAPERED EDGE is facing UP toward the
torque converter housing.
Install the sun gear into the planetary assembly.
23. NOTE: Be sure the bearing race is installed in the sun gear.
Install the low/reverse sun gear and bearing race into the planetary carrier with the race side facing
down.
1. Low/reverse sun gear
2. Bearing race
24. NOTE: Place the manual control lever in PARK when installing the rear planetary gearset to hold the
rear ring gear stationary.
Install the planetary carrier.
25. NOTE: Friction and steel plate quantity are model dependent and vary based on engine
displacement. For additional information, refer to the Clutch Plate Quantity Chart in the Specifications
portion of this section.
Soak the low/reverse clutch plates in clean automatic transmission fluid.
26. Install the low/reverse clutch plates, starting with the pressure plate and alternating between the
friction and steel plates and ending with the wave spring plate on the top.
27. NOTE: Inspect the T7 thrust bearing and selective shim for damage or scoring.
Install the T7 thrust bearing and the selective shim.
28. NOTE: Align the OWC in the transmission case so the bias spring fits into the transmission case.
Install the OWC as shown so the bias spring can be installed as shown.
29. Install the bias spring.
30. NOTE: Make sure that when installing the center support the feed holes on the center support are
lined up with the feed holes in the case.
Install the center support into the case.
31. NOTICE: Install the snap ring with the beveled surface facing up and the snap ring gap in the 3
o'clock or the 9 o'clock position.
NOTE: Rotate the case to a horizontal position.
Using the Retaining Ring Pliers, install the center support snap ring. Make sure the snap ring is fully
seated.
35. Rotate the transmission to the vertical position and install the slip plane washer.
36. Position a new output shaft seal on the Output Seal (4X2) Installer and Spindle/Axle Shaft Installer.
37. Using the Output Seal (4X2) Installer and Spindle/Axle Shaft Installer, install the output shaft seal.
39. Loosely install a new output shaft flange retaining nut.
plunger on the output shaft flange.
41. NOTE: Loosely install the flange nut or an inaccurate reading may be recorded.
Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft flange and record the
reading. The reading should be within 0.6-0.9 mm (0.024-0.035 in).
z If the reading is not within specification, install a different (either thinner or thicker) selective
shim.
42. Tighten the output shaft flange retaining nut.

43. After installing the new output shaft flange retaining nut, stake the slots to prevent it from coming
loose.
plunger on the output shaft.
45. Using the Dial Indicator Gauge with Holding Fixture, lift up on the output shaft and record the reading.
The reading should be within 0.15-0.35 mm (0.005-0.013 in).
z If the reading is not within the specification, install a different (either thinner or thicker) select fit
thrust gear shim.
All vehicles
46. Rotate the transmission in the vertical position with the torque converter housing facing up and install
the T6 bearing.
47. Install the direct (B) clutch assembly.
48. Install the T5 roller bearing on the direct (B) clutch assembly.
49. Install the forward (A)/overdrive (E) clutch assembly.
50. Install the selective shim.
51. If the front pump was not disassembled and assembled, install a new front pump O-ring seal and
lubricate it with petroleum jelly.
52. Install a new front pump seal on the Fluid Pump Seal Installer.
53. Using the Fluid Pump Seal Installer, install the front pump seal.
54. Install the Transmission Fluid Pump Remover on the front pump.
55. Lubricate the transmission case pump bore with petroleum jelly. Using the Transmission Fluid Pump
Remover, position the pump assembly in the case and rotate the pump to insert the pump splines into
the front planetary sun gear. Rotate the pump to align the pump-to-case bolts and push the pump into
the case.
56. NOTE: Failure to replace the fasteners will result in transmission fluid leakage.
Install 13 new front pump-to-case bolts and washers. Tighten in a crisscross pattern.
z Tighten pump fasteners with washers to 10 Nm (89 lb-in).
z Tighten fasteners without washers to 10 Nm (89 lb-in).
57. Install the Transmission End Play Gauge on the input shaft to measure the end play.
z Tighten the wing nut.
58. Install the Dial Indicator Gauge with Holding Fixture on the Transmission End Play Gauge.
z Push down on the Transmission End Play Gauge and zero the Dial Indicator Gauge.
z Lift up on the Transmission End Play Gauge and record the measurement on the Dial Indicator
Gauge. The measurement should be between 0.2-0.4 mm (0.008-0.015 in). If the
measurement is not within specification, install a new selective front pump shim.
z Measure the original shim, install a thinner or a thicker shim to achieve the correct
measurement.
59. Rotate the transmission in the horizontal position with the main control area facing up and install 3
new center support feed tube seals.
60. NOTE: Make sure the transmission fluid filter seal has been removed. If it has not, use a pick and
remove the seal.
NOTE: Add 0.118L (4 oz) of clean transmission fluid to prime the pump.
Install the front pump adapter seal and prime the fluid pump.
61. Install the thermal bypass valve into the case.
62. Align the guide pins in the alignment holes in the transmission case and position the mechatronic
assembly in place.
1. Alignment holes
2. Guide pins
63. NOTE: The mechatronic assembly will not lay flush on the case, this is a normal condition with the
rubber feed tubes, the bolts will pull the mechatronic assembly down.
Slightly lift the mechatronic assembly and align the manual valve in the manual valve linkage and
position the mechatronic in place.
64. Install the 11 mechatronic assembly bolts and tighten in the sequence shown.
66. With the release tab up and unlocked, push the outer shell of the bulkhead connector sleeve into the
transmission. Make sure the bulkhead connector sleeve is fully seated into the molded leadframe.
67. Press down on the tab and lock the outer shell of the bulkhead connector sleeve in place. Make sure
the locking tab is securely locked.
68. Install a new transmission fluid filter.
69. NOTE: The fluid pan gasket can be reused if not damaged.
70. Install the transmission fluid pan and transmission fluid pan bolts. Tighten in a crisscross pattern.
71. Using the Torque Converter Handle, install the torque converter.
72. If the Overdrive clutch FRICTIONS were replaced, install 1 6R ATF Additive Kit XL-16.

Transmission — Early Build
Special Tool(s)
307-091 (T81P-7902-C)

307-003 (T57L-500-B)

Seal
205-256
Remover, Input Shaft Oil Seal

308-375
Remover, Koastal Sleeve

307-717
Remover, Needle Bearing

307-562 (includes 307-562/1 and
307-562/2)
Remover, Pilot Bearing

308-001 (T58L-101-B)

Pump
307-553

307-343 (T95P-77001-AHR)
Slide Hammer
100-001 (T50T-100-A)
All vehicles
1. Install the Transmission Holding Fixture on the torque converter housing and install the transmission
on a bench.
2. Using the Torque Converter Handle, remove the torque converter.
3. Remove the transmission fluid pan bolts and the transmission fluid pan.
4. Remove the transmission fluid pan gasket.
5. Remove and discard the transmission fluid filter.
6. Press the release tab and lift up on the bulkhead connector sleeve retainer to release the bulkhead
connector sleeve shell.
7. With the transmission bulkhead connector sleeve retainer released, use the Koastal Sleeve Remover
to pull the outer shell of the bulkhead connector sleeve out of the transmission.
8. Inspect the bulkhead connector sleeve seals.

z If necessary, replace the seals.
9. Remove the 11 bolts from the main control assembly.
10. Remove the main control assembly.
11. Remove the front pump adapter seal and the transmission fluid filter seal. Inspect for cracks or
damage.
12. NOTE: Note the color, size and location while removing for correct assembly.
Remove and discard the 3 center support feed tube seals.

13. Remove the thermal bypass valve from the case.
14. Inspect the thermal bypass valve for damage and install a new valve if damaged.
15. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove and discard the front pump seal.
16. Remove and discard the 13 front pump-to-case bolts and washers.
17. Using the Transmission Fluid Pump Remover and Slide Hammer, remove the front pump support.
18. NOTE: The selective shim may come out while removing the front pump.
Inspect the back of the front pump for the selective shim and remove If necessary.
19. Remove and discard the front pump O-ring seal.
20. If the selective shim is not on the pump, using a magnet, remove it from the forward (A)/overdrive (E)
clutch assembly.
21. Remove the forward (A)/overdrive (E) clutch assembly.
22. Remove the caged T5 roller bearing from the direct (B) clutch assembly.
23. Remove the direct (B) clutch assembly.
24. Remove the bias spring.
25. Using the Retaining Ring Pliers, remove the center support snap ring.
26. Remove the center support and T6 bearing.
27. NOTE: When removing the OWC , note the position for assembly.
Remove the OWC .
28. NOTE: The selective shim might stick to the T7 thrust bearing during removal of the center support.
Remove the selective shim and the T7 thrust bearing.
29. NOTE: The selective shim might stick to the back of the center support assembly during removal.
Remove the selective shim from the center support assembly.
30. NOTE: Some of the clutch plates may stay in the case when removing the planetary carrier and the
low/reverse clutch pack. Remove any clutch plates from the transmission that were not removed with
the carrier and keep the clutch plates together.
Remove the planetary carrier and the low/reverse clutch pack as an assembly.
31. Remove the No. 2 sun gear and race.
32. NOTE: Remove the bearings with the sun gear.
NOTE: When removing the sun gear, note that the tapered edge is facing up toward the torque
converter housing.
Remove the No. 3 sun gear from the planetary assembly.
33. Remove the top T8 and the bottom T9 roller bearings from the sun gear.
34. Remove the T9 roller bearing race from the bottom of the carrier.
35. Remove the T10 thrust bearing from either the rear planetary carrier or the output shaft assembly.
36. NOTICE: The output shaft flange retaining nut has been staked to prevent it from coming
loose. Prior to removing the nut, remove the stake to prevent damage to the output shaft.
Place the manual control lever in the PARK position and remove and discard the output shaft flange
retaining nut.
37. Remove the output shaft flange seal and the output shaft flange.
38. Remove the planetary carrier hub, output shaft assembly and T11 bearing.
39. Remove and discard the output shaft seal.
40. Remove the slip plane washer.
41. Remove the T12 thrust bearing.
42. Using the Pilot Bearing Remover, remove the thrust bearing spacer.
43. Install the Needle Bearing Remover on the bearing.
44. Install the Front Wheel Hub Oil Seal Installer on the Needle Bearing Remover and remove the
bearing.
45. Remove the planet carrier hub, output shaft assembly and T11 bearing.
47. Remove the snap ring from the case.
48. NOTICE: Use care when installing the Needle Bearing Remover. Look inside the transmission
case to make sure that the Needle Bearing Remover contacts the bearing only and not the lip
of the case, or damage to the case will occur.
Using the Needle Bearing Remover and the Front Wheel Hub Oil Seal Installer, remove the bearing
assembly.
All vehicles
49. Remove and discard the 4 park rod actuating plate bolts and the park rod actuating plate.
50. Remove the manual control lever detent plate and park pawl actuator rod from the transmission case.
1. Remove and discard the roll pin.
2. Slide the manual control lever shaft out of the case.
3. Hold the manual control lever spacer to keep it from falling into the case.
4. Remove the manual valve detent lever and park pawl actuator rod as an assembly.
51. Remove and discard the manual control lever shaft seal.
52. Remove the bolt from the back of the case to gain access to the park pawl pin.
53. From the inside of the case, push the park pawl pin out toward the back side of the case while holding
the park pawl return spring and the park pawl. Remove the park pawl pin then remove the park pawl
and spring.
1. Park pawl pin
3. Park pawl
54. Remove and discard the 2 bolts and the park detent spring.

Transmission — Late Build
Special Tool(s)
Actuator Pin
303-D012 (D80L-100-H)
Collet, 1 1/4 Inch to 1 1/2 Inch

303-D022 (D80L-100-T)

307-091 (T81P-7902-C)

307-003 (T57L-500-B)

Seal
205-256

308-375

307-717
Remover, Needle Bearing

307-562 (includes 307-562/1 and
307-562/2)

Pump
307-553

307-343 (T95P-77001-AHR)
Slide Hammer
100-001 (T50T-100-A)
All vehicles
1. Install the Transmission Holding Fixture on the torque converter housing and install the transmission
on a bench.
2. Using the Torque Converter Handle, remove the torque converter.
3. Remove the transmission fluid pan bolts and the transmission fluid pan.
5. Remove and discard the transmission fluid filter.
6. Press the release tab and lift up on the bulkhead connector sleeve retainer to release the bulkhead
connector sleeve shell.

9. Remove the 11 bolts from the main control assembly.
10. Remove the main control assembly.
11. Remove the front pump adapter seal and the transmission fluid filter seal. Inspect for cracks or
damage.
12. NOTE: Note the color, size and location while removing for correct assembly.
Remove and discard the 3 center support feed tube seals.

13. Remove the thermal bypass valve from the case.
14. Inspect the thermal bypass valve for damage and install a new valve if damaged.
15. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove and discard the front pump seal.
16. Remove and discard the 13 front pump-to-case bolts and washers.
17. Using the Transmission Fluid Pump Remover and Slide Hammer, remove the front pump support.
18. NOTE: The selective shim may come out while removing the front pump.
Inspect the back of the front pump for the selective shim and remove If necessary.
19. Remove and discard the front pump O-ring seal.
20. If the selective shim is not on the pump, using a magnet, remove it from the forward (A)/overdrive (E)
clutch assembly.
21. Remove the forward (A)/overdrive (E) clutch assembly.
22. Remove the caged T5 roller bearing from the direct (B) clutch assembly.
23. Remove the direct (B) clutch assembly.
24. Remove the bias spring.
25. Using the Retaining Ring Pliers, remove the center support snap ring.
26. Remove the center support and T6 bearing.
27. NOTE: When removing the OWC , note the position for assembly.
Remove the OWC .
28. NOTE: The selective shim might stick to the T7 thrust bearing during removal of the center support.
Remove the selective shim and the T7 thrust bearing.
29. NOTE: The selective shim might stick to the back of the center support assembly during removal.
Remove the selective shim from the center support assembly.
30. NOTE: Some of the clutch plates may stay in the case when removing the planetary carrier and the
low/reverse clutch pack. Remove any clutch plates from the transmission that were not removed with
the carrier and keep the clutch plates together.
Remove the planetary carrier and the low/reverse clutch pack as an assembly.
31. Remove the No. 2 sun gear and race.
32. NOTE: Remove the bearings with the sun gear.
NOTE: When removing the sun gear, note that the tapered edge is facing up toward the torque
converter housing.
Remove the No. 3 sun gear from the planetary assembly.
33. Remove the top T8 and the bottom T9 roller bearings from the sun gear.
34. Remove the T9 roller bearing race from the bottom of the carrier.
35. Remove the T10 thrust bearing from either the rear planetary carrier or the output shaft assembly.
36. Remove the stakes from the output shaft flange retaining nut.
Place the manual control lever in the PARK position and remove and discard the output shaft flange
retaining nut.
38. Remove the output shaft flange and the output shaft flange seal.
39. Remove the planetary carrier hub, output shaft assembly and T11 bearing.
40. Remove the output shaft seal and the slip plane washer.
z Discard the output shaft seal.
41. Remove the output shaft ball bearing snap ring.
42. Using the Slide Hammer, Actuator Pin 303-D012, Collet, 1 1/4 Inch to 1 1/2 Inch 303-D022, remove
the output shaft ball bearing.
43. Remove the planet carrier hub, output shaft assembly and T11 bearing.
All vehicles
Remove the snap ring.
46. NOTICE: Use care when installing the Needle Bearing Remover. Look inside the transmission
case to make sure that the Needle Bearing Remover contacts the bearing only and not the lip
of the case, or damage to the case will occur.
Using the Needle Bearing Remover and the Front Wheel Hub Oil Seal Installer, remove the bearing
assembly.
47. Remove and discard the 4 park rod actuating plate bolts and the park rod actuating plate.
48. Remove the manual control lever detent plate and park pawl actuator rod from the transmission case.
1. Remove and discard the roll pin.
3. Hold the manual control lever spacer to keep it from falling into the case.
4. Remove the manual valve detent lever and park pawl actuator rod as an assembly.
49. Remove and discard the manual control lever shaft seal.
50. Remove the bolt from the back of the case to gain access to the park pawl pin.
51. From the inside of the case, push the park pawl pin out toward the back side of the case while holding
the park pawl return spring and the park pawl. Remove the park pawl pin then remove the park pawl
and spring.
1. Park pawl pin
3. Park pawl
52. Remove and discard the 2 bolts and the park detent spring.

Direct Clutch Assembly
Special Tool(s)
Compressor, Clutch Spring
307-015 (T65L-77515-A)

307-552

Fixture
100-002 (TOOL-4201-C) or
equivalent
End Play Gauge, Clutch

307-555
Material
Item Specification
(Canada)
Direct Clutch Assembly
Part
1 7D483 Direct clutch pressure plate retaining ring
2 7B066 Direct clutch pressure plate (thickness model
dependant)
3 7B164 Direct clutch internal splined friction plates (quantity
model dependant)
4 7B442 Direct clutch external splined steel plates (quantity
model dependant)
5 — Direct clutch cushion plate (wave spring)
7 7A577 Piston retaining ring
8 7A262 Direct clutch balance piston
9 7A548 Direct clutch balance piston seal
10 7B488 Return spring
11 7A262 Direct clutch apply piston
12 7A548 Direct clutch apply piston outer seal
13 7C099 Direct clutch apply piston inner seal
14 — Direct clutch bushing hubs (part of 7F283) (2 required)
15 — Gear shaft tube sleeve (part of 7F283)
16 7F283 Direct clutch cylinder
17 7D020 Seal shell cylinders
Disassembly
1. Remove and discard the 2 scarf cut seals and the roller bearing.
3. Remove the direct clutch snap ring.
4. Remove the direct clutch steel and friction plates.
5. Install the Clutch Spring Compressors onto the direct clutch assembly.
6. Using the Clutch Spring Compressors, compress the direct clutch return spring and remove the direct
clutch return spring retainer.
7. Remove the balance piston.
8. Remove the direct clutch return spring.
9. Remove the direct clutch piston.
10. Remove and discard the outer O-ring seal from the balance piston.
11. Remove and discard the outer and inner O-ring seals from the apply piston.
12. Inspect the components of the direct clutch for damage. If damage is indicated, install new
Assembly
1. Install a new inner and outer O-ring seal on the apply piston.
2. Install a new outer O-ring seal on the balance piston.
3. Lightly coat the O-ring seals in clean transmission fluid and install the direct clutch piston.
4. Install the direct clutch return spring.
5. Install the balance piston.
6. Install the Clutch Spring Compressors onto the direct clutch assembly.
7. Using the Clutch Spring Compressors, compress the direct clutch return spring and install the direct
clutch return spring retainer.
8. NOTE: Friction and steel plate quantity will vary based on engine displacement. For additional
information, refer to the Clutch Plate Quantity Chart in the Specifications portion of this section.
Soak the new direct clutch in clean transmission fluid.
9. Install the new direct clutch plates, starting with the wave spring then a steel plate and alternating
between steel and friction plates, and ending with the pressure plate on the top.
10. Install the direct clutch snap ring.
11. NOTE: Inspect and install a new thrust bearing as required.
Install the T5 thrust bearing.
12. NOTE: All direct clutch plates, friction and steel are of a wave-type design.
Install the direct clutch assembly into the Clutch End Play Gauge and install the Dial Indicator Gauge
with Holding Fixture and position the plunger so it fits into the opening of the snap ring.
13. With the Dial Indicator Gauge set at zero, lift up on the steel pressure plate so it is against the select
fit snap ring. Record this reading as reading A.
14. Rotate the direct clutch assembly 180 degrees from the opening of the snap ring, take a second
reading and record this reading as reading B.
Description Reading
Reading A
Reading B
Add reading A to reading B for a total end clearance
Divide the total reading by 2 for an average end clearance
15. NOTE: If the final measurement is not within specification, install a new snap ring until the correct
specification is achieved.
z 0.5-1.3 mm (0.019-0.051 in).
If the free pack end clearance between the bottom of the snap ring and the top of the pressure plate
is high, remeasure using a thicker select fit snap ring. If the free pack end clearance between the
bottom of the snap ring and the top of the pressure plate is low, remeasure using a thinner select fit
snap ring.
16. Install 2 new scarf cut seals and the roller bearing.

Forward Clutch Assembly
Special Tool(s)
307-525

Fixture
100-002 (TOOL-4201-C) or
equivalent

307-555
Material
Item Specification
(Canada)
Forward Clutch Assembly (A Clutch)
Part
1 7A360 Forward clutch drum
2 7A548 Forward clutch piston outer O-ring seal
3 7A548 Forward clutch piston inner O-ring seal
4 7A262 Forward clutch piston
5 7A480 Forward clutch piston return spring
6 7A548 Forward clutch balance dam O-ring seal
7 7H360 Forward clutch balance dam
8 7H365 Forward clutch balance dam retaining ring
9 7H579 Sun gear retaining ring
10 7D063 Sun gear
12 7A398 Planetary gear
13 7E085 Forward clutch cushion spring
14 7E314 Forward clutch external splined steel plates (quantity
model dependent)
15 7B164 Forward clutch internal splined friction plates (quantity
model dependent)
16 7B066 Forward clutch pressure plate
17 7D483 Forward clutch plate retaining ring
Disassembly
1. If the T2 thrust bearing is on the forward clutch assembly, remove it from the forward clutch
assembly.
2. Remove the front planetary carrier and sun gear from the forward clutch assembly.
z With a small screwdriver or a suitable pick inserted into the front planetary assembly, push on
the retaining ring in 4 places while lifting up on the front planetary assembly.
3. Remove the forward clutch pack snap ring.
4. NOTE: Inspect the forward clutch drum and the friction and steel plates for damage. Install new
Remove and inspect the forward clutch steel and friction plates.
z If the plates are damaged, install a new forward clutch assembly.
z If no damage is indicated, the forward clutch may be reassembled.
5. For correct alignment during assembly, make an identifying mark on the balance dam and the center
part of the housing.
6. NOTE: The bottom of the Clutch Spring Compressor will need to be installed from the back side of
the forward clutch assembly.
Using the Clutch Spring Compressor, slightly collapse the balance dam to gain access to the
retaining ring and remove the retaining ring.
7. Remove the balance dam.
8. Remove and discard the O-ring seal from the balance dam.
9. Remove the forward clutch return spring.
10. Install the forward clutch on the front pump to remove the forward clutch piston. Apply a small amount
of shop air to remove the piston.
11. Remove and discard the inner and outer piston O-ring seals.
12. Remove the sun gear from the planet assembly.
13. NOTE: The T1 thrust bearing may have stuck to the sun gear when it was removed.
Remove the T1 bearing from the planetary carrier.
14. Remove the transmission fluid collector plate from the front planetary carrier.
15. Clean and inspect the components of the forward clutch assembly for damage and install new
Assembly
1. NOTE: If a new planetary assembly is being installed, the new planetary assembly may not come
with the snap ring installed.
Install the planetary assembly snap ring, if necessary.
2. Make sure the planetary snap ring is oriented as shown.
3. Install the transmission fluid collector plate on the front planetary carrier.
4. Install the T1 bearing onto the sun gear.
5. Install the sun gear into the planet assembly with the T1 bearing facing down and the recessed part of
the gear up.
6. Install new O-ring seals onto the forward clutch piston.
7. Lightly coat the O-ring seals with clean transmission fluid and install the forward clutch piston into the
forward clutch drum.
8. Install the forward clutch return spring.
9. Install a new O-ring seal onto the forward clutch balance dam. Lightly coat the O-ring seal with clean
transmission fluid.
10. Align the marks made during disassembly and install the balance dam into the forward clutch drum.
11. NOTE: Prior to releasing the Clutch Spring Compressor, make sure that the snap ring is fully seated.
Using the Clutch Spring Compressor, slightly collapse the balance dam to install the retaining ring.
Install the retaining ring.
information, refer to the Clutch Plate Quantity chart in the Specifications portion of this section.
Soak the new forward clutch plates in clean transmission fluid.
13. Install the new forward clutch plates, starting with the wave spring then a steel plate and alternating
between friction and steel plates and install the pressure plate.
14. Install the forward clutch plate snap ring.
15. NOTE: All forward clutch plates, friction and steel are of a wave-type design.
Install the forward clutch assembly into the Clutch End Play Gauge and install the Dial Indicator
Gauge with Holding Fixture and position the plunger so it fits into the opening of the snap ring.
17. Rotate the forward clutch assembly 180 degrees from the opening of the snap ring, take a second
Description Reading
Reading A
Reading B
z 0.71-1.10 mm (0.028-0.043 in)
snap ring.
19. Install the sun gear and planetary gearset into the forward clutch drum. Make sure it snaps and locks
in place.

Forward/Overdrive Clutch Assembly — Assembly
Special Tool(s)
307-555
Material
Item Specification
(Canada)
Assembly
1. Position the forward clutch assembly in the Clutch End Play Gauge and install the overdrive clutch
pack onto the forward clutch and planetary gear set.
2. Install the intermediate shaft assembly.
3. NOTE: Inspect and install new thrust bearings as required.
Install the T4 intermediate shaft bearing.
4. Install the forward clutch hub and sun shaft assembly.
5. Install a new the direct clutch hub.
6. NOTICE: Do not install the snap ring on the forward clutch hub with the snap ring gap in the
same position as the original snap ring or damage to the transmission can occur.
Install a new direct clutch outer shell retaining ring with the snap ring gap positioned approximately
120 degrees from the index mark made on the forward clutch hub during disassembly.
1. New snap ring gap
2. Index mark from original snap ring gap

Forward/Overdrive Clutch Assembly — Disassembly
Special Tool(s)
307-555
Material
Item Specification
(Canada)
Disassembly
1. Position the forward/overdrive clutch assembly in the Clutch End Play Gauge 307-555.
2. Index-mark the direct clutch outer shell snap ring gap location to the side of the forward clutch hub
using a suitable paint marker.
1. Index mark
2. Snap ring gap
3. NOTICE: Compress the snap ring out of the groove 180 degrees from the snap ring gap or
damage to the forward clutch hub can occur.
Using a suitable tool, remove and discard the direct clutch outer shell retaining ring by compressing
the snap ring 180 degrees from the snap ring gap.
1. Snap ring gap
2. 180 degrees from the snap ring gap
4. Remove and discard the direct clutch hub.
5. Remove the forward clutch and sun shaft assembly.
6. NOTE: The bearing may stick in the forward clutch drum.
Remove the intermediate shaft bearing.
7. Remove the intermediate shaft assembly.
8. If the T3 thrust bearing stuck to the intermediate shaft assembly, remove it from the intermediate
shaft assembly. If the T3 thrust bearing is on the overdrive clutch, remove it from the overdrive clutch
assembly.
9. Remove the overdrive clutch pack from the forward clutch pack.

Intermediate Clutch Assembly
Special Tool(s)
307-525

Fixture
100-002 (TOOL-4201-C) or
equivalent

307-555
Material
Item Specification
(Canada)
Intermediate Clutch Assembly
Part
2 7D483 Intermediate clutch pack retaining ring
3 7B066 Intermediate clutch pressure plate
4 7B164 Intermediate clutch internal splined friction plates
5 7B442 Intermediate clutch external splined steel plates
6 7E085 Intermediate clutch cushion spring
7 7A577 Intermediate clutch snap ring
8 7B043 Intermediate clutch return spring retaining ring
9 7A480 Intermediate clutch piston return spring
10 7E005 Intermediate clutch piston (model dependant)
11 7F225 Intermediate clutch piston inner seal
12 7F224 Intermediate clutch piston outer seal
14 7A130 Intermediate/low/reverse clutch center support
15 7G199 Center support seals (2 — 7G199, 1 — 7G087, 1 —
7G484)
Disassembly
NOTICE: The intermediate clutch plate quantity is model dependent on engine size. Check the clutch
plate quantity charts in specifications for the correct clutch plate quantity. Failure to install the
correct clutch plate quantity will result in transmission failure.
NOTICE: The intermediate clutch piston is model dependent on engine size due to the different
quantity of intermediate clutch plates. If installing a new intermediate clutch piston, check to make
sure the height of the new piston is the same as the original piston. Failure to install the correct
piston will result in transmission failure.
2. Remove the intermediate clutch plate snap ring.
3. Remove the intermediate clutch plates.
4. Using the Clutch Spring Compressor, remove and discard the intermediate clutch return spring
retainer.
5. Remove the intermediate clutch return spring top plate.
6. Remove the intermediate clutch return spring.
7. Applying a slight amount of air to the port, remove the intermediate clutch piston.
8. Remove and discard the inner and outer intermediate clutch piston O-ring seals.
Assembly
1. Install new inner and outer intermediate clutch piston O-ring seals.
2. Lightly coat the O-ring seals in clean automatic transmission fluid and install the intermediate clutch
piston.
3. Install the intermediate clutch return spring.
4. Install the intermediate clutch return spring top plate.
5. Using the Clutch Spring Compressor, install a new intermediate clutch return spring retainer.
information, refer to the Clutch Plate Quantity Chart in the Specifications portion of this section.
Soak the new intermediate clutch plates in clean automatic transmission fluid.
7. Install the new intermediate clutch plates, starting with the wave spring then a steel plate and
alternating between friction and steel plates, and ending with the pressure plate.
8. Install the intermediate clutch plate snap ring.
9. NOTE: All intermediate clutch plates, friction and steel are of a wave-type design.
Install the intermediate clutch assembly into the Clutch End Play Gauge and install the Dial Indicator
Gauge with Holding Fixture and position the plunger so it fits into the opening of the snap ring.
11. Rotate the intermediate clutch assembly 180 degrees from the opening of the snap ring, take a
second reading and record this reading as reading B.
Description Reading
Reading A
Reading B
z 0.7-1.1 mm (0.027-0.043 in).
snap ring.

Low/Reverse Clutch Assembly
Special Tool(s)
307-525
Depth Micrometer
303-D075 (D92P-4201-A) or
equivalent

Fixture
100-002 (TOOL-4201-C) or
equivalent

307-555
Gauge, D-Clutch Measurement

307-554
Material
Item Specification
(Canada)
Low/Reverse Clutch Assembly
Part
1 7A130 Intermediate/low/reverse clutch center support
3 7F225 Low/reverse clutch piston center seal
4 7D403 Low/reverse clutch cylinder outer seal
6 7B070 Low/reverse clutch return spring
7 7H318 Low/reverse clutch return spring retainer
8 7D483 Low/reverse clutch return spring snap ring
9 7E085 Low/reverse clutch cushion spring
10 7B164 Low/reverse clutch internal splined friction plates
(internally splined to the rear planetary carrier)
11 7B442 Low/reverse clutch external splined steel plates
(externally splined to the case)
12 7B066 Low/reverse clutch pressure plate (externally splined to
the case) (select fit)
Disassembly
NOTICE: The low/reverse clutch plate quantity is model dependent on engine size. Check the clutch
plate quantity charts in specifications for the correct clutch plate quantity. Failure to install the
correct clutch plate quantity will result in transmission failure.
NOTE: The low/reverse clutch plates are installed in the case during the transmission assembly procedure.
1. Using the Clutch Spring Compressor, remove and discard the low/reverse clutch return spring
retainer.
2. Remove and discard the low/reverse clutch return spring retainer.
3. Remove the low/reverse clutch return spring.
4. Apply a slight amount of air to the port, remove the low/reverse clutch piston from the low/reverse
clutch drum.
5. Remove and discard the low/reverse outer piston O-ring seal.
6. Remove and discard the low/reverse drum O-ring seal.
Assembly
Low/reverse piston
1. Install new low/reverse outer piston O-ring seal.
2. Install new low/reverse drum O-ring seal.
3. Lubricate the O-ring seal with clean transmission fluid. Align the alignment tab on the piston with the
groove in the center support and install the low/reverse piston.
4. Install the low/reverse clutch return spring.
5. Install a new low/reverse clutch return spring retainer. Align the alignment tab on the retainer with the
groove in the center support and install the low/reverse piston return spring retainer.
6. Using the Clutch Spring Compressor, compress the low/reverse clutch return spring and install the
retaining ring.
Low/reverse clutch stackup
7. NOTE: All low/reverse clutch plates, friction and steel are of a wave-type design.
Install the D-Clutch Measurement Gauge into the case.
8. With the D-Clutch Measurement Gauge positioned in the case, use the Depth Micrometer to measure
the case stop depth.
Description Reading
Measure the distance from the top of the upper gauge bar to the top of the lower gauge
bar. Record this reading as the case measurement. Record as reading A.
9. Measure the clutch pack height.
Description Reading
A. Place the low/reverse clutch pack on the Clutch End Play Gauge with the wave spring
down and the pressure plate on top. Using the Dial Indicator Gauge with Holding
Fixture, place the plunger on the pressure plate. Slide the clutch to the side so the
plunger of the Dial Indicator is touching the gauge plate of the Clutch End Play Gauge.
Zero out the Dial Indicator Gauge.
B. Carefully lift the plunger enough to slide the clutch pack under the plunger to take a
reading. Record this reading. Rotate the clutch pack 180 degrees and take a second
reading. Add the first and second readings together and divide the total by 2. Record
this reading as B.
10. Using the Depth Micrometer, measure the piston to center support shoulder height.
Description Reading
Measure the piston to center support shoulder height. Record this measurement. Rotate
the center support 180 degrees and record this measurement. Add the first and the
second measurements, then divide by 2. Record this as reading C.
11. Calculate the end clearance.
Description Reading
Subtract B and C from A to determine end clearance
Total C measurement
End clearance specification 1.0-1.6 mm
(0.039-0.062 in)
Compare the end clearance to the specification. If the end clearance is out of specification, select the
next thinner or thicker plate as required and repeat Steps 10, 11 and 12.

Main Control
Material
Item Specification
(Canada)
Part
2 — Main control valve body (upper)
3 7E195 Main control valve check ball (8 required)
5 — Main control valve body (lower)
6 — Main control valve
7 7H187 Main control filter
8 7B155 Transmission fluid filter
9 7J191 Transmission solenoid damper valve assembly

10 W707886 Main control assembly short bolt — connects upper
and lower half together (19 required)
11 W707884 Main control assembly long bolt — connects molded
leadframe to main control valve assembly (6 required)
12 — Transmission shift control solenoids
Main Control Upper Half

1 7A092 Main control valve assembly (ditch plate) (upper half)
2 7E195 Main control valve check ball (8 required)
3 — Transmission clutch D2 latch valve
4 — Transmission clutch valve spring
5 — Transmission clutch valve spring plug
6 7G007 Transmission clutch valve spring plug retaining clip
8 — Transmission clutch B regulator valve
11 — Transmission clutch valve

15 — Transmission clutch valve
Main Control Lower Half
Part
1 — Main control valve assembly (lower half)
2 — Transmission shift control solenoid hold-down bracket

3 — Transmission shift control solenoid hold-down bracket
bolt M5 x 0.80 x 12 (8 required)
4 7G484 Transmission ON/OFF shift solenoid
6 — Transmission clutch A latch valve
7 — Transmission spring retainer plate
9 — Transmission clutch B latch valve
10 7F194 Transmission spring retainer plate
11 7G383 Transmission VFS (6 required)
12 — Transmission solenoid regulator valve spring
13 — Transmission solenoid pressure regulator valve
14 — Transmission solenoid plug
15 7G007 Transmission valve plug retainer
16 — Transmission clutch D1 latch valve
20 — Transmission drive enable valve
21 — Transmission solenoid valve spring
24 — Transmission solenoid multiplex valve
25 — Transmission solenoid valve spring
29 — Transmission clutch A pressure regulator valve
30 — Transmission clutch regulator valve sleeve
31 — Transmission valve return plug
33 7G077 Transmission valve plug return clip
35 — Transmission clutch E pressure regulator valve
38 — Transmission clutch E latch valve
39 — Transmission clutch control valve spring

42 — Transmission bypass clutch control valve spring
43 — Transmission bypass clutch control valve
46 — Transmission manual oil pressure regulator valve
spring
47 — Transmission main oil pressure regulator valve
48 — Transmission manual oil pressure regulator valve
sleeve
50 — Transmission converter regulator valve
51 — Transmission converter regulator valve spring
54 — Transmission lube control valve
55 — Transmission lube control valve spring
58 W527007-S Retaining ring
59 — Transmission control manual valve
Check Ball Location
Item Description
1 Reverse/drive control check ball
2 Shift solenoid control check ball

3 Intermediate clutch exhaust control check ball
4 Direct clutch exhaust control check ball
5 Low/reverse clutch exhaust control check ball
6 Forward clutch exhaust control check ball
7 Overdrive clutch exhaust control check ball
8 Reverse exhaust control check ball
9 Clutch exhaust valve
10 Converter drain back valve
11 Large filter screen
12 Small filter screen
Shift Solenoid Location
Part
1 7G383 SSA , Forward (1,2,3,4) clutch, normally low VFS
(brown nozzle).
2 7G383 SSB , Direct (3,5,R) clutch, normally high VFS (black
nozzle).
3 7G383 SSC , Intermediate (2,6) clutch, normally low VFS
(brown nozzle).
4 7G383 LPC solenoid, normally high VFS (black nozzle).

5 7G383 SSD , low/reverse/overdrive clutch, normally high VFS
(black nozzle).
6 7G484 SSE , normally off ON/OFF solenoid.
7 7G383 TCC solenoid, normally low VFS (brown nozzle).
Disassembly
NOTE: Make an identifying mark on each solenoid and the corresponding bore for correct assembly.
NOTE: Solenoids may visually appear the same but their designs/functions are different. Use care not to
assemble the main control assembly incorrectly. Incorrect solenoid installation results in poor transmission
shift quality.
NOTE: Note the location of the 8 check balls, 6 solenoid dampers, 2 internal valves and springs and 2 filter
screens for reassembly.
1. Make an identifying mark on each solenoid and the corresponding bore for correct assembly.
2. Remove the 6 long molded leadframe-to-valve body bolts from the molded leadframe.
3. Carefully separate the molded leadframe from the main control assembly.
1. Molded leadframe
2. Main control assembly
4. Remove 19 short molded leadframe-to-valve body bolts from the main control assembly.
5. Separate the lower half of the main control assembly from the upper half of the main control
assembly.
6. Remove and discard the main control valve body separator plate.
7. Remove the solenoid dampers, check balls, converter drain back valve and filter screens from the
main control assembly. Note the location for assembly.
1. Solenoid dampers
2. Check balls
3. Converter drain back valve
4. Small filter screen
5. Large filter screen
8. Remove the retaining clips, caps, valves and valve springs from each bore of the main control
assembly. Note the location and order for assembly.
9. Using clean mineral spirits, clean the upper half of the main control assembly.
10. Remove the 8 solenoid hold down bracket bolts and the solenoid hold down bracket.
11. Remove the solenoids.
12. Remove the retaining clips, caps, valves and valve springs from each bore of the main control
assembly. Note the location and order for assembly.
13. Using clean mineral spirits, clean the lower half of the main control assembly.
Assembly
1. NOTE: Many components and surfaces in the main control valve body are precision machined.
Careful handling during disassembly, cleaning, inspection and assembly prevents unnecessary
damage to machined surfaces.
Install the retaining clips, caps, valves and valve spring into each bore.
2. NOTE: Many components and surfaces in the main control valve body are precision machined.
Careful handling during disassembly, cleaning, inspection and assembly prevents unnecessary
damage to machined surfaces.
Install the retaining clips, caps, valves and valve spring into each bore.
3. NOTICE: A VFS is calibrated from the factory and are not all the same. To replace a VFS ,
match the replacement solenoid nozzle color and the band number with the original solenoid
or harsh/erratic shifts, harsh/soft engagement or damage to the transmission can occur.
Inspect the solenoid screens for contamination and install new solenoids if needed. Lubricate the
solenoid O-rings with clean transmission fluid.
If replacing a solenoid, use the solenoid exploded view at the beginning of this procedure to identify
what type of solenoid is being replaced. The solenoid can be a normally high VFS with a black
nozzle, normally low VFS with a brown nozzle or an ON/OFF solenoid.
If replacing a VFS , record the band number and the solenoid nozzle color to get the correct part
number for the solenoid.
1. Screens
2. O-rings
3. Solenoid nozzle
4. Solenoid band number
4. Install the solenoids into their correct bores as indicated during disassembly.
5. Install the shift control solenoid hold down bracket and the 8 hold down bracket bolts.
6. NOTICE: Toward the back of the upper valve body there is a hydraulic passage that is shaped
as though it receives a check ball. This passage does not require a check ball. Be sure not to
mistake this hydraulic passage for a passage that does require a check ball or damage to the
transmission can occur.
Install the solenoid dampers, check balls, converter drain back valve and filter screens.
1. Solenoid dampers
2. Check balls
3. Converter drain back valve
4. Small filter screen
5. Large filter screen
6. Empty hydraulic passage (no check ball)
7. Align the guide pins on the molded leadframe with the holes in the main control upper valve body and
install the valve body onto the molded leadframe.
1. Molded leadframe
2. Main control upper valve body
3. Guide pins
8. NOTICE: If the drain back valves are not installed correctly in the separator plate, damage to
the transmission can occur.
Position the new main control separator plate on the main control upper valve body.
Check the 2 drain back valves to be sure they are correctly positioned in the separator plate when the
separator plate is pressed flush against the main control upper valve body.
1. Main control separator plate
2. Drain back valves
9. Position the main control lower valve body on the 2 molded leadframe alignment studs, align the
manual valve with the TR sensor on the molded leadframe and install the main control lower valve
body.
1. Main control lower valve body
2. Manual valve
3. TR sensor
10. Install the 6 long molded leadframe-to-valve body bolts hand-tight.
11. Install the 19 short main control assembly lower-to-upper valve body bolts. Tighten the bolts in the
sequence shown.
z Tighten bolts 1 through 6 to 6 Nm (53 lb-in).
z Tighten bolts 7 through 25 to 7 Nm (62 lb-in).

Overdrive Clutch Assembly
Special Tool(s)
Compressor, Spring Washer
307-209

Fixture
100-002 (TOOL-4201-C) or
equivalent

307-555
Material
Item Specification
(Canada)
Overdrive (O/D) Clutch Assembly
Part
1 7F207 Input shaft
2 7A548 Overdrive (O/D) clutch piston outer seal
3 7A548 O/D clutch piston inner seal
4 7A262 O/D clutch piston
5 7B070 O/D clutch piston spring
6 7A548 O/D balance piston outer seal
7 7H360 O/D balance piston
8 7C122 O/D balance piston snap ring
9 7B164 O/D clutch internal splined clutch friction plates
10 7B442 O/D clutch external splined clutch steel plates (quantity
model dependent)
11 7B066 O/D pressure plate
12 7D483 O/D clutch retaining ring
13 7C096 Bearing T3
Disassembly
1. Position the Overdrive (O/D) clutch assembly in the Clutch End Play Gauge and remove the T3 thrust
bearing.
2. Remove the O/D clutch pack snap ring.
3. Remove the O/D clutch pack.
4. Using the Spring Washer Compressor and a press, remove and discard the O/D clutch balance
piston retaining ring.
5. Remove the O/D clutch balance piston.
6. Remove the O/D clutch return spring.
7. Remove the O/D clutch apply piston.
8. Remove and discard the outer O-ring seal on the O/D clutch balance piston.
9. Remove and discard both the inner (one large and one small) O-ring seals on the O/D clutch apply
piston.
10. Remove and discard the 3 scarf cut seals.
Assembly
1. Install the 3 new scarf cut seals and the roller bearing.
2. Install a new outer O-ring seal on the O/D clutch balance piston.
3. Install 2 new inner O-ring seals on the O/D clutch apply piston.
4. Lubricate all the O-ring seals with clean transmission fluid. Install the O/D clutch apply piston into the
drum with the O-ring seals and the 3 pads facing down toward the drum.
5. NOTE: The fingers on the return spring are facing down toward the piston.
Install the O/D clutch return spring.
6. NOTE: The cone shape of the balance piston must face up when installed correctly.
Lubricate all the O-ring seals with clean transmission fluid. Install the O/D clutch balance piston.
7. Using the Spring Washer Compressor, install a new O/D clutch balance piston retaining ring.
8. Soak the new O/D clutch plates in clean transmission fluid.
information, refer to the Clutch Plate Quantity chart in the Specifications portion of this section.
Install the new O/D clutch plates, starting with a steel plate and alternating between friction and steel
plates, and ending with the pressure plate on the top.
10. Install the O/D clutch pack snap ring.
11. NOTE: All O/D clutch plates, friction and steel are of a wave-type design.
Install the O/D clutch assembly into the Clutch End Play Gauge and install the Dial Indicator Gauge
with Holding Fixture and position the plunger so it fits into the opening of the snap ring.
13. Rotate the O/D clutch assembly 180 degrees from the opening of the snap ring, take a second
Description Reading
Reading A
Reading B
z 0.5-0.9 mm (0.019-0.035 in)
snap ring.
15. NOTE: Inspect and install new thrust bearings as required.
Install the T3 thrust bearing.

Pump Assembly
Special Tool(s)
307-556
Material
Item Specification
(Canada)

3 7A248C Pump body seal
4 7A103 Pump plate assembly

5 7A248A Pump plate assembly seal
6 W707871- Pump plate assembly-to-front pump body bolt (11
S300 required)
Disassembly
1. Remove the front pump washer.
2. If the O-ring seal was not removed during disassembly, remove and discard the front pump O-ring
seal from the pump assembly.
3. Remove and discard the front pump seal rings from the stator support.
4. Index-mark the pump body to the pump plate assembly.

1. Pump body
2. Pump plate assembly
3. Index mark
5. Remove the 11 pump plate assembly-to-pump body bolts.
6. Push down on the loose pump plate assembly-to-pump body bolts to remove the pump body from the
pump plate assembly and remove the 11 bolts.
7. Remove and discard the pump body outer seal.
8. Remove the fluid pump gears.
9. Inspect the inner and the outer pump gears for damage.
z Clean all pump components in solvent.
z Dry the parts with compressed air.
z Inspect the pump gears, faces, gear teeth and mating surfaces for damage or scoring.
z Install a new pump as necessary.
10. Inspect the pump body and pump plate thrust surfaces for damage or scoring.
1. Pump body
3. Pump gear thrust surfaces
11. Inspect the input shaft bushing for damage or scoring. If the bushing is damaged, install a new pump.
12. Inspect the torque converter hub bushing for damage or scoring. If the bushing is damaged, install a
new pump.
Assembly
1. NOTE: Prior to installation, lightly lubricate the pump gears with clean automatic transmission fluid.
Install the pump gears with the dot facing the pump plate assembly.
2. Install a new pump body outer seal.
3. Align the marks made during disassembly to correctly assemble the pump. Press the pump body into
the pump plate assembly. Visually inspect the pump body-to-pump plate assembly bolt holes to be
sure that the pump body and pump plate are correctly aligned.
1. Pump body
3. Pump gear thrust surfaces
4. Install the pump plate assembly-to-front pump body bolts.
5. NOTICE: Make sure that the seal ends of each seal ring are hooked together or fluid leakage
can occur.
Install the 2 front pump seal rings onto the stator support. Make sure the seals are fully seated in the
stator support seal grooves and the seal ends are oriented 180 degrees apart.
6. Install the pump outer diameter front pump O-ring seal.
7. Install a new front pump seal on the Fluid Pump Seal Installer 307-556.
8. Using the Fluid Pump Seal Installer 307-556, install the front pump seal.
9. NOTE: Lightly lubricate the thrust washer with petroleum jelly to hold it in place during assembly.
Install the pump thrust washer.

Fluid Pan, Gasket and Filter
Material
Item Specification
(Canada)
Removal
NOTICE: The use of any transmission fluid other than specified can result in the transmission failing
to operate in a normal manner or transmission failure.
4. NOTE: The transmission fluid filter may be reused if no excessive contamination is indicated.
Remove and discard the transmission fluid filter.
5. Clean and inspect the transmission fluid pan and magnet.
Installation
NOTE: If the transmission is being repaired for a contamination-related failure, install a new transmission
fluid filter and seal assembly. The transmission fluid filter may be reused if no excessive contamination is
indicated.
1. Inspect the transmission case for the transmission fluid filter seal. If the seal is in the case, carefully
remove the seal without scratching the case.
2. Make sure that the seal is on the transmission fluid filter and lubricate the seal with automatic
transmission fluid.
If required, install a new transmission fluid filter.
4. Position the magnet in the transmission fluid pan.
6. Install the transmission fluid pan and tighten the bolts in a crisscross pattern.
7. Using the Adding Additional Transmission Fluid procedure, fill and check the transmission fluid. Refer
to Transmission Fluid Drain and Refill .

Main Control
Special Tool(s)
307-717
Removal
NOTE: The Solenoid Body Strategy Data Download procedure must be performed if a new main control
assembly is installed.
the connector.
6. Pull the release tab and pull down on the bulkhead connector sleeve retainer.

9. NOTICE: During removal of the main control assembly, the thermal bypass valve may fall out
of the transmission case. Damage to the valve may occur if the valve falls out.
Remove the 11 bolts from the main control assembly and remove the main control assembly and the
bypass valve.
Installation
1. Inspect the bias spring to make sure it is positioned correctly in the transmission case.
2. NOTE: Before installing the main control assembly into the transmission case, verify the presence
and orientation of the thermal bypass valve, pump adapter seal and center support feed tube seals.
Also note that one or more of the center support feed tube seals may have remained in the main
control assembly during removal and should be installed into the transmission case at this time.
Verify the 3 center support feed tube seals are in place.

3. Verify the rubber adapter is in place.
4. Coat the thermal bypass valve with petroleum jelly to hold it in place and install the thermal bypass
valve into the transmission case.
5. Position the main control assembly in place and loosely install the 11 bolts.
1. Align the manual valve and control lever linkage.
6. Tighten the main control bolts in the sequence shown.

8. With the release tab down and unlocked, push the outer shell of the bulkhead connector sleeve into
the transmission. Make sure the bulkhead connector sleeve is fully seated into the molded leadframe.
9. Press up on the tab and lock the outer shell of the bulkhead connector sleeve in place. Make sure
that the locking tab is securely locked.
Install a new transmission fluid pan gasket, if required.
12. Install the transmission fluid pan and tighten the transmission fluid pan bolts in a crisscross pattern.
13. Connect the transmission vehicle harness connector by pushing it in and twisting the outer shell to
lock it in place.
14. Make sure the transmission fluid is at the correct level. Refer to Transmission Fluid Drain and Refill .
15. NOTE: If an individual solenoid was replaced clear the adaptive strategy.
Perform a Road Test — Adaptive Drive Cycle after the adaptive strategy is cleared. Refer to Shift
Point Road Test .
16. NOTE: If the main control assembly was replaced, perform the Solenoid Body Strategy Data
Download. Refer to Solenoid Body Strategy .
Perform a Road Test — Adaptive Drive Cycle after the Solenoid Body Strategy Data Download. Refer
to Shift Point Road Test .

Manual Control Lever Shaft and Seal
Special Tool(s)
307-559

307-717
Removal
2. If equipped, remove the nut and the selector lever cable splash shield.
3. Clean the cable adjustment lock of any debris.
4. NOTICE: To prevent selector lever cable damage, do not apply force to the selector lever cable
between the manual control lever and the selector lever cable bracket.
NOTE: The column shift is shown, the floor shift is similar.
Disconnect the transmission selector lever cable end from the manual control lever.
Remove the transmission fluid pan gasket.
the connector.
9. Pull the release tab and pull down on the bulkhead connector sleeve retainer.

12. NOTICE: During removal of the main control, the thermal bypass valve will fall out of the
transmission case. Damage to the valve will occur if the valve falls out.
Remove the 11 bolts from the main control and remove the main control assembly and the bypass
valve.
13. Remove the park rod actuating plate.
14. Remove the manual control lever.

1. Remove the roll pin.
3. Hold the spacer to keep it from falling out of the case.
4. Remove the manual valve inner lever and the park rod as an assembly.
15. Remove and discard the manual control lever seal.
Installation
1. Position a new manual control lever seal in place.
2. Using the Shifter Fluid Seal Installer, install a new manual control lever shaft seal.
3. Install the manual control lever in the case.

1. Slide the manual control lever in the case.
2. Position the spacer in place while sliding the manual control lever into the spacer.
3. Position the manual valve inner lever while sliding the manual control lever and lining up the
roll pin hole.
4. Install the roll pin.
4. Position the park rod in place. Push down on the park pawl and position the park rod in place.
5. While holding the park rod down, install the park rod actuating plate.
6. NOTE: Before installing the main control assembly into the transmission case, verify the presence
and orientation of the thermal bypass valve, pump adapter seal and center support feed tube seals.
Also note that one or more of the center support feed tube seals may have remained in the main
control assembly during removal and should be installed into the transmission case at this time.
Verify the 3 center support feed tube seals are in place.

7. Verify the rubber adapter is in place.
8. Coat the thermal bypass valve with petroleum jelly to hold it in place and install the thermal bypass
valve in the transmission case.
9. Position the main control in place and loosely install the 11 bolts.
1. Align the manual valve and control lever linkage.
10. Tighten the main control bolts in the sequence shown.

12. With the release tab down and unlocked, push the outer shell of the bulkhead connector sleeve into
the transmission. Make sure the bulkhead connector sleeve is fully seated into the molded leadframe.
13. Press up on the tab and lock the outer shell of the bulkhead connector sleeve in place. Make sure
that the locking tab is securely locked.
If necessary, install a new transmission fluid pan gasket.
16. Install the transmission fluid pan and tighten the transmission fluid pan bolts in a crisscross pattern.
17. Connect the transmission vehicle harness connector by pushing it in and twisting the outer shell to
lock it in place.
NOTE: The column shift is shown, the floor shift is similar.
Install the selector lever cable end on the manual control lever.
19. If equipped, install the selector lever cable splash shield and the nut.
20. Fill the transmission with clean transmission fluid. Refer to Transmission Fluid Drain and Refill .

Output Shaft Seal
Special Tool(s)
Installer, Output Seal (4X2)
307-715
Installer, Spindle/Axle Shaft

205-199 (T83T-3132-A1)

307-637

307-638

308-375
Slide Hammer
100-001 (T50T-100-A)
NOTE: Early build RWD shown, late build RWD and 4WD similar.

1 7045 Output shaft flange retaining nut RWD
2 7052 Output shaft flange seal RWD
3 — Output shaft flange (model dependent) RWD
4 7052 Output shaft seal (model dependent)
Removal
All vehicles
All Rear Wheel Drive (RWD) vehicles
2. Remove the rear driveshaft. Refer to Section 205-01 .
Early Build Rear Wheel Drive (RWD) vehicles
3. NOTE: The output shaft flange reatining nut has been staked to prevent it from coming loose. Prior to
removing the nut, remove the stake to prevent damage to the output shaft.
Remove and discard the output shaft flange retaining nut.
5. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the output shaft seal.
Late Build Rear Wheel Drive (RWD) vehicles
6. Remove the stakes from the output shaft flange retaining nut.
Remove and discard the output shaft flange retaining nut.
10. Remove the transfer case. Refer to Section 308-07B .
11. Using the Input Shaft Oil Seal Remover and Slide Hammer, remove the output shaft seal.
Installation
Early Build Rear Wheel Drive (RWD) vehicles
1. Position a new output shaft seal on the 6R80 Rear Seal 4X2 Installer.
3. Install the output shaft flange.
4. Install the output shaft flange seal and a new output shaft flange nut.
z After installing the new output shaft flange nut, it must be staked at the slots to prevent it from
coming loose.
Late Build Rear Wheel Drive (RWD) vehicles
5. Position a new output shaft seal on the Output Seal (4X2) Installer and Spindle/Axle Shaft Installer.
6. Using the Output Seal (4X2) Installer and Spindle/Axle Shaft Installer, install the output shaft seal.
8. Install the new output shaft flange retaining nut.

9. After installing the output shaft flange retaining nut, stake the slots to prevent it from coming loose.
All Rear Wheel Drive (RWD) vehicles
10. Install the rear driveshaft. Refer to Section 205-01 .
13. Using the 6R80 Rear Seal 4X4 Installer, install a new output shaft seal.
14. Install the transfer case. Refer to Section 308-07B .
All vehicles
15. Fill and check the transmission fluid. Refer to Transmission Fluid Level Check .

Shift Solenoids (SS)
Material
Item Specification
(Canada)
Part
1 W707884 Main control-to-molded leadframe bolts
3 W707885 Solenoid hold-down bracket bolt (8 required)
4 7Z369 Solenoid hold-down bracket
5 7G383 SSA , Forward (1,2,3,4) clutch, normally low VFS
(brown nozzle).
6 7G383 SSB , Direct (3,5,R) clutch, normally high VFS (black
nozzle).
7 7G383 SSC , Intermediate (2,6) clutch, normally low VFS
(brown nozzle).
8 7G383 LPC solenoid, normally high VFS (black nozzle).
9 7G383 SSD , low/reverse/overdrive clutch, normally high VFS
(black nozzle).
10 7G484 SSE , normally off ON/OFF solenoid.
11 7G383 TCC solenoid, normally low VFS (brown nozzle).
Removal
1. Remove the main control. Refer to Main Control .
2. Remove the 6 long bolts from the molded leadframe.
3. Carefully separate the molded leadframe from the main control assembly.
1. Molded leadframe.
2. Main control.
4. Remove the 8 solenoid bracket bolts and the solenoid bracket.
If replacing more then 1 solenoid, number the solenoids and number the main control solenoid ports
to correspond to the solenoid. Pull the solenoid(s) out of the main control valve body.
Installation
Use the solenoid exploded view at the beginning of this procedure to identify what type of solenoid is
being replaced. The solenoid can be a normally high VFS with a black nozzle, normally low VFS with
a brown nozzle or an ON/OFF solenoid.
If replacing a VFS , record the band number and the solenoid nozzle color to get the correct part
number for the solenoid.
Lubricate the solenoid O-rings with clean transmission fluid.
1. Solenoid Nozzle
2. Solenoid band number
2. Position the solenoid(s) in the main control in the correct port(s) as marked during removal.
3. Position the solenoid bracket in place and install the 8 bolts.

4. NOTE: The TR sensor pin must be aligned with the manual control valve during installation.
Position the molded leadframe on the main control.

1. Molded leadframe.
2. Main control.
3. TR sensor pin.
5. Install the 6 long bolts into the molded leadframe. Tighten the bolts in the sequence shown.
6. Install the main control. Refer to Main Control .

Transmission Insulator and Retainer
Transmission Insulator and Retainer Rear Wheel Drive (RWD)

1 6068 Transmission insulator and retainer
2 W713728 Transmission insulator and retainer bolt
3 N621945 Transmission insulator and retainer nut
Transmission Insulator and Retainer 4WD

1 6068 Transmission insulator and retainer
2 W713728 Transmission insulator and retainer bolt
3 N621945 Transmission insulator and retainer nut
Removal
All vehicles
2. Remove the RH exhaust heat shield bolt from the transmission support crossmember.
3. Remove the LH exhaust heat shield bolt from the transmission support crossmember.
RWD vehicles
5. Remove the LH isolator cap bolt.
6. Position a high-lift transmission jack under the transmission.
7. Remove and discard the 4 transmission support crossmember nuts and bolts (2 each side) and
remove the transmission support crossmember.
8. Remove the 3 transmission insulator and retainer bolts and remove the transmission insulator and
retainer.
4WD vehicles
9. If equipped, remove the 4 skid plate bolts and remove the skid plate.
11. Remove the LH insolator cap bolt.
12. NOTE: Right side shown, left side similar. Transmission crossmember removed for clarity.
Remove the 4 transmission insulator and retainer bolts.
13. Support the transfer case.
14. Remove and discard the 4 transmission support crossmember nuts and bolts.
15. Remove the transmission insulator and retainer.
Installation
RWD vehicles
1. Install the transmission insulator and retainer and the 3 bolts.

2. Install the transmission support crossmember and the 4 new transmission support crossmember nuts
and bolts (2 each side).
3. Lower the transmission onto the transmission support crossmember and install the 2 transmission
insulator and retainer nuts.
4. Install the LH isolator cap bolt.

4WD vehicles
5. Loosely install the transmission insulator and retainer and the 4 bolts.
6. Position the transmission support crossmember and loosely install the 2 transmission insulator and
retainer nuts.
7. Install the 4 new transmission support crossmember bolts and nuts.

z Tighten the transmission insulator and retainer bolts to 90 Nm (66 lb-ft).
z Tighten the transmission support crossmember bolts and nuts to 90 Nm (66 lb-ft).
z Tighten the transmission insulator and retainer nuts to 103 Nm (75 lb-ft).
8. Install the bolt for the LH isolator cap bolt.

All vehicles
9. Install the LH exhaust heat shield bolt to the transmission support crossmember.
10. Install the RH exhaust heat shield bolt to the transmission support crossmember.
4WD vehicles
11. If equipped, install the skid plate and the 4 skid plate bolts.

Transmission — Four Wheel Drive (4WD)
Special Tool(s)
307-346 (T97T-7902-A)

Material
Item Specification
(Canada)
XL-5 B
Installation
All vehicles
NOTE: Prior to installing a new transmission or an overhauled transmission with a new main control, record
the solenoid strategy identification tag. If a new main control was installed, install the replacement solenoid
body tag over the original identification tag. REFER to Solenoid Body Strategy .
1. NOTICE: Prior to installation of the transmission, lubricate the torque converter pilot hub with
multi-purpose grease or damage to the torque converter or engine crankshaft can occur.
2. If equipped, align the torque converter stud and flexplate hole near the paint marks at the 12 o'clock
position.
4.
NOTICE: The torque converter housing is piloted into position by dowels in the rear of the
engine block. The torque converter must rest squarely against the flexplate. This indicates the
torque converter pilot is not binding in the engine crankshaft.
NOTE: Make sure the transmission jack contacts the outer ribs of the transmission fluid pan.
NOTE: If transmission was disassembled, follow the add transmission fluid to the transmission steps.
If transmission is being replaced, remove the transmission fluid fill plug and verify transmission is
filled with transmission fluid.
Add transmission fluid to the transmission.

z Slightly tilt the transmission rearward.
z Remove the transmission fluid fill plug transmission fluid level indicator assembly.
z Add 11.35L (12 qt) of transmission fluid to the transmission through the transmission fluid fill
hole.
z Install the transmission fluid fill plug.
5. NOTICE: The torque converter housing is piloted into position by dowels in the rear of the
Position and secure the transmission on the high-lift transmission jack. Raise and position the
transmission into the vehicle behind the engine.
6. Remove the Torque Converter Retainer.
7. NOTICE: Make sure the transmission wiring harness is not between the engine block and
transmission prior to moving the transmission toward the engine or damage can occur.
NOTE: Make sure the torque converter is fully seated in the transmission before aligning the
transmission to the engine.
With the transmission in a horizontal position, move it toward the engine and position it on the dowel
pins.
Vehicles equipped with a 5.0L or 6.2L engine
8.
NOTE: Install the top 2 transmission-to-engine bolts before installing the rest of the bolts.
NOTE: Install the top left transmission-to-engine bolt through the fuel line bracket first, then through
the transmission case.
Install 6 of the 7 transmission-to-engine bolts.

9. NOTE: Install the top 2 transmission-to-engine bolts through the fuel line bracket first, then through
Install the 10 transmission-to-engine bolts.

All vehicles
10. Connect the wiring harness retainers to the top of the transmission.
11. Connect the transmission electrical connector by pushing it in and twisting the outer shell to lock it in
place.
12. Install 4 new flexplate-to-torque converter nuts.
13. Install the rubber torque converter nut access cover.
14. Install the flexplate inspection cover and the flexplate inspection cover bolts.

All vehicles
17. Install the starter motor. REFER to Section 303-06 .
18. Reposition the transmission fluid cooler tubes and bracket and install the transmission fluid cooler
tube bracket nut.
19. NOTE: Inspect the case to make sure the old transmission fluid cooler tube O-rings are not stuck in
the case.
Install new transmission fluid cooler tube O-rings on the transmission fluid cooler tubes.
20. NOTICE: Install a new transmission fluid cooler tube bracket bolt.
Install the transmission fluid cooler tubes and a new transmission fluid cooler tube bracket bolt.
21. NOTE: The column shift is shown, the floor shift similar.
Install the selector lever cable bracket and selector lever cable bracket bolts.
22. Align the transmission fluid cooler tube bracket and install the remaining transmission-to-engine bolt.
All vehicles
23. Install the fuel line bracket and the fuel line bracket bolt.
24. Position a jack stand under the transmission, and remove the high-lift transmission jack.
25. NOTE: Do not reuse the old transfer case-to-transmission bolts.
If the transfer case was removed from the transmission during removal, install the transfer case using
a high-lift transmission jack. Install 9 new transfer case-to-transmission bolts.
z Tighten the bolts evenly in a cross pattern to 17 Nm (150 lb-in).
26. Connect the vent hose to the transfer case.
27. Connect the electrical connector and attach the 2 harness retainer clips to the transfer case.
28. Install the shift cable mounting bracket and the 2 nuts.
29. Connect the cable end to the shift lever.
30. Install the front and rear driveshafts. REFER to Section 205-01 .
31. Install the exhaust Y-pipe. REFER to Section 309-00 .
32. Connect the battery ground cable. REFER to Section 414-01 .
33. Adjust the selector lever cable and install the selector lever cable end on the manual control lever.
Verify the selector lever cable is correctly adjusted. REFER to Section 307-05 .
35. If a new transmission or a new main control was installed, the solenoid body strategy must be
updated. REFER to Solenoid Body Strategy .
36. If the transmission was overhauled, the adaptive drive cycle must be updated. REFER to Shift Point
Road Test .
(195ºF-215ºF).
Transmission Fluid or Removing Transmission Fluid. REFER to Transmission Fluid Drain and Refill .


Transmission — Rear Wheel Drive (RWD)
Special Tool(s)
307-346 (T97T-7902-A)

Material
Item Specification
(Canada)
XL-5 B
Installation
All vehicles
NOTE: Prior to installing a new transmission or an overhauled transmission with a new main control, record
the solenoid strategy identification tag. If a new main control was installed, install the replacement solenoid
body tag over the original identification tag. REFER to Solenoid Body Strategy .
1. NOTICE: Prior to installation of the transmission, lubricate the torque converter pilot hub with
multi-purpose grease or damage to the torque converter or engine crankshaft can occur.
2. If equipped, align the torque converter stud and flexplate hole near the paint marks at the 12 o'clock
position.
4.
NOTICE: The torque converter housing is piloted into position by dowels in the rear of the
NOTE: Make sure the transmission jack contacts the outer ribs of the transmission fluid pan.
NOTE: If transmission was disassembled, follow the add transmission fluid to the transmission steps.
If transmission is being replaced, remove the transmission fluid fill plug and verify transmission is
filled with transmission fluid.
Add transmission fluid to the transmission.

z Slightly tilt the transmission rearward.
z Remove the transmission fluid fill plug transmission fluid level indicator assembly.
z Add 11.35L (12 qt) of transmission fluid to the transmission through the transmission fluid fill
hole.
z Install the transmission fluid fill plug.
5. NOTICE: The torque converter housing is piloted into position by dowels in the rear of the
Position and secure the transmission on the high-lift transmission jack. Raise and position the
transmission into the vehicle behind the engine.
6. Remove the Torque Converter Retainer.
7. NOTICE: Make sure the transmission wiring harness is not between the engine block and
transmission prior to moving the transmission toward the engine or damage can occur.
NOTE: Make sure the torque converter is fully seated in the transmission before aligning the
transmission to the engine.
With the transmission in a horizontal position, move it toward the engine and position it on the dowel
pins.
8.
NOTE: Install the top 2 transmission-to-engine bolts before installing the rest of the bolts.
NOTE: Install the top left transmission-to-engine bolt through the fuel line bracket first, then through
Install 6 of the 7 transmission-to-engine bolts.

9. NOTE: Install the top 2 transmission-to-engine bolts through the fuel line bracket first, then through
Install the 10 transmission-to-engine bolts.

All vehicles
10. Connect the wiring harness retainers to the top of the transmission.
11. Connect the transmission electrical connector by pushing it in and twisting the outer shell to lock it in
place.
13. Install the rubber torque converter nut access cover.
14. Install the flexplate inspection cover and the flexplate inspection cover bolts.

All vehicles
17. Install the starter motor. REFER to Section 303-06 .
18. Reposition the transmission fluid cooler tubes and bracket and install the transmission fluid cooler
tube bracket nut.
19. NOTE: Inspect the case to make sure the old transmission fluid cooler tube O-rings are not stuck in
the case.
Install new transmission fluid cooler tube O-rings on the transmission fluid cooler tubes.
20. NOTICE: Install a new transmission fluid cooler tube bracket bolt.
Install the transmission fluid cooler tubes and a new transmission fluid cooler tube bracket bolt.
21. NOTE: The column shift is shown, the floor shift similar.
Install the selector lever cable bracket and selector lever cable bracket bolts.
22. Align the transmission fluid cooler tube bracket and install the remaining transmission-to-engine bolt.
Vehicles equipped with 3.7L engine
23. Install the transmission damper and the 2 transmission damper bolts.
All vehicles
24. Install the fuel line bracket and the fuel line bracket bolt.
25. Position a jack stand under the transmission, and remove the high-lift transmission jack.
26. Install the driveshaft. REFER to Section 205-01 .
27. Install the exhaust Y-pipe. REFER to Section 309-00 .
28. Connect the battery ground cable. REFER to Section 414-01 .
29. Adjust the selector lever cable and install the selector lever cable end on the manual control lever.
Verify the selector lever cable is correctly adjusted. REFER to Section 307-05 .
31. If a new transmission or a new main control was installed, the solenoid body strategy must be
updated. REFER to Solenoid Body Strategy .
32. If the transmission was overhauled, the adaptive drive cycle must be updated. REFER to Shift Point
Road Test .
(195ºF-215ºF).
Transmission Fluid or Removing Transmission Fluid. REFER to Transmission Fluid Drain and Refill .


Transmission — Four Wheel Drive (4WD)
Special Tool(s)
307-346 (T97T-7902-A)
Removal
NOTE: Refer to the Transmission Cooler Flushing Job Aid on the FMCDealer website.
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. REFER to Section 100-02 .
2. Disconnect the battery ground cable. REFER to Section 414-01 .
3. If transmission disassembly or installation of a new transmission is necessary, remove the 21

transmission fluid pan bolts and remove the transmission fluid pan. Drain the transmission fluid into a
container.
4. Install the transmission fluid pan and the 21 transmission fluid pan bolts. Tighten transmission fluid
pan bolts in a crisscross pattern.
5. Remove the exhaust Y-pipe. REFER to Section 309-00 .
6. NOTE: It is only necessary to remove the transfer case from the transmission if a new transmission is
being installed or if the transmission is going to be disassembled for a transmission related repair.
Remove the transfer case. REFER to Section 308-07B .
NOTE: Make sure the transmission is securely fastened to the transmission jack.
Using a high-lift transmission jack, support the transmission and remove the jack stand.
8. Remove the fuel line bracket bolt from the left side of the transmission and position the fuel line
bracket aside.
Vehicles equipped with a floor shift
NOTE: The 3.5L engine is shown, the 3.7L, 5.0L and 6.2L engines are similar.
Rotate the cable adjustment lock upward and remove the selector lever cable from the manual control
lever.
Vehicles equipped with a column shift
13. Rotate the cable adjustment lock upward and remove the selector lever cable from the manual control
lever.
All vehicles
14. NOTE: The column shift is shown, the floor shift is similar.
Remove the selector lever cable bracket bolts and remove the selector lever cable bracket.
15. Remove the transmission-to-engine bolt.
All vehicles
16. Remove and discard the transmission fluid cooler tube bracket bolt.
17. NOTE: The 3.5L and 3.7L engine is shown, the 5.0L and the 6.2L engines are similar.
Remove the transmission fluid cooler tube bracket nut and position the transmission fluid cooler tube
bracket and tubes aside.
18. Remove the starter motor. REFER to Section 303-06 .
20. Remove and discard the 4 flexplate-to-torque converter nuts.
21. Remove the flexplate inspection cover bolts and the flexplate inspection cover.
22. Remove the rubber torque converter nut access cover.
All vehicles
24. NOTICE: Do not pull on the wiring harness to disconnect the electrical connector or damage
to the electrical connector will occur.
Disconnect the electrical connector by twisting the outer shell and pulling back on the electrical
connector.
25. Disconnect the wiring harness retainers from the top of the transmission.
26. transmission, transfer case, and axle assemblies to their

NOTICE: Make sure to not pinch the transmission wiring harness between the transmission
and the body or damage can occur.
NOTE: The top 2 transmission-to-engine bolts secure the fuel line bracket to the transmission case.
Remove the 10 transmission-to-engine bolts.
27.
NOTE: Remove the top 2 transmission-to-engine bolts before removing the rest of the bolts.
NOTE: The top left transmission-to-engine bolt secures the fuel line bracket to the transmission case.
Remove the 6 remaining transmission-to-engine bolts.
All vehicles
28. Slide the transmission back enough to install the Torque Converter Retainer.
29. Remove the transmission from the vehicle.
30. If the transmission is being disassembled to install new parts, or if a new or remanufactured
transmission is being installed, clean and backflush the transmission fluid cooler, the auxiliary
transmission fluid cooler (if equipped) and the transmission fluid cooler tubes to prevent contaminants
from entering the transmission. REFER to Transmission Fluid Cooler Backflushing and Cleaning .

Transmission — Rear Wheel Drive (RWD)
Special Tool(s)
307-346 (T97T-7902-A)
Removal
NOTE: Refer to the Transmission Cooler Flushing Job Aid on the FMCDealer website.
All vehicles
2. Disconnect the battery ground cable. REFER to Section 414-01 .
3. If transmission disassembly or installation of a new transmission is necessary, remove the 21

transmission fluid pan bolts and remove the transmission fluid pan. Drain the transmission fluid into a
container.
4. Install the transmission fluid pan and the 21 transmission fluid pan bolts. Tighten transmission fluid
pan bolts in a crisscross pattern.
5. Remove the exhaust Y-pipe. REFER to Section 309-00 .
6. Remove the driveshaft. REFER to Section 205-01 .
NOTE: Make sure the transmission is securely fastened to the transmission jack.
Using a high-lift transmission jack, support the transmission and remove the jack stand.
8. Remove the fuel line bracket bolt from the left side of the transmission and position the fuel line
bracket aside.
Vehicles equipped with 3.7L engine Rear Wheel Drive (RWD)
10. Remove the 2 transmission damper bolts and remove the transmission damper.
Vehicles equipped with a floor shift
NOTE: The 3.5L engine is shown, the 3.7L, 5.0L and 6.2L engines are similar.
lever.
Vehicles equipped with a column shift
14. Rotate the cable adjustment lock upward and remove the selector lever cable from the manual control
lever.
All vehicles
15. NOTE: The column shift is shown, the floor shift is similar.
Remove the selector lever cable bracket bolts and remove the selector lever cable bracket.
16. Remove the transmission-to-engine bolt.
All vehicles
17. Remove and discard the transmission fluid cooler tube bracket bolt.
18. NOTE: The 3.5L and 3.7L engine is shown, the 5.0L and the 6.2L engines are similar.
Remove the transmission fluid cooler tube bracket nut and position the transmission fluid cooler tube
bracket and tubes aside.
19. Remove the starter motor. REFER to Section 303-06 .
22. Remove the flexplate inspection cover bolts and the flexplate inspection cover.
23. Remove the rubber torque converter nut access cover.
All vehicles
25. NOTICE: Do not pull on the wiring harness to disconnect the electrical connector or damage
to the electrical connector will occur.
Disconnect the transmission electrical connector by twisting the outer shell and pulling back on the
26. Disconnect the wiring harness retainers from the top of the transmission.
27.
NOTE: The top 2 transmission-to-engine bolts secure the fuel line bracket to the transmission case.
Remove the 10 transmission-to-engine bolts.
28.
NOTE: Remove the top 2 transmission-to-engine bolts before removing the rest of the bolts.
NOTE: The top left transmission-to-engine bolt secures the fuel line bracket to the transmission case.
Remove the 6 remaining transmission-to-engine bolts.
All vehicles
29. Slide the transmission back enough to install the Torque Converter Retainer.
30. Remove the transmission from the vehicle.
31. If the transmission is being disassembled to install new parts, or if a new or remanufactured
transmission is being installed, clean and backflush the transmission fluid cooler, the auxiliary
transmission fluid cooler (if equipped) and the transmission fluid cooler tubes to prevent contaminants
from entering the transmission. REFER to Transmission Fluid Cooler Backflushing and Cleaning .
SECTION 307-02: Transaxle/Transmission Cooling 2014 F-150 Workshop Manual

Material
Capacity
Motorcraft® MERCON® LV MERCON® 12.30L
Automatic Transmission Fluid LV (13.0 qt)
XT-10-QLVC
Item Specification
Transmission Fluid
This transmission fluid is not interchangeable with any other transmission fluids. Check the transmission
fluid level indicator to determine the correct transmission fluid.
Axle carrier mounting bushing bolt 115 85 —
Forward skid plate (6 required) 48 35 —
Heat shield nut—Raptor 48 35 —
Heat shield nut—Raptor 23 17 —
Rearward skid plate (4 required) 48 35 —
Selector lever cable splash shield nut 12 — 106
Starter motor ground cable eyelet nut 25 18 —
Starter solenoid B-terminal eyelet nut 12 — 106
Starter solenoid S-terminal eyelet 5 — 44
Sway bar nut (4 required) a — — —
Transmission fluid cooler tube bracket bolt 12 — 106
Transmission fluid cooler tube bracket-to-front of the engine nut—3.5L GTDI and 3.7L 12 — 106
Transmission fluid cooler tube bracket-to-front of the engine nut—5.0L (4V) 12 — 106
Transmission fluid cooler tube bracket-to-front of the engine nut—6.2L (2V) 40 30 —
Transmission fluid cooler tube bracket-to-starter motor stud nut—3.5L GTDI and 3.7L 12 — 106
a — — —
Transmission fluid cooler tubes-to-transmission bolt
Transmission-to-engine bolt—6.2L (2V) and 5.0L (4V) 48 35 —

Transmission Cooling
The transmission fluid cooling system without an auxiliary transmission fluid cooler consists of the following:
z An in-tank transmission fluid cooler inlet tube

z A non-repairable in-tank transmission fluid cooler
z An in-tank transmission fluid cooler outlet tube
The transmission fluid cooling system with an auxiliary transmission fluid cooler consists of the following:
z An in-tank transmission fluid cooler inlet tube

z A non-repairable in-tank transmission fluid cooler
z An auxiliary transmission fluid cooler inlet tube
z An auxiliary transmission fluid cooler
z An auxiliary transmission fluid cooler outlet tube
Located inside the transmission case is a thermal bypass valve. The thermal bypass is used to route fluid to
the cooler when operating temperatures increase, or to return fluid directly to the transmission lube circuit.
When the transmission fluid temperature is below 185°F (85°C) no fluid is routed to the cooler. It is essential
that the transmission fluid level be checked and adjusted only when the fluid temperature is verified with a
scan tool.
The transmission fluid flows from the transmission bottom fitting, to the in-tank transmission fluid cooler, to
the auxiliary transmission fluid cooler, if so equipped, and returns to the transmission top fitting.
For the transmission fluid cooler backflushing and cleaning procedure, refer to Section 307-01 .
3.5L GTDI and 3.7L Engines Without an Auxiliary Transmission Fluid Cooler
Part
1 7B028 In-tank transmission fluid cooler outlet tube
2 7B028 Transmission fluid cooler tube radiator inlet
3 7Z465 Transmission fluid cooler inlet and outlet tube
secondary latches
4 7R081 Transmission fluid cooler tubes
5.0L (4V) Engine Without an Auxiliary Transmission Fluid Cooler
Part
2 7B028 Transmission fluid cooler tube radiator inlet
secondary latches
4 7R081 Transmission fluid cooler tubes
3.5L GTDI, 3.7L and 5.0L Engines With an Auxiliary Transmission Fluid Cooler
Part
1 7C410 Auxiliary transmission fluid cooler inlet hose
2 7A095 Auxiliary transmission fluid cooler
3 7B028 In-tank transmission fluid cooler inlet tube
secondary latches
5 7B028 Auxiliary transmission fluid cooler outlet hose
6.2L (2V) Engine With an Auxiliary Transmission Fluid Cooler
Part
secondary latches

NOTICE: When internal wear/damage occurs in the transmission, metal particles, clutch plate
material and band material can travel into the torque converter, the transmission fluid cooler tubes,
the in-tank transmission fluid cooler and the auxiliary transmission fluid cooler, if so equipped.
These contaminants are a major cause of recurring transmission concerns. To prevent future
concerns, remove these contaminants from the cooling system before placing the transmission back
into use.
1. Visually inspect for obvious signs of mechanical damage, incorrect component installation and
system leaks. Repair as necessary.
z Install a new or remanufactured radiator when transmission fluid is found leaking from the in-
tank transmission fluid cooler. Refer to Section 303-03 .
z Install a new auxiliary transmission fluid cooler if there is leakage from the auxiliary
transmission fluid cooler.
2. If the fault is not visually evident, GO to Symptom Chart - Transmission Cooling or GO to Symptom
Chart - NVH .
Symptom Chart — Transmission Cooling
Symptom Chart — Transmission Cooling

z Transmission z Excessive vehicle or z REFER to the Vehicle
overheating towing loads, severe Specification Manual for load
vehicle use and GVW information.
REFER to the Owner's
Literature.
z Incorrect transmission z CHECK and if necessary,
fluid level ADJUST the transmission
fluid to the correct level.
z Transmission fluid z CHECK transmission fluid
condition condition.
z Incorrect transmission z REFER to Specifications in
fluid type this section.
z Transmission cooling z CARRY OUT the
system damaged, Transmission Fluid Cooler
blocked, restricted or Backflushing and Cleaning.
installed incorrectly REFER to Section 307-01 .
z System leaks z INSPECT for leakage.
z Engine overheating z REFER to Section 303-03 .
z Powertrain control system z CARRY OUT On-Board

electrical inputs/outputs, Diagnostic (OBD) test.
vehicle wiring harnesses, REFER to the Powertrain
PCM, Torque Converter Control/Emissions Diagnosis
Clutch (TCC) solenoid (PC/ED) manual.
z Internal transmission z REPAIR as necessary.
concerns
z Transmission z Transmission fluid cooler z REFER to the Component
fluid leak at tubes-to-transmission fluid Test in this section.
radiator in-tank cooler fitting
cooler
z Vibration — a high frequency z Transmission fluid z CHECK the
(20-80 Hz) that is felt through cooler tubes transmission fluid
the seat or selector lever. grounded out cooler tubes. REPAIR
Changes with engine speed as necessary.
Component Test
Transmission Fluid Cooler Leaks at Radiator
Transmission fluid may leak between the radiator transmission fluid cooler and the transmission fluid cooler
fitting (not the transmission fluid cooler tube into the transmission fluid cooler fitting), which may result in a
residue of transmission fluid on the radiator tank around the transmission fluid cooler fitting. Insufficient
thread sealer on the transmission fluid cooler fitting may cause this.

Transmission Fluid Cooler Tubes — 3.5L GTDI, 3.7L
Special Tool(s)
Cooler Line
307-569
Material
Item Specification
XT-10-QLVC
3.5L GTDI and 3.7L Transmission Fluid Cooler Tubes
Part
1 W715131 Transmission fluid cooler tubes-to-transmission bolt
2 W709450 Transmission fluid cooler tube bracket nut
4 W709450 Transmission fluid cooler tube bracket-to-front of
engine nut
secondary latches
6 W500212 Transmission fluid cooler tube bracket bolt
9 7C107 Transmission fluid cooler hose clamps
10 7J227 Transmission fluid cooler tube O-rings (4 required)
11 7B147 Selector lever cable splash shield (if equipped)
12 W520111 Selector lever cable splash shield nut
(with selector lever cable splash shield)
3.5L GTDI and 3.7L With Auxiliary Transmission Fluid Cooler

Removal
02 .
2. If equipped, remove the 4 fasteners and the splash shield.
3. If equipped, remove the 12 pushpins and the air deflector.
5. Remove the transmission fluid cooler tube secondary latches.
6. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes
from the transmission fluid cooler hoses.
7. Remove the transmission fluid cooler tube bracket nut from the front of the engine.
8. Remove the transmission fluid cooler tube bracket nut from the starter motor stud bolt.
9. If equipped, remove the selector lever cable splash shield nut and the selector lever cable splash
shield.
10. NOTE: The transmission fluid cooler tube O-rings may remain in the transmission case. Carefully
remove them from the case if retained.
Remove and discard the transmission fluid cooler tubes-to-transmission bolt and separate the
transmission fluid cooler tubes from the transmission.
11. Remove and discard the 4 O-rings on the transmission fluid cooler tubes.
12. Remove the transmission fluid cooler tubes from the transmission.
Installation
1. Route the transmission fluid cooler tubes and position them in place.
2. NOTE: Inspect the transmission case to make sure that the transmission fluid cooler tube O-rings did
not remain in the transmission case. Carefully remove and discard them from the case if retained.
Install 4 new O-rings on the transmission fluid cooler tubes.
3. NOTICE: Install a new transmission fluid cooler tubes-to-transmission bolt.
Install the transmission fluid cooler tubes and a new transmission fluid cooler tubes-to-transmission
bolt.
4. If equipped, install the selector lever cable splash shield and the splash shield nut.
5. Install the transmission fluid cooler tube bracket nut to the starter motor stud bolt.
6. Install the transmission fluid cooler tube bracket nut to the front of the engine.
7. Connect the transmission fluid cooler tubes to the transmission fluid cooler hoses.
8. Install the transmission fluid cooler tube secondary latches.

10. If equipped, install the air deflector and the 12 pushpins.
11. If equipped, install the splash shield and the 4 fasteners.
12. Fill the transmission with fluid and verify correct operation. For additional information, refer to
Transmission Fluid Level Check in Section 307-01 .
13. Check for leaks.

Transmission Fluid Cooler Tubes — 5.0L (4V), 6.2L (2V)
Special Tool(s)
Cooler Line
307-569
Material
Item Specification
XT-10-QLVC
5.0L (4V) Transmission Fluid Cooler Tubes
Part
2 W714012 Transmission-to-engine bolt
engine nut
secondary latches
6 W500212 Transmission fluid cooler tube bracket bolt

6.2L (2V) Transmission Fluid Cooler Tubes
Part
2 W714012 Transmission-to-engine bolt
engine nut
secondary latches

5.0L (4V) With Auxiliary Transmission Fluid Cooler

Removal
All vehicles
02 .
4WD
3. If equipped, remove the 6 bolts and the forward skid plate.
4. Remove the 4 bolts and the rearward skid plate.
All vehicles
NOTE: 5.0L (4V) Shown, 6.2L (2V) similar.
5. Remove the transmission fluid cooler tube secondary latches.
NOTE: 5.0L (4V) Shown, 6.2L (2V) similar.
6. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission fluid cooler tubes
from the transmission fluid cooler hoses.
7. Remove the transmission fluid cooler tube bracket nut from the front of the engine.
8. Remove the transmission-to-engine bolt and transmission fluid cooler tube bracket from the engine.
10. NOTE: The transmission fluid cooler tube O-rings may remain in the transmission case. Carefully
remove them from the case if retained.
Remove and discard the transmission fluid cooler tubes-to-transmission bolt and separate the
transmission fluid cooler tubes from the transmission.
11. Remove and discard the 4 O-rings on the transmission fluid cooler tubes.
Raptor
12. Remove the 2 nuts and the heat shield.
All vehicles
13. NOTE: Right side shown, left side similar.
Remove and discard the 4 nuts and lower the front sway bar.
4WD
14. Remove the starter terminal cover.
16. Remove the nut and disconnect the starter solenoid B-terminal eyelet.
17. Remove the nut and disconnect the starter motor ground cable eyelet.
18. Detach the starter wiring harness from the oil pan.
19. Remove the starter wiring harness form the front engine cover stud and position the starter wiring
harness aside.
20. NOTE: Rotate the steering column so that the pinch bolt for the steering column coupler allows
clearance for the upper front axle carrier mounting bushing bolt.
21. Position a jack stand under the right side of the front axle.
23. Lower the right side of the front axle.
All vehicles
24. Remove the transmission fluid cooler tubes.
Installation
All vehicles
1. Route the transmission fluid cooler tubes and position them in place.
4WD
2. Raise the right side of the front axle.


5. Position the starter wiring harness to the front of the engine cover stud.
6. Attach the starter wiring harness to the oil pan.
7. Connect the starter motor ground cable eyelet and install the nut.
8. Connect the starter solenoid B-terminal eyelet and install the nut.
9. Connect the starter solenoid S-terminal eyelet and install the nut.
10. Install the terminal cover.
All vehicles
NOTE: Right side shown, left side similar.
11. Position the sway bar in place and install 4 new nuts.
Raptor
12. Install the heat shield and the 2 nuts.

1. Tighten to 48 Nm (35 lb-ft).
2. Tighten to 23 Nm (17 lb-ft).
All vehicles
13. NOTE: Inspect the transmission case to make sure that the transmission fluid cooler tube O-rings did
not remain in the transmission case. Carefully remove and discard them from the case if retained.
Install 4 new O-rings on the transmission fluid cooler tubes.
14. NOTICE: Install a new transmission fluid cooler tubes-to-transmission bolt.
Install the transmission fluid cooler tubes and a new transmission fluid cooler tubes-to-transmission
bolt.
16. Install the transmission fluid cooler tube bracket and the transmission-to-engine bolt.
5.0L (4V)
17. Install the transmission fluid cooler tube bracket and the nut to the front of the engine.
6.2L (2V)
18. Install the transmission fluid cooler tube bracket and the nut to the front of the engine.
All vehicles
19. Connect the transmission fluid cooler tubes to the transmission fluid cooler hoses.
20. Install the transmission fluid cooler tube secondary latches.
4WD
21. Install the rearward skid plate and the 4 bolts.

22. If equipped, install the forward skid plate and the 6 bolts.
All vehicles
24. Fill the transmission with fluid and verify correct operation. For additional information, refer to
Transmission Fluid Level Check in Section 307-01 .
25. Check for leaks.

Transmission Fluid Cooler
Material
Item Specification
XT-10-QLVC
Part
1 8005 Radiator
2 7C410 In-tank transmission fluid cooler outlet hose
5 7C107 Clamps
secondary latches
Removal
1. Remove the transmission fluid cooler inlet hose from the transmission fluid cooler.
z Discard the clamp.
2. Remove the transmission fluid cooler outlet hose from the transmission fluid cooler.
z Discard the clamp.
3. Remove the transmission fluid cooler.
Installation
1. Install the transmission fluid cooler.
2. Install a new transmission fluid cooler outlet hose clamp.
3. Install the transmission fluid cooler outlet hose to the transmission fluid cooler.
4. Install a new transmission fluid cooler inlet hose clamp.
5. Install the transmission fluid cooler inlet hose to the transmission fluid cooler.
6. Fill the transmission with transmission fluid. For additional information, refer to Transmission Fluid
Level Check in Section 307-01 .
7. Check for leaks.
SECTION 307-05: Automatic Transaxle/Transmission External Controls 2014 F-150 Workshop Manual
Selector lever bolt (column shift) 18 — 159
Selector lever mechanism (column shift) 10 — 89
Selector lever cable bracket bolts 25 18 —
Selector lever assembly bolts (floor shift) 8 — 71
External Controls — Column Shift
Special Tool(s)

1. Verify the customer concern by operating the transmission external control.
2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart:

z Damaged Brake Shift Interlock Actuator z Failed fuse(s):
(BSIA) Body Control Module (BCM) 18
z Damaged Tow/Haul switch (10A)
z Damaged SelectShift™ switch BCM 42 (5A)
z PCM
z Loose or damaged connections
z Damaged wiring harness
z Corroded or damaged terminals
3. If the fault is not visually evident, determine the symptom. GO to Symptom Chart - External Controls,
Column Shift or GO to Symptom Chart - NVH Column Shift .
DTC Chart
DTC Chart
B1319:11 Brake Shift Shift Interlock (BSI) BSIA system BSIA GO to
Interlock Output Circuit: Circuit malfunction inoperative. Pinpoint
Actuator (BSIA), short to ground Test A .

BCM
Actuator (BSIA), short to voltage or Test A .
BCM open
P0815 Upshift Switch Upshift switch The PCM signal input Upshift switch GO to
Circuit concerns, open or voltage status is out of inoperative. Pinpoint
shorted circuit range Test D .
P0816 Downshift Downshift switch The PCM signal input Downshift switch GO to
Switch Circuit concerns, open or voltage status is out of inoperative. Pinpoint
shorted circuit range Test D .
P1780 Tow/Haul Transmission Control The PCM did not Tow/Haul is GO to
Switch Switch (TCS) receive a Tow/Haul inoperative or Pinpoint
(Overdrive (O/D) switch input during the does not operate Test C .
cancel) circuit out of Key ON Engine correctly.
self-test range Running (KOER) self-
test
Symptom Chart — External Controls, Column Shift
Symptom Chart — External Controls, Column Shift

z The Brake Shift z Circuitry z GO to Pinpoint Test A .
Interlock Actuator z Fuse(s):
(BSIA) system does Body Control
not release/lock Module
correctly (BCM) 18
(10A)
z BSIA
z Selector lever cable z VERIFY selector lever cable
adjustment. REFER to
Adjustment — Column Shift in
this section.
z Transmission Range z Selector lever cable z TIGHTEN bolts holding the
(TR) indicator bracket selector lever cable bracket.
(PRNDL) does not REFER to Selector Lever
correspond to the Cable Adjustment — Column
selected gear Shift in this section.
z Instrument Panel z REFER to Section 413-01 .
Cluster (IPC)
malfunction
z Selector lever cable z VERIFY cable is fully seated in
loose in the selector the selector lever cable
lever cable bracket bracket. REFER to Selector
Lever Cable — Column Shift
in this section.
z Selector lever cable z VERIFY selector lever cable
adjustment. REFER to
this section.
z Clip securing the z INSTALL clip correctly.
selector lever cable REFER to Selector Lever
to the steering Cable — Column Shift in this
column bracket section.
z TR indicator z IPC malfunction z REFER to Section 413-00 .
(PRNDL) does not
illuminate
z TR sensor z CHECK for TR sensor DTCs.
z The Tow/Haul switch z Tow/Haul switch z GO to Pinpoint Test C
does not operate z Tow/Haul switch not
correctly cycled during self-
test
z Circuitry
z The Tow/Haul z IPC z REFER to Section 413-01 .
indicator lamp is not z PCM
operating correctly z Circuitry
z The SelectShift™ z SelectShift™ switch z GO to Pinpoint Test D .
switch is not z PCM
operating correctly z Circuitry
z Water enters inside z Cable assembly z SECURE grommet to floor
the vehicle grommet panel. REFER to Selector
in this section.
z Torn selector lever z INSTALL a new selector lever
cable assembly cable. REFER to Selector
grommet Lever Cable — Column Shift
in this section.
z Excessive shift effort z Selector lever cable z INSTALL a new selector lever
cable. REFER to Selector
in this section.
z Cable bracket z ADJUST cable. REFER to
this section. TIGHTEN cable
bracket screws. REFER to
z Selector lever will not z Selector lever cable z VERIFY selector lever cable
shift from PARK adjustment. REFER to
this section.
z Column bracket clip z INSTALL a new bracket clip.
REFER to Selector Lever
Cable — Column Shift in this
section.
z Broken selector z INSTALL a new selector lever
lever cable cable. REFER to Selector

in this section.
z Brake Shift Interlock z GO to Pinpoint Test A .
Actuator (BSIA)
system failure
z Vehicle will not z Selector lever cable z VERIFY selector lever cable
crank/start in park adjustment. REFER to
but will crank/start in Selector Lever Cable
neutral Adjustment — Column Shift in
this section.
z TR sensor z CHECK for TR sensor DTCs.
Symptom Chart — NVH Column Shift
Symptom Chart — NVH Column Shift
z Vibration — a high z Selector lever z CHECK the selector lever
frequency (20-80 Hz) that cable incorrectly cable. REPAIR as
is felt through the seat or routed, grounded necessary. REFER to
selector lever. Changes out or loose Selector Lever Cable —
with engine speed Column Shift in this section.
z Rattle, buzz or other z Selector lever z TIGHTEN the selector lever
noise loose bolts. REFER to Selector
Lever — Column Shift in
this section.
z Selector lever z INSTALL a new selector
lever. REFER to Selector
Lever — Column Shift in
this section.
z Cable assembly z SECURE the grommet to
grommet the floor panel. REFER to
Selector Lever Cable —
Column Shift in this section.
Pinpoint Tests
Refer to Wiring Diagrams Cell 30 , Transmission Controls for schematic and connector information.
Tow/Haul Connector — C2399
Pin Number Circuit Function

1 Tow/Haul Power
2 Tow/Haul Signal
3 SelectShift™ Upshift
4 SelectShift™ Ground
5 SelectShift™ Downshift
PINPOINT TEST A: THE BSIA SYSTEM DOES NOT RELEASE/LOCK CORRECTLY
NOTE: Inspect the selector lever cable before proceeding with this pinpoint test.

A1 CHECK THE STOPLAMPS
z Apply the brake pedal and observe the stoplamps. Yes
z Do the stoplamps illuminate? VERIFY the BCM fuse 18 (10A) is
OK, If OK GO to A2 . If not OK,
REFER to the Wiring Diagrams
manual to identify the possible
causes of the circuit short.
No
A2 CHECK THE BSIA OUTPUT CIRCUIT
z Disconnect: Brake Shift Interlock Actuator (BSIA) C2008 . Yes
z Ignition ON. GO to A3 .
z Measure the voltage between the BSIA C2008-4, circuit
CET53 (BU/OG), harness side and ground. No
If the voltage was greater than 10
volts with the brake pedal applied or
not applied, GO to A4 . Otherwise,
GO to A5 .
z Depress the brake pedal.

z With the brake pedal depressed, measure the voltage
between the BSIA C2008-4, circuit CET53 (BU/OG),
z Is the voltage greater than 10 volts with the brake
pedal applied and 0 volts with the brake pedal not
applied?
A3 CHECK THE BSIA GROUND CIRCUIT FOR AN OPEN
z Ignition OFF. Yes
z Measure the resistance between the BSIA C2008-1, REPLACE the BSIA . REFER to
circuit GD133 (BK), harness side and ground. Brake Shift Interlock Actuator —
Column Shift in this section. CLEAR
the DTC. TEST the system for
normal operation.
No
REPAIR circuit GD133 (BK) for an
open. CLEAR the DTC. TEST the

A4 CHECK THE BSIA OUTPUT CIRCUIT FOR A SHORT TO
POWER
z Ignition OFF. Yes
z Disconnect: BCM C2280B. REPAIR circuit CET53 (BU/OG) for
z Inspect C2008 and C2280B for damaged, pushed-out a short to power. CLEAR the DTC.
terminals or loose wires. TEST the system for normal
z Measure the voltage between the BSIA C2008-4, circuit
CET53 (BU/OG), harness side and ground. No
GO to A5 .
A5 CHECK THE BSIA POWER CIRCUIT FOR AN OPEN

z Measure the resistance between the BSIA C2008-4, Yes
circuit CET53 (BU/OG) and BCM C2280B-49, CET53 GO to A6 .
(BU/OG) harness side.
No
REPAIR circuit CET53 (BU/OG) for
an open. CLEAR the DTC. TEST

A6 CHECK FOR CORRECT BCM OPERATION
z Check for: REPLACE the BCM . REFER to
corrosion Section 418-00 . CLEAR the DTC.
damaged pins TEST the system for normal
z Connect all the BCM connectors and make sure they seat
correctly. No
z Operate the system and verify the concern is still present. The system is operating correctly at
z Is the concern still present? this time. The concern may have
been caused by a loose or corroded
connector.
PINPOINT TEST C: THE TOW/HAUL SWITCH DOES NOT OPERATE CORRECTLY
NOTE: Vehicles equipped with a 3.5L engine use PCM C1551B.

C1 CHECK DTCs
z Ignition ON. Yes
z Connect the scan tool. GO to C2 .
z Start the engine and RUN the Key ON Engine
Running (KOER) self-test. No
z Is DTC P1780 set? No trouble found with the Tow/Haul system.
REFER to Section 413-01 if the Tow/Haul
lamp does not illuminate.
C2 CHECK THE BCM FUSE 42 (5A)
z Ignition OFF. Yes
z Remove Body Control Module (BCM) fuse 42 GO to C4 .
(5A).
z Check fuse: BCM 42 (5A). No
z Is the resistance less than 5 ohms? GO to C3 .

C3 CHECK THE TOW/HAUL POWER CIRCUIT FOR
A SHORT TO GROUND
z Disconnect: Tow/Haul C2399. Yes
z Disconnect: BCM C2280B. GO to C4 .
z Inspect C2399 and C2280B for damaged,
pushed-out terminals or loose wires. No
z Measure the resistance between the Tow/Haul REPAIR circuit CBP42 (GN) for a short to
C2399-1, circuit CBP42 (GN), harness side and ground. CLEAR the DTC. RERUN the
ground. KOER self-test and test the system for
normal operation.

C4 CHECK THE TOW/HAUL POWER CIRCUIT FOR
VOLTAGE
z Disconnect: Tow/Haul C2399. Yes
z Inspect C2399 for damaged, pushed-out terminals GO to C5 .
or loose wires.
z Ignition ON. No
z Measure the voltage between the Tow/Haul REPAIR circuit CBP42 (GN) for an open.
switch C2399-1, circuit CBP42 (GN), harness side CLEAR the DTC. RERUN the KOER self-
and ground. test and test the system for normal
operation.

C5 CHECK THE TOW/HAUL INPUT CIRCUIT FOR A
SHORT TO GROUND
z Disconnect: PCM C175T. Yes
z Disconnect: PCM C1381T. GO to C6 .
z Disconnect: PCM C1551B.
z Inspect the connector for damaged, pushed-out No
terminals, corrosion or loose wires. REPAIR circuit CET34 (BN/GN) for a short
z Measure the resistance between Tow/Haul switch to ground. REPLACE the BCM 42 (5A).
C2399-2, circuit CET34 (BN/GN) and ground. CLEAR the DTC. RERUN the KOER self-
test and test the system for normal
operation.

C6 CHECK THE TOW/HAUL INPUT CIRCUIT FOR
AN OPEN
z Enter the following diagnostic mode on the scan REPLACE the selector lever. REFER to
tool: TCS_DEPRES. Selector Lever — Column Shift in this
z Connect a fused jumper from Tow/Haul switch, section. CLEAR the DTC. RERUN the
C2399-1 to C2399-2, harness side. KOER self-test and test the system for
normal operation.
No
INSPECT and REPAIR circuit CET34
(BN/GN) for an open. If an open circuit is
not found, REPLACE the PCM. PERFORM
the Solenoid Body Strategy Data Download
procedure. REFER to Section 307-01 .
RERUN the KOER self-test and test the
z Does the TCS_DEPRES PID display YES?
PINPOINT TEST D: THE SELECTSHIFT™ SWITCH IS NOT OPERATING CORRECTLY
NOTE: Vehicles equipped with a 5.0L or 6.2L engine use PCM C1381B.

D1 CHECK DTCs
z Ignition ON. Yes
z Connect the scan tool. GO to D2 .
z Is DTC P0815 set? GO to D5 .
D2 CHECK THE UPSHIFT CIRCUIT FOR VOLTAGE
z Ignition OFF. Yes
z Disconnect: Tow/Haul C2399. GO to D4 .
z Inspect C2399 for damaged, pushed-out terminals,
corrosion or loose wires. No
z Measure the voltage between the Tow/Haul switch
C2399-3, circuit CET43 (GY), harness side and
ground.

D3 CHECK THE UPSHIFT CIRCUIT FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: PCM C175B. GO to D4 .
z Disconnect: PCM C1551B. No
z Inspect the connector for damaged, pushed-out REPAIR circuit CET43 (GY) for an open.
terminals, corrosion or loose wires. CLEAR the DTCs. RERUN the KOER
z For 3.7L engine vehicles, measure the resistance self-test and test the system for normal
between the Tow/Haul switch C2399-3, circuit operation.
CET43 (GY) and PCM C175B-23, harness side.
z For 5.0L or 6.2L engine vehicles, measure the

resistance between the Tow/Haul switch C2399-3,
circuit CET43 (GY) and PCM C1381B-23, harness
side.
z For 3.5L engine vehicles, measure the resistance

between the Tow/Haul switch C2399-3, circuit

D4 CHECK THE SIGNAL RETURN CIRCUIT FOR AN
OPEN
z Connect: PCM C175B. Yes
z Connect: PCM C1381B. INSTALL a new selector lever, REFER to
z Connect: PCM C1551B. Selector Lever — Column Shift in this
z Ignition ON. section. CLEAR the DTCs. RERUN the
z Measure the voltage between Tow/Haul switch KOER self-test and test the system for
C2399-3 and C2399-4 harness side. normal operation.
No
INSPECT and REPAIR the signal return
circuit RE407 (YE/VT) for an open. If an
open circuit is not found, REPLACE the
PCM. PROGRAM the PCM with the latest
calibration level. PERFORM the solenoid
strategy download procedure, REFER to
solenoid body strategy in Section 307-
01 . RERUN the KOER self-test and test

D5 CHECK THE DOWNSHIFT CIRCUIT FOR VOLTAGE
z Ignition OFF. Yes
z Disconnect: Tow/Haul C2399. GO to D7 .
z Measure the voltage between the Tow/Haul switch
C2399-5, circuit CET42 (GN/VT), harness side and
ground.
D6 CHECK THE DOWNSHIFT CIRCUIT FOR AN OPEN

z Ignition OFF. Yes
z Disconnect: PCM C175B. GO to D7 .
z Inspect the connector for damaged, pushed-out REPAIR circuit CET42 (GN/VT) for an
terminals, corrosion or loose wires. open. CLEAR the DTCs. RERUN the
z For 3.7L engine vehicles, measure the resistance KOER self-test and test the system for
between the Tow/Haul switch C2399-5, circuit normal operation.
CET42 (GN/VT) and PCM C175B-24, harness side.

circuit CET42 (GN/VT) and PCM C1381B-24,
harness side.

CET42 (GN/VT) and PCM C1551B-88, harness
side.

D7 CHECK THE SIGNAL RETURN CIRCUIT FOR AN
OPEN

z Connect: PCM C1551B. Selector Lever — Column Shift in this
z Measure the voltage between tow/haul switch KOER self-test and test the system for
C2399-5 and C2399-4 harness side. normal operation.
No
External Controls — Floor Shift
Special Tool(s)

1. Verify the customer concern by operating the transmission external control.
2. Visually inspect for obvious signs of mechanical and electrical damage; refer to the following chart:

z Damaged Brake Shift Interlock Actuator z Failed fuse(s):
(BSIA) Body Control Module (BCM) 18
z Damaged Tow/Haul switch (10A)
z Damaged SelectShift™ switch BCM 42 (5A)
z PCM
z Loose or damaged connections
z Damaged wiring harness
z Corroded or damaged terminals
3. If the fault is not visually evident, determine the symptom. GO to Symptom Chart - External Controls,
Floor Shift or GO to Symptom Chart - NVH Floor Shift .
DTC Chart
DTC Chart
Actuator (BSIA), short to ground Test e .

BCM
Actuator (BSIA), short to voltage or Test e .
BCM open
P0815 Upshift Switch Upshift switch The PCM signal input Upshift switch GO to
Circuit concerns, open or voltage status is out of inoperative. Pinpoint
shorted circuit range Test H .
P0816 Downshift Downshift switch The PCM signal input Downshift switch GO to
Switch Circuit concerns, open or voltage status is out of inoperative. Pinpoint
shorted circuit range Test H .
P1780 Tow/Haul Transmission Control The PCM did not Tow/Haul is GO to
Switch Switch (TCS) receive a Tow/Haul inoperative or Pinpoint
(Overdrive (O/D) switch input during the does not operate Test G .
cancel) circuit out of Key ON Engine correctly.
self-test range Running (KOER) self-
test
Symptom Chart — External Controls, Floor Shift
Symptom Chart — External Controls, Floor Shift

z The Brake Shift Interlock z Circuitry z GO to Pinpoint Test E .
Actuator (BSIA) system z Fuse(s):
does not release/lock Body Control
correctly Module (BCM)
18 (10A)
z BSIA
z Selector lever cable z VERIFY selector lever
cable adjustment.
REFER to Selector
Lever Cable
Adjustment — Floor
Shift in this section.
z The shift control is out of z Selector lever cable z GO to Pinpoint Test F .
correct gear relationship and bracket
z Selector lever
linkage
z Transmission Range (TR) z Selector lever cable z TIGHTEN bolts holding
indicator (PRNDL) does bracket selector lever cable
not correspond to the bracket. REFER to
selected gear Selector Lever Cable
z Selector lever cable z SECURE selector lever
loose at the selector cable. REFER to
lever Selector Lever Cable
z Selector lever cable z VERIFY selector lever

cable adjustment.
REFER to Selector
Lever Cable
z TR indicator (PRNDL) does z Instrument Panel z REFER to Section 413-
not illuminate Cluster (IPC) 00 .
malfunction
z Circuitry
z TR sensor z CHECK for TR sensor
DTCs. REFER to
Section 307-01 .
z The ignition key cannot be z Wiring, terminals or z REFER to Section 211-
returned to the OFF connectors 05 .
position or the ignition key z Ignition lock cylinder
can be turned to the OFF z Key removal inhibit
position when the selector solenoid (part of the
lever is not in PARK ignition switch)
z Park detect switch
(part of the selector
lever)
z Selector lever cable
z Mechanical damage
to the selector lever,
selector lever cable
or selector lever
knob
z The PRNDL indicator does z Wiring, terminals or z REFER to Section 413-
not illuminate P connectors 01 .
z PCM concern
z IPC
z Park detect switch
(part of the selector
lever)
z The Tow/Haul switch does z Tow/Haul switch z GO to Pinpoint Test G .
not operate correctly z Tow/Haul switch not
cycled during self-
test
z Circuitry
z The Tow/Haul lamp is not z IPC z REFER to Section 413-
operating correctly z PCM 01 .
z Circuitry
z The SelectShift™ switch is z SelectShift™ switch z GO to Pinpoint Test H .
not operating correctly z PCM
z Circuitry
z Water enters inside the z Cable assembly z SECURE grommet to
vehicle grommet floor panel. REFER to
— Floor Shift in this
section.
z Torn selector lever z INSTALL a new
cable assembly selector lever cable.
grommet REFER to Selector
Lever Cable — Floor

z Excessive shift effort z Selector lever cable z INSTALL a new
selector lever cable.
REFER to Selector
z Cable bracket z ADJUST cable.
TIGHTEN cable
bracket screws.
REFER to Selector
z Selector lever will not shift z Selector lever cable z VERIFY selector lever
from PARK cable adjustment.
REFER to Selector
Lever Cable
z Selector lever knob z INSTALL a new
selector lever knob.
REFER to Selector
Lever Knob in this
section.
z Broken selector lever z INSTALL a new
cable selector lever cable.
REFER to Selector
z Brake Shift Interlock z GO to Pinpoint Test E .
Actuator (BSIA)
system failure
z Vehicle will not crank/start z Selector lever cable z VERIFY selector lever
in park but will crank/start cable adjustment.
in neutral REFER to Selector
Lever Cable
z TR sensor z CHECK for TR sensor
DTCs. REFER to
Section 307-01 .
Symptom Chart — NVH Floor Shift
Symptom Chart — NVH Floor Shift

z Vibration — a high z Selector lever z CHECK the selector lever
frequency (20-80 Hz) that cable incorrectly cable. REPAIR as
is felt through the seat or routed, grounded necessary. REFER to
selector lever. Changes out or loose Selector Lever Cable —
with engine speed Floor Shift in this section.
z Rattle, buzz or other noise z Selector lever z TIGHTEN the selector lever
loose bolts. REFER to Selector
Lever — Floor Shift in this
section.
knob lever knob. REFER to
Selector Lever Knob in this
section.
lever. REFER to Selector
Lever — Floor Shift in this
section.
z Cable assembly z SECURE the grommet to
grommet the floor panel. REFER to
Selector Lever Cable —
Floor Shift in this section.
Pinpoint Tests
Refer to Wiring Diagrams Cell 30 , Transmission Controls for schematic and connector information.
Selector Lever Connector — C3245
Pin Number Circuit Function

1 BSIA Power
2 Key Lock Solenoid (inhibit removal)
3 Transmission Park Detect
4 Illumination
5 Ground
6 Tow/Haul Power
7 Tow/Haul Signal
8 Not Used
9 SelectShift™ Upshift
10 SelectShift™ Downshift
11 SelectShift™ Ground
12 Not Used
PINPOINT TEST E: THE BSIA SYSTEM DOES NOT RELEASE/LOCK CORRECTLY
NOTE: Inspect the selector lever cable before proceeding with this pinpoint test.

E1 CHECK THE STOPLAMPS
z Apply the brake pedal and observe the stoplamps. Yes
z Do the stoplamps operate correctly? GO to E2 .
No
E2 CHECK THE BSIA POWER CIRCUIT FOR VOLTAGE
z Disconnect: Floor Shifter C3245. Yes
z Ignition ON. GO to E3 .
z Measure the voltage between the BSIA C3245-1,
circuit CET53 (BU/OG), harness side and ground. No
VERIFY the BCM fuse 18 (10A) is OK, If
OK REPAIR circuit CET53 (BU/OG) for
an open. CLEAR the DTC. TEST the
system for normal operation. If not OK,
REFER to the Wiring Diagrams manual
to identify the possible causes of the
circuit short.
If voltage was present with the brake

pedal not applied, GO to E4 .
z Apply the brake pedal.

z With the brake pedal applied, measure the voltage
between the BSIA C3245-1, circuit CET53 (BU/OG),
z Is the voltage greater than 10 volts with the brake
pedal applied and 0 volts with the brake pedal not
applied?
E3 CHECK THE BSIA GROUND CIRCUIT FOR AN
OPEN
z Ignition OFF. Yes
z Measure the resistance between the selector lever INSTALL a new selector lever. REFER
C3245-5, circuit GD138 (BK/WH), harness side and to Selector Lever — Floor Shift in this
ground. section. CLEAR the DTC. TEST the
No
REPAIR circuit GD138 (BK/WH) for an
open. CLEAR the DTC. TEST the

E4 CHECK THE BSIA OUTPUT CIRCUIT FOR A SHORT
TO POWER
z Disconnect: BCM C2280B. Yes
z Inspect C3245 and C2280B for damaged, pushed- REPAIR circuit CET53 (BU/OG) for a
out terminals or loose wires. short to power. CLEAR the DTC. TEST
z Ignition ON. the system for normal operation.
z Measure the voltage between the selector lever
C3245-1, circuit CET53 (BU/OG), harness side and No
ground. GO to E5 .

E5 CHECK FOR CORRECT BCM OPERATION
z Check for: Install a new BCM . REFER to Section
corrosion 418-00 . CLEAR the DTC. TEST the
damaged pins system for normal operation.
pushed-out pins
z Connect all the BCM connectors and make sure they No
seat correctly. The system is operating correctly at this
z Operate the system and verify the concern is still time. The concern may have been
present. caused by a loose or corroded
z Is the concern still present? connector.
PINPOINT TEST F: THE SHIFT CONTROL IS OUT OF CORRECT GEAR RELATIONSHIP

F1 CHECK THE SHIFT CONTROL
LINKAGE
z Ignition ON. Yes
z Apply the brake pedal. INSTALL a new selector lever. REFER to Selector Lever —
Floor Shift in this section. TEST the system for normal
z Gain access to the selector operation.

lever linkage.
z Position the selector lever in No
all ranges. GO to F2 .
z Observe all selector lever
linkage during operation.
z Is the selector lever linkage
damaged?
F2 CHECK THE SELECTOR
LEVER CABLE
z Check the selector lever cable Yes
and bracket installation and VERIFY the selector lever cable adjustment. ADJUST the
tightness. selector lever cable if necessary. REFER to Selector Lever
z Is the selector lever cable Cable Adjustment — Floor Shift in this section. GO to F3 .
correctly installed and
adjusted? No
REPAIR as necessary. TEST the system for normal operation.
F3 CHECK THE LINKAGE/CABLE
FOR CORRECT GEAR
RELATIONSHIP
z Apply the brake pedal. Yes
z Position the selector lever in System OK. TEST the system for normal operation.
all ranges.
z Does the indicator match No
the gear selection? REFER to Selector Lever Cable — Floor Shift in this section.
PINPOINT TEST G: THE TOW/HAUL SWITCH DOES NOT OPERATE CORRECTLY

G1 CHECK DTCs
z Ignition ON. Yes
z Connect the scan tool. GO to G2 .
z Is DTC P1780 set? No trouble found with the Tow/Haul
system. REFER to Section 413-01 if
Tow/Haul lamp does not illuminate.
G2 CHECK THE BCM FUSE 42 (5A)
z Ignition OFF. Yes
z Remove Body Control Module (BCM) fuse 42 (5A). GO to G4 .
z Check fuse: BCM 42 (5A).
z Is the resistance less than 5 ohms? No
GO to G3 .
G3 CHECK THE TOW/HAUL POWER CIRCUIT FOR A
SHORT TO GROUND
z Disconnect: Selector Lever C3245. Yes
z Disconnect: BCM C2280B. GO to G4 .
z Inspect C3245 and C2280B for damaged, pushed-
out terminals or loose wires. No
z Measure the resistance between the selector lever REPAIR circuit CBP42 (GN) for a short to
C3245-6, circuit CBP42 (GN), harness side and ground. CLEAR the DTC. RERUN the
ground. KOER self-test and test the system for
normal operation.

G4 CHECK THE TOW/HAUL POWER CIRCUIT FOR
VOLTAGE
z Disconnect: Selector Lever C3245. Yes
z Inspect C3245 for damaged, pushed-out terminals GO to G5 .
or loose wires.
z Ignition ON. No
z Measure the voltage between the selector lever REPAIR circuit CBP42 (GN) for an open.
C3245-6, circuit CBP42 (GN), harness side and CLEAR the DTC. RERUN the KOER self-
ground. test and test the system for normal
operation.

G5 CHECK THE TOW/HAUL INPUT CIRCUIT FOR A
SHORT TO GROUND
z Disconnect: PCM C175T. Yes
z Disconnect: PCM C1381T. GO to G6 .
z Inspect the connector for damaged, pushed-out No
terminals, corrosion or loose wires. REPAIR circuit CET34 (BN/GN) for a
z Measure the resistance between the selector lever short to ground. CLEAR the DTC.
C3245-7, circuit CET34 (BN/GN) and ground. RERUN the KOER self-test and test the

G6 CHECK THE TOW/HAUL INPUT CIRCUIT FOR AN
OPEN
z Enter the following diagnostic mode on the scan REPLACE the selector lever. REFER to
tool: TCS_DEPRES. Selector Lever — Floor Shift in this
z Connect a fused jumper from the selector lever section. CLEAR the DTC. RERUN the
switch, C3245-6 circuit CBP42 (GN) to C3245-7 KOER self-test and test the system for
circuit CET34 (BN/GN) harness side. normal operation.
No
INSPECT and REPAIR circuit CET34
(BN/GN) for an open. If an open circuit is
not found, REPLACE the PCM.
PERFORM the Solenoid Body Strategy
Data Download procedure. REFER to
Section 307-01 . RERUN the KOER self-
test and test the system for normal
operation.
z Does the TCS_DEPRES PID display YES?
PINPOINT TEST H: THE SELECTSHIFT™ SWITCH IS NOT OPERATING CORRECTLY
NOTE: Vehicles equipped with a 5.0L or 6.2L engine use PCM C1381B.

H1 CHECK DTCs
z Ignition ON. Yes
z Connect the scan tool. GO to H2 .
z Is DTC P0815 set? GO to H5 .
H2 CHECK THE UPSHIFT CIRCUIT FOR VOLTAGE
z Ignition OFF. Yes
z Disconnect: Selector Lever C3245. GO to H4 .

z Ignition ON. GO to H3 .
C3245-9, circuit CET43 (GY), harness side and
ground.

H3 CHECK THE UPSHIFT CIRCUIT FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: PCM C175B. GO to H4 .
z Inspect the connector for damaged, pushed-out REPAIR circuit CET43 (GY) for an open.
terminals, corrosion or loose wires. CLEAR the DTCs. RERUN the KOER
z For 3.7L engine vehicles, measure the resistance self-test and test the system for normal
between the Tow/Haul switch C3245-9, circuit operation.

circuit CET43 (GY) and PCM C1381B-23, harness
side.


H4 CHECK THE SIGNAL RETURN CIRCUIT FOR AN
OPEN
z Connect: PCM C1551B. Selector Lever — Floor Shift in this
z Measure the voltage between the selector lever KOER self-test and test the system for
C3245-9, circuit CET43 (GY) and C3245-11, circuit normal operation.
RE407 (YE/VT) harness side.
No
REPAIR the signal return circuit RE407
(YE/VT) for an open. If an open circuit is
not found, REPLACE the PCM.

H5 CHECK THE DOWNSHIFT CIRCUIT FOR VOLTAGE
z Ignition OFF. Yes
z Disconnect: Selector Lever C3245. GO to H7 .
z Ignition ON. GO to H6 .
C3245-10, circuit CET42 (GN/VT), harness side and
ground.

H6 CHECK THE DOWNSHIFT CIRCUIT FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: PCM C175B. GO to H7 .
z Inspect the connector for damaged, pushed-out REPAIR circuit CET42 (GN/VT) for an
terminals, corrosion or loose wires. open. CLEAR the DTCs. RERUN the
z For 3.7L engine vehicles, measure the resistance KOER self-test and test the system for
between the selector lever C3245-10, circuit CET42 normal operation.
(GN/VT) and PCM C175B-24, harness side.

circuit CET42 (GN/VT) and PCM C1381B-24,
harness side.

CET42 (GN/VT) and PCM C1551B-88, harness
side.
H7 CHECK THE SIGNAL RETURN CIRCUIT FOR AN
OPEN
z Connect: PCM C1551B. Selector Lever — Floor Shift in this
z Measure the voltage between the selector lever section. CLEAR the DTCs. RERUN the
C3245-10, circuit CET42 (GN/VT) and C3245-11, KOER self-test and test the system for
circuit RE407 (YE/VT) harness side. normal operation.
No
Brake Shift Interlock Override — Column Shift
NOTE: If it is necessary to use the override procedure to move the selector lever out of the PARK position, it
is possible that a fuse has blown. GO to Pinpoint Test A .
This vehicle is equipped with a brake shift interlock feature that prevents the selector lever from being
moved out of PARK when the ignition is in the ON position until the brake pedal is applied.
If the selector lever cannot be moved out of the PARK position when the ignition is in the ON position and
the brake pedal is applied:
1. Apply the parking brake. Turn the ignition key to the off position and remove the key.
2. Tilt and telescope the steering column to the full downward and rearward position.
3. NOTICE: Make sure to use extra care when detaching the selector lever boot clips from
steering column shrouds or damage to the selector lever boot may occur causing replacement
of the selector lever assembly. The selector lever boot is not serviceable separately.
Position the selector lever boot aside.

1. Push forward on the selector lever boot at the area indicated and remove the boot from the
upper and lower steering column shrouds.
4. NOTE: The BSIA spindle can be accessed through the selector lever boot opening.
Move the BSIA spindle outward, apply the brake pedal and position the selector lever into NEUTRAL.
5. NOTICE: Make sure to use extra care and follow the installation sequence when installing the
selector lever boot to the steering column shrouds or damage to the boot may occur causing
replacement of the selector lever assembly. the selector lever boot is not serviceable
separately.
Install the selector lever boot in the sequence shown.

1. Install the front of the selector lever boot.
2. Install the bottom of the selector lever boot.
3. Install the top of the selector lever boot.
4. Install the back of the selector lever boot.
6. Start the vehicle.
Brake Shift Interlock Override — Floor Shift
NOTE: If it is necessary to use the override procedure to move the selector lever out of the PARK position, it
is possible that a fuse has blown. GO to Pinpoint Test A .
This vehicle is equipped with a brake shift interlock feature that prevents the selector lever from being
moved out of PARK when the ignition is in the ON position, until the brake pedal is applied.
If the selector lever cannot be moved out of the PARK position when the ignition is in the ON position and
the brake pedal is applied:
1. Apply the park brake and remove the ignition key.
2. Remove the instrument panel to floor console finish panel.
3. Remove the floor console upper finish panel.

z Starting at the rear of the upper finish panel, carefully pry up the upper finish panel and
disconnect the electrical connectors.
4. Apply the brake pedal. Press and hold the Brake Shift Interlock Actuator (BSIA) lever while moving
the selector lever into NEUTRAL.
5. Connect and install the floor console upper finish panel.
6. Install the instrument panel to floor console finish panel.
7. Start the vehicle.
Selector Lever Cable Adjustment — Column Shift
2. Place the selector lever in DRIVE.
lever.
6. Place the manual control lever in the (D) position.

1. Rotate the manual control lever counterclockwise 3 detents into the manual 1st position.
2. Rotate the manual control lever clockwise 3 detents into the (D) position.
7. Connect the selector lever cable onto the manual control lever and move the locking tab down.
z Listen for the audible click, then push back on the locking tab to verify it is locked.
z Pull back on the selector lever cable to verify it is installed correctly to the manual lever.
9. Verify the vehicle will start in PARK or NEUTRAL and the backup lamps illuminate in REVERSE.
Selector Lever Cable Adjustment — Floor Shift
02 .
lever.
6. Place the manual control lever in the (D) position.

z Rotate the manual control lever counterclockwise 3 detents into the manual 1st position.
z Rotate the manual control lever clockwise 3 detents into the (D) position.
Brake Shift Interlock Actuator — Column Shift

1 3530 Upper steering column shroud
2 3530 Lower steering column shroud
3 W710485 Lower steering column shroud screws (3 required)
4 3Z719 Brake Shift Interlock Actuator (BSIA)
5 3F907 BSIA screw

6 W790181 Selector lever mechanism bolts (3 required)
7 7210B Selector lever mechanism
8 W712000 Selector lever bolt
9 7210A Selector lever
10 — Park position switch (part of 3Z719)
1. Remove the selector lever mechanism. For additional information, refer to Selector Lever Mechanism
— Column Shift in this section.
2. Remove the Brake Shift Interlock Actuator (BSIA) screw.
3. Remove the BSIA .

1. Gently pry out the clip.
2. While prying out the clip, simultaneously remove the BSIA from the selector lever mechanism
housing.
4. Remove the park position switch.

1. Press the spring loaded pin.
2. While pressing in on the spring loaded pin, rotate the park position switch clockwise and
remove it from the selector lever mechanism.
Installation
1. Install the park position switch.

1. Place the large plunger on the park position switch in the locating hole and position the switch
as shown.
2. Rotate the park position switch counterclockwise making sure the tab locks under the housing
lip.
2. Verify small plunger is fully extended.
3. Install the BSIA .

1. Insert the BSIA into the selector lever mechanism housing.
2. Gently push the snap lock clip in place.
4. Install the BSIA screw.

5. Install the selector lever mechanism. For additional information, refer to Selector Lever Mechanism —
Column Shift in this section.
Brake Shift Interlock Actuator — Floor Shift
NOTE: The Brake Shift Interlock Actuator (BSIA) is not serviced separately. If a new BSIA is required, install
a new floor shift selector lever assembly.
1. For additional information, refer to Selector Lever — Floor Shift in this section.
Selector Lever — Column Shift

3 — Tow/Haul switch electrical connector (part of 7210A)
4 W712000 Selector lever bolt
2. Disconnect the Tow/Haul switch electrical connector.
3. Remove and discard the selector lever bolt.

4. Remove the selector lever.
Selector Lever — Floor Shift
Selector Lever — Floor Shift

1 — Console upper trim panel
2 7E395 Selector lever cable
3 7210 Selector lever assembly
4 N606678-S Selector lever assembly bolts (4 required)

5 7213 Selector lever knob
Removal

3. NOTICE: Do not pry on selector lever cable or the selector lever pin may be damaged.
Disconnect the selector lever cable end from the selector lever pin by gently pulling the selector lever
cable end straight off the selector lever arm.
4. NOTE: The selector lever bezel has been removed for clarity. Do not remove the selector lever bezel.
Remove the 4 selector lever assembly bolts.
5. Disconnect the selector lever cable from the selector lever cable bracket.
6. Disconnect the selector lever harness connector and remove the selector lever from the vehicle.
Installation
1. NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs
are locked in place. Press the selector lever cable into the bracket and listen for the selector lever
cable to click in place. Pull back on the selector lever cable to make sure that it is locked into the
bracket.
Install the selector lever cable in the selector lever cable bracket.
2. Position the selector lever assembly in the console and install the 4 bolts.
3. Connect the selector lever harness connector.
4. Connect the selector lever cable onto the selector lever arm.
z Listen for the audible click.
z Pull back on the selector lever cable to make sure that it is installed correctly.
7. Adjust the selector lever cable. For additional information, refer to Selector Lever Cable Adjustment
— Floor Shift in this section.
Selector Lever Bezel

1 045A76 Console upper trim panel
3 7D443 Selector lever bezel
Removal

3. Remove and discard the RH selector lever knob cover.

1. Start at the bottom front.
2. Move towards the top front and remove the cover.
4. Remove and discard the LH selector lever knob cover.

5. Remove and discard the RH selector lever knob screw.
6. Remove and discard the LH selector lever knob screw.
7. Disconnect the select shift and the Tow/Haul electrical connectors and remove the selector lever
knob.
8. Lift the tabs on the selector lever bezel and lift the bezel.
9. Disconnect the electrical harness from the bezel and remove the selector lever bezel.
Installation
1. Connect the electrical harness to the selector lever bezel.
2. Install the selector lever bezel onto the selector lever housing.
3. Connect the select shift and the Tow/Haul electrical connectors and install the selector lever knob.
4. Install a new LH selector lever knob screw.
5. Install a new RH selector lever knob screw.
6. Install a new LH selector lever knob cover.
7. Install a new RH selector lever knob cover.
Selector Lever Button
NOTE: The selector lever button is part of the selector lever knob.
1. To install a new selector button, a new selector lever knob must be installed. For additional
information, refer to Selector Lever Knob in this section.
Selector Lever Cable — Column Shift

1 W708211 Selector lever cable routing clip
2 — Grommet (part of 7E395)

4 7H181 Retaining clip
6 — Retaining pushpin (part of 7E395)
7 — Retainer (part of 7E395)
Removal
2. Remove the steering column shrouds. REFER to Section 211-04 .
3. Position the selector lever into the D position.
assembly between the selector lever mechanism and the steering column bracket.
Disconnect the selector lever cable from the steering column.

1. Disconnect the selector lever cable from the selector lever mechanism.
2. Carefully lift the locking tab and disconnect the selector lever cable from the steering column
bracket.
3. Disconnect the selector lever cable retainer.
5. Push the rubber grommet and selector lever cable through the floor pan.
6. Detach the selector lever cable from the routing clip.
8. Clean cable adjustment lock of any debris.
assembly between the manual control lever and the selector lever cable bracket.
Move the locking tab up and disconnect the selector lever cable from the manual control lever.
10. Remove the selector lever cable from the selector lever cable bracket.
Installation
1. Place the manual control lever in DRIVE.

1. Rotate the manual lever counterclockwise 3 detents into the manual 1st position.
2. Rotate the manual lever clockwise 3 detents into Drive.
are locked in place. Press the selector lever cable into the bracket and listen for the cable to click in
place. Pull back on the selector lever cable to make sure that it is locked into the bracket.
Install the selector lever cable into the selector lever cable bracket.
3. Attach the selector lever cable to the routing clip.
4. Push the rubber grommet and selector lever cable up through the floor pan.
are locked in place. Press the selector lever cable into the bracket and listen for the cable to click in
place. Pull back on the selector lever cable to make sure that it is locked into the bracket.
Connect the selector lever cable onto the steering column.

1. Connect the selector lever cable retainer.
2. Connect the selector lever cable onto the steering column bracket.
3. Connect the selector lever cable onto the selector lever mechanism.
Listen for the audible click.
Pull back on the selector lever cable to make sure that it is correctly installed.
6. Install the steering column shrouds. REFER to Section 211-04 .
7. Unlock the lock tab on the selector lever cable by sliding it up.
Selector Lever Cable — Floor Shift

1 — Selector lever cable clip

3 — Rubber grommet (part of 7E395)
4 — Selector lever cable clip (part of 7E395)
5 — Selector lever cable eyelet (part of 7E395)
6 — Heat shield (part of 7E395) (3.5L GTDI)
7 W708211 Selector lever cable routing clip
Removal
02 .

4. NOTICE: Do not pry on selector lever cable or the selector lever pin may be damaged.
Disconnect the selector lever cable end from the selector lever pin by gently pulling the selector lever
cable end straight off the selector lever arm.
5. Remove the center console LH kick panel.
6. Disconnect the selector lever cable from the selector lever cable bracket.
7. Push the rubber grommet and selector lever cable through the floor panel.
8. Detach the selector lever cable from the routing clip.
10. NOTE: The 3.5L is shown. The 3.7L, 5.0L and 6.2L do not have a heat shield.
Clean cable adjustment lock of any debris.
Move the locking tab up and disconnect the selector lever cable from the manual control lever.
12. Remove the selector lever cable from the selector lever cable bracket.
Installation
NOTE: When installing the selector lever cable, make sure that the selector lever cable locking tabs
are locked in place. Press the selector lever cable into the selector lever cable bracket and listen for
the selector lever cable to click into place. Pull back on the selector lever cable to make sure that it is
locked into the selector lever cable bracket.
Attach the selector lever cable to the selector lever cable bracket.
2. Attach the selector lever cable to the routing clip.
3. Install the rubber grommet and selector lever cable through the floor panel.
are locked in place. Press the selector lever cable into the selector lever cable bracket and listen for
the selector lever cable to click into place. Pull back on the selector lever cable to make sure that it is
locked into the selector lever cable bracket.
Connect the selector lever cable onto the selector lever.

1. Connect the selector lever cable onto the selector lever cable bracket.
2. Connect the selector lever cable onto the selector lever arm.
Listen for the audible click.
Pull back on the selector lever cable to make sure that it is installed correctly.
5. Install the center console LH kick panel.
9. Place the manual control lever in DRIVE.

1. Rotate the manual lever counterclockwise 3 detents into the manual 1st position.
2. Rotate the manual lever clockwise 3 detents into Drive.
Selector Lever Knob

1 — Console upper trim panel
3 7L468 Selector lever knob covers
4 W790088 Selector lever knob screws
Removal

3. Remove and discard the RH selector lever knob cover.

4. Remove and discard the LH selector lever knob cover.

5. Remove and discard the RH selector lever knob screw.
6. Remove and discard the LH selector lever knob screw.
7. Disconnect the SelectShift™ and the Tow/Haul electrical connectors and remove the selector lever
knob.
Installation
1. Connect the SelectShift™ and the Tow/Haul electrical connectors and install the selector lever knob.
2. Install a new LH selector lever knob screw.
3. Install a new RH selector lever knob screw.
4. Install a new LH selector lever knob cover.
5. Install a new RH selector lever knob cover.
Selector Lever Mechanism — Column Shift

4 7210B Selector lever mechanism
5 W790181 Selector lever mechanism bolts (3 required)
6 — Selector lever bolt (part of 7210A)
1. NOTE: To access the top selector lever mechanism bolts, position the selector lever in NEUTRAL
before removing the selector lever.
Remove the selector lever. For additional information, refer to Selector Lever — Column Shift in this
section.
2. Disconnect the Brake Shift Interlock Actuator (BSIA) electrical connector.
3. Disconnect the selector lever cable.
4. Remove and discard the 3 bolts and remove the selector lever mechanism.
SelectShift™ Switch — Column Shift
NOTE: The SelectShift™ switch is part of the selector lever.
1. To install a new SelectShift™ switch, a new selector lever must be installed. For additional
information, refer to Selector Lever — Column Shift in this section.
SelectShift™ Switch — Floor Shift
NOTE: The SelectShift™ switch is part of the selector lever knob.
1. To install a new SelectShift™ switch, a new selector lever knob must be installed. For additional
Tow/Haul Switch — Column Shift
NOTE: The Tow/Haul switch is part of the selector lever.
1. To install a new Tow/Haul switch, a new selector lever must be installed. For additional information,
refer to Selector Lever — Column Shift in this section.
Tow/Haul Switch — Floor Shift
NOTE: The Tow/Haul switch is part of the selector lever knob.
1. To install a new Tow/Haul switch, a new selector lever knob must be installed. For additional
SECTION 308-07A: Four Wheel Drive (4WD) Systems 2014 F-150 Workshop Manual
Material
Ultra Silicone Sealant — —
TA-29
Axle nut 40 30 —
Front brake flexible hose bracket bolt 12 — 106
Shift lever assembly-to-floorpan bolt 24 18 —
Tie-rod nut 115 85 —
Transfer Case Control Module (TCCM) screws 7 — 62
Transfer case shift motor bolts 10 — 89
Transfer case shift motor bracket bolt 10 — 89
Transfer case shift motor bracket nut 3 — 27
Four Wheel Drive (4WD) Systems
Electronic Shift-On-The-Fly (ESOF) System
The Electronic Shift-On-The-Fly (ESOF) system consists of the following components:
z Mode Select Switch (MSS), located on the instrument panel

z Transfer Case Control Module (TCCM), located near the passenger kick panel
z Integrated Wheel End (IWE) solenoid, located in left rear of the engine compartment
z Integrated Wheel Ends (IWEs), located at each front wheel hub
z Transfer case assembly (includes shift motor and synchronization clutch)
Vehicles equipped with an ESOF system allow the operator to choose between 2-Wheel Drive (2WD) (2H)
and 2 different Four-Wheel Drive (4WD) modes. The transfer case is shifted electronically based on the
MSS position. Under normal driving conditions, the transfer case is in 2WD (2H), but when desired, the
operator may shift into 4WD high (4H) or 4WD low (4L). The operator can shift between 2WD (2H) and 4WD
high (4H) at any speed. When shifting into or out of 4WD low (4L) range, the TCCM requires that the vehicle
speed is less than 5 km/h (3 mph) and the transmission in NEUTRAL.
The transfer case is equipped with an electronically controlled clutch which is located inside the case. This
clutch is used to synchronize the speed of the front driveline with the rear driveline during 2WD (2H) to 4WD
high (4H) shifts.
2-Speed Torque-On-Demand
The 2-speed torque-on-demand system consists of the following components:
z MSS , located on the instrument panel

z TCCM , located near the passenger kick panel
z IWE solenoid, located in left rear of the engine compartment
z IWEs , located at each front wheel hub
Vehicles equipped with the 2-speed torque-on-demand system allow the operator to choose between 2WD
and 3 different 4WD modes. The transfer case is shifted electronically based on the MSS position. Under
normal driving conditions, the unit is in 2WD (2H), but when desired, the operator may shift into 4WD AUTO
(4A), 4WD high (4H), or 4WD low (4L). When shifting into or out of 4WD (4L) range, the TCCM requires that
the vehicle speed is less than 5 km/h (3 mph) and the transmission is in NEUTRAL.
clutch is used to synchronize the speed of the front driveline with the rear driveline during 2WD (2H) to 4WD
high (4H) or 4WD AUTO (4A) shifts. The clutch also provides torque to the front driveline in all 4WD modes.
Integrated Wheel End (IWE) System
The IWE system consists of the following components:
1 IWEs (spring-loaded vacuum hubs)

2 Vacuum hoses
3 IWE solenoid
4 Vacuum reservoir
The IWE system, used on ESOF and 2-speed torque-on-demand equipped vehicles, uses vacuum hubs that
engage or disengage the front wheel hubs from the front halfshafts.
The IWE solenoid receives engine vacuum from the vacuum reservoir. When the 4WD system is in 2H
mode, the TCCM supplies a ground path to the IWE solenoid to apply vacuum to the IWEs (disengaging the
front hubs from the front halfshafts). When operating in any 4x4 mode, the TCCM does not supply the
ground path to the IWE solenoid, vacuum is not applied to the IWEs and an internal spring keeps the front
hubs engaged to the front halfshafts. Vehicles equipped with a 3.5L engine are also equipped with an
electrically-driven brake booster vacuum pump located behind the LH headlamp assembly. For additional
information, refer to Section 206-07 . As a first step in service, eliminate obvious items such as loose wiring
connections, loose vacuum connections or damaged vacuum lines.
Electronic Locking Differential (ELD) System
The Electronic Locking Differential (ELD) system consists of the following components:
z ELD field coil, located at the rear differential
z Rear differential
z MSS (unique for ELD equipped vehicles, the ELD switch is integrated with the MSS ), located on
instrument panel
The optional ELD system, allows the operator to lock the rear differential side gears on slippery and/or off
road surfaces. ELD operation is requested by pulling out on the MSS on 4X4 equipped vehicles, and by
rotating the switch from OFF to ON on 4x2 vehicles.
Off-Road Mode
NOTE: Off-road mode is specifically calibrated for off-road driving conditions and should never be used on
pavement.
The SVT Raptor comes equipped with a special off-road function. An off-road button is located on the floor
console. A light on the button illuminates when this feature is activated.
The off-road function consists of the following components:
z Off-road mode switch

z TCCM
Off-road mode affects 4 vehicle functions:
z It allows unique transmission shifting that optimizes off-road performance.

z Off-road mode provides optimized throttle response tailored for off-road performance driving.
z When off-road mode is engaged, the standard vehicle speed thresholds for the ELD are lifted.
z When off-road mode is engaged, the AdvanceTrac settings are altered for optimized off-road
performance.
Neutral Flat Tow
NOTICE: 2WD vehicles cannot be towed with any wheels on the ground as vehicle or transmission
damage may occur.
NOTICE: Failing to put the transfer case in the NEUTRAL position will damage vehicle components.
Vehicles equipped with a Four-Wheel Drive (4WD) system have neutral flat tow software in the TCCM .
Following the neutral flat tow activation procedure commands the transfer case shift motor into a neutral
position. Locking the transfer case in neutral will prevent damage to the transmission while towing a 4WD
vehicle on all 4 wheels (such as when being towed behind a motorhome).
Neutral Flat Tow Activation and Deactivation
Activation
vehicle to be able to roll even if the transmission is in park (P). Make sure the foot brake is
depressed and the vehicle is in a secure and safe position while the transfer case is being shifted to
its neutral position. Failure to follow this instruction may result in serious personal injury.
transfer case from shifting properly and may allow the vehicle to roll even if the transmission is in
park (P). Failure to follow this instruction may result in serious personal injury.
NOTICE: 2-Wheel Drive (2WD) vehicles cannot be flat towed with any of the wheels on the ground.
Vehicle or transmission damage will occur.
NOTICE: Failure to put the transfer case in its NEUTRAL position will damage vehicle components.
NOTE: Four-Wheel Drive (4WD) vehicles can be flat towed by placing the transfer case in its NEUTRAL
position.
NOTE: Neutral flat tow status can be checked at any time by opening the driver door or turning the ignition
to the ACC or ON position and checking the display in the IPC .
1. Turn the ignition to the ON position. Do not start the engine.
2. Press and hold the brake pedal.
3. Shift the Mode Select Switch (MSS) to 2H.
4. Shift the transmission to NEUTRAL.
5. Rotate the MSS from 2H to 4L and back to 2H 5 times within 7 seconds.

z If completed successfully, the Instrument Panel Cluster (IPC) displays "NEUTRAL TOW
LEAVE IN N" or "NEUTRAL TOW ENABLED LEAVE TRANSMISSION IN NEUTRAL",
indicating that the vehicle is safe to tow with all wheels on the ground.
z If the message is not shown in the display, the entire procedure must be performed again.
z An audible noise may be heard as the transfer case shifts into neutral position, this is normal
operation.
6. Leave the transmission in NEUTRAL and turn the ignition as far as it will go toward the OFF position
(it will not turn fully off when the transmission is in NEUTRAL). The key must be left in the ignition
while towing. To lock and unlock your vehicle, use the keyless entry keypad or extra set of keys.
7. Release the brake pedal.
Deactivation
NOTE: Neutral flat tow status can be checked at any time by opening the driver door or turning the ignition
to the ACC or ON position and checking the display in the IPC .
1. Press and hold the brake pedal.
2. Turn the ignition to the ON position. Do not start the engine.
3. Shift the transmission out of NEUTRAL and into any gear.
4. Release the brake pedal.

z If completed successfully, the IPC displays 4X2, then "NEUTRAL TOW DISABLED".
z If the indicator light and message do not display, the entire procedure must be performed
again.
z An audible noise may be heard as the transfer case shifts out of NEUTRAL position, this is
normal operation.
Special Tool(s)
Flex Probe Kit
equivalent


The ELD system allows the operator to lock the rear differential side gears. When the ELD is engaged both
rear wheels turn at the same speed, providing added traction on slippery and/or off road surfaces. The
operator can engage the ELD per the charts below:
ELD Engagement Speeds — 4WD Vehicles

Switch Position Engage Disengage Re-engage
2H/4A/4H 31 km/h (19 mph) a 42 km/h (25 mph) 31 km/h (19 mph) a
4L 90 km/h (56 mph) a 100 km/h (62 mph) 90 km/h (56 mph) a
a The ELD system engages/re-engages at or below the speed noted.
ELD Engagement Speeds — 2WD Vehicles

Off N/A N/A N/A
On 31 km/h (19 mph) a 42 km/h (25 mph) 31 km/h (19 mph) a

a The ELD system engages/re-engages at or below the speed noted.
When the operator activates the ELD , the ELD icon displays in the IPC message center. If the vehicle is
driven above the disengage speed, the IPC message center no longer displays the ELD icon, alerting the
operator that the ELD is disengaged. Once the vehicle drops below the re-engage speed, the IPC message
center displays the ELD icon again. If there is a malfunction with the ELD system, a "CHECK LOCKING
DIFFERENTIAL" message is displayed in the IPC message center, letting the operator know the ELD is not
engaged.
The differential locks when a PWM controlled magnetic field coil located inside the differential energizes. A
collar within the differential moves toward a differential side gear and engages a dog clutch within the
differential. This locks the differential side gears and creates the locked differential.
The TCCM activates the ELD . When the ELD is engaged, the TCCM sends PWM voltage to the ELD field
coil located in the differential. This voltage is initially 98% duty cycle, and then tapers off to 40% duty cycle
after 30 seconds. In order for the TCCM to activate the ELD , certain conditions must be met.
TCCM Input Conditions

z MSS set to ELD position
z Average rear wheel speed versus average front wheel speed must be less than 7 km/h (4.3 mph) (via
HS-CAN communication from ABS module)
z Operating range (voltage between 9-16 volts)
z DTC setting range (voltage between 10-15 volts)
z Ignition in the ON position
z Throttle Position (TP) less than 50%
z Rear axle assembly z Battery Junction Box (BJB) fuses:

z Matching tire sizes 20 (20A)
29 (10A)
54 (5A)
68 (25A)
z Body Control Module (BCM) fuse 34 (10A) (vehicles with ELD only)
z Mode Select Switch (MSS)
z Electronic Locking Differential (ELD) field coil
z Transfer Case Control Module (TCCM)
If the cause is not visually evident, connect the scan tool to the DLC .
5. NOTE: The VCM LED prove out confirms power and ground from the DLC are provided to the VCM .


z verify the ignition is in the ON position.

418-00 .
8. Carry out the self-test diagnostics for the TCCM .
9. If the DTCs retrieved are related to the concern, go to the TCCM DTC Chart in this section. For all
other DTCs, refer to Section 419-10 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Electronic Locking
Differential (ELD) System in this section.
DTC Charts
Transfer Case Control Module (TCCM) DTC Chart — ELD System
NOTE: This module utilizes a 5-character DTC followed by a 2-character failure type code. The failure type
code provides information about specific fault conditions such as opens or shorts to ground. have an
additional 2-character DTC status code suffix to assist in determining DTC history.
NOTE: Network DTCs (U-codes) are often a result of intermittent concerns such as damaged wiring or low
battery voltage occurrences. Additionally, vehicle repair procedures such as module reprogramming often
set network DTCs. Replacing a module to resolve a network DTC is unlikely to resolve the concern. To
prevent repeat network DTC concerns, inspect all network wiring, especially connectors. Test the vehicle
battery, refer to Section 414-01 .

P0562:00 System Voltage Low: No GO to Pinpoint Test M .
P0563:00 System Voltage High: No GO to Pinpoint Test M .
P185A:00 Differential Lock-Up Input GO to Pinpoint Test Y .
Switch Circuit High: No

P185B:00 Differential Lock-Up GO to Pinpoint Test Z .
Indicator Circuit Low: No
P185C:00 Differential Lock-Up GO to Pinpoint Test AA .
Indicator Circuit High: No
P185D:00 Differential Lock-Up GO to Pinpoint Test AB .
Control Circuit
Performance: No Sub
Type Information
P187C:00 Differential Lock-Up GO to Pinpoint Test AC .
Control Circuit/Open: No
P187D:00 Differential Lock-Up GO to Pinpoint Test AC .
Control Circuit Low: No
P187E:00 Differential Lock-Up GO to Pinpoint Test AD .
Control Circuit High: No
U0100:00 Lost Communication With GO to Pinpoint Test AE .
ECM/PCM "A": No Sub
Type Information
U0121:00 Lost Communication With GO to Pinpoint Test AF .
Anti-Lock Brake System
(ABS) Control Module: No
U0140:00 Lost Communication With GO to Pinpoint Test AG .
Body Control Module
(BCM): No Sub Type
Information
U0418:00 Invalid Data Received REFER to Section 206-09 to diagnose the wheel speed sensor
From Brake System concern.
Control Module: No Sub
Type Information
U2300:54 Central Configuration: This DTC can set if one or more expected configuration data
Missing Calibration identifications is missing (gearbox type, tire circumference) from
the BCM . CARRY OUT a self-test of the BCM . If DTCs are
present, REFER to Section 419-10 . If no DTCs are present,
CLEAR the DTCs. CARRY OUT a self-test. If U2300:54 returns,
INSTALL a new TCCM . REFER to Transfer Case Control Module
(TCCM) in this section.
U2300:55 Central Configuration: Not This DTC can set upon power up only until all expected
Configured configuration data parameters (gearbox type, axle ratio, tire
circumference) is received from the BCM . CARRY OUT a self-
test of the BCM . If DTCs are present, REFER to Section 419-10 .
If no DTCs are present, CLEAR the DTCs. CARRY OUT self-test.
If U2300:55 returns, INSTALL a new TCCM . REFER to Transfer
Case Control Module (TCCM) in this section.
U2300:56 Central Configuration: This DTC can set if one expected configuration data parameter is
Invalid / Incompatible out of range (gearbox type, axle ratio, tire circumference) from the
Configuration BCM . CARRY OUT a self-test of the BCM . If DTCs are present,
REFER to Section 419-10 . If no DTCs are present, CLEAR the

DTCs. CARRY OUT a self-test. If U2300:56 returns, INSTALL a
new TCCM . REFER to Transfer Case Control Module (TCCM) in
this section.
U2300:64 Central Configuration: This DTC can set if the expected axle ratio or tire circumference is
Signal Plausibility Failure out of range from the BCM . CARRY OUT a self-test of the BCM .
If DTCs are present, REFER to Section 419-10 . If no DTCs are
present, CLEAR the DTCs. CARRY OUT a self-test. If U2300:64
returns, INSTALL a new TCCM . REFER to Transfer Case Control
Module (TCCM) in this section.
U3000:41 Control Module: General CLEAR the DTC. REPEAT the self-test. If DTC U3000:41 is
Checksum Failure retrieved, INSTALL a new TCCM . REFER to Transfer Case
Control Module (TCCM) in this section.
U3000:46 Control Module: CLEAR the DTC. REPEAT the self-test. If DTC U3000:46 is
Calibration / Parameter retrieved, INSTALL a new TCCM . REFER to Transfer Case
Memory Failure Control Module (TCCM) in this section.
U3000:49 Control Module: Internal CLEAR the DTC. REPEAT the self-test. If DTC U3000:49 is
Electronic Failure retrieved, INSTALL a new TCCM . REFER to Transfer Case
U300D:11 Ignition Input On/Start: GO to Pinpoint Test L .
All other — REFER to the TCCM DTC Chart in of this section.
TCCM
DTCs
Symptom Chart — Electronic Locking Differential (ELD) System
Symptom Chart
z No communication with the z Wiring, z CHECK the module
TCCM terminals or communications network.
connectors REFER to Section 418-00 .
z Scan tool
z DLC
z TCCM
z Rear wheels binding when z Wiring, z GO to Pinpoint Test AD .
turning corners with the terminals or
MSS in 2WD or OFF connectors
z ELD field coil
z TCCM
z Rear
differential
Pinpoint Tests
Pinpoint Test Y: DTC P185A:00
Refer to Wiring Diagrams Cell 34 , Four-Wheel Drive Systems for schematic and connector information.
Normal Operation
When the MSS is engaged to lock the rear differential, a PWM signal is sent to the ELD field coil by the
TCCM through the differential lock control circuit. This PWM signal is initially 98% duty cycle to lock the
differential and decreases to 40% duty cycle once the differential is locked. If the differential does not lock,
the TCCM continues to send the signal for a set amount of time. Once the differential is locked, the indicator
will illuminate steady.
z DTC P185A:00 (Differential Lock-Up Input Switch Circuit High: No Sub Type Information) — When
not in locking mode, the TCCM C2371A pin 15 senses whether the ELD mode switch circuit has high
voltage and if the differential is always engaged. This DTC will not set unless the MSS is set to 2H or
OFF. If the ELD is functioning normally, the differential will immediately lock when the MSS is
activated and the ELD operating conditions are qualified. This DTC will only display during the self-
test function.

z TCCM
PINPOINT TEST Y: DTC P185A:00
NOTE: Make sure the battery is fully charged before carrying out this pinpoint test.

Y1 CHECK FOR TCCM DTCs
NOTE: Failure to place the MSS in 2H or OFF prior to Yes

carrying out a self-test of the TCCM (to disable the ELD field If only DTC P185A:00 is
coil) results in inaccurate self-test. retrieved, GO to Y2 .
z Ignition ON. For any other DTCs, REFER to
z Set the MSS in 2H ( ESOF or 2 speed-torque-on-demand). the TCCM DTC Chart in this
z Set the MSS in OFF ( 2WD ). section.
z Enter the following diagnostic mode on the scan tool: Self-
Test — TCCM . No
z Are any DTCs present? IDENTIFY the customer concern
and GO to Symptom Chart -
Electronic Locking Differential
(ELD) System in this section.
Y2 CHECK FOR A SHORT TO VOLTAGE ON THE LOCKER
MODE SWITCH CIRCUIT
z Ignition OFF. Yes
z Disconnect: TCCM C2371A. GO to Y3 .
z Ignition ON.
z With the MSS in 2H or OFF (depending upon vehicle option No
content), measure the voltage between TCCM C2371A-15, GO to Y4 .
circuit CCF32 (WH/GN), harness side and ground.

Y3 CHECK FOR A SHORT TO VOLTAGE ON THE LOCKER
MODE SWITCH CIRCUIT WITH THE MSS DISCONNECTED
z Ignition OFF. Yes
z Disconnect: MSS . REPAIR circuit CCF32 (WH/GN).
z Ignition ON. CLEAR the DTCs. TEST the
z Measure the voltage at TCCM C2371A-15, circuit CCF32 system for normal operation.
(WH/GN), harness side and ground.
No
INSTALL a new MSS . REFER to
Mode Select Switch (MSS) in this
normal operation.

Y4 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
z Disconnect and inspect all TCCM connectors. INSTALL a new TCCM . REFER
z Repair: to Transfer Case Control Module
corrosion (install new connector or terminals - clean (TCCM) in this section. TEST the
module pins) system for normal operation.
damaged or bent pins - install new terminals/pins
pushed-out pins - install new pins as necessary No
z Connect all TCCM connectors. Make sure they are seated The system is operating correctly
correctly. at this time. Concern may have
z Operate the system and verify the concern is still present. been caused by a loose or
z Is the concern still present? corroded connector. ADDRESS
the root cause of the connector
or pin issues.
Pinpoint Test Z: DTC P185B:00
Normal Operation
z DTC P185B:00 (Differential Lock-Up Indicator Circuit Low: No Sub Type Information) — When not in
locking mode, the TCCM C2371A-20 senses the indicator circuit is shorted to ground and the
indicator is always illuminated. This DTC should not set for an open circuit.

z TCCM
PINPOINT TEST Z: DTC P185B:00
NOTE: Make sure the battery is fully charged before performing this pinpoint test.

Z1 CHECK THE TCCM 4WD SWITCH STATUS
(4X4_SW) PID
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: GO to Z2 .
DataLogger — TCCM .
z Set the MSS to 4H and pull the knob to lock the rear No
differential. INSTALL a new MSS . REFER to Mode
z Monitor the 4X4_SW PID. Select Switch (MSS) in this section.
z Does the 4X4_SW PID indicate 4H mode? CLEAR the DTCs. TEST the system for
normal operation.
Z2 CHECK THE REAR ELD INDICATOR CIRCUIT FOR
A SHORT TO GROUND
z Ignition OFF. Yes
z Disconnect: TCCM C2371A. GO to Z3 .
z Disconnect: MSS .
z Measure the resistance between TCCM C2371A-20, No
circuit CCF33 (GY/YE), harness side and ground. REPAIR circuit CCF33 (GY/YE). CLEAR
the DTCs. TEST the system for normal
operation.

Z3 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
z Disconnect and inspect all TCCM connectors. INSTALL a new TCCM . REFER to
z Repair: Transfer Case Control Module (TCCM)
corrosion (install new connector or terminals - in this section. TEST the system for
clean module pins) normal operation.

terminals/pins No
necessary time. Concern may have been caused
z Connect all TCCM connectors. Make sure they are by a loose or corroded connector.
seated correctly. ADDRESS the root cause of the
z Operate the system and verify the concern is still connector or pin issues.
present.
Pinpoint Test AA: DTC P185C:00
Normal Operation
differential and decreases to 40% duty cycle once the differential is locked. When the differential is fully
locked, the indicator will illuminate steady.
z DTC P185C:00 (Differential Lock-Up Indicator Circuit High: No Sub Type Information) — When the
driver engages the ELD the TCCM C2371A-20 senses the indicator circuit has high voltage and is not
illuminated.

z TCCM
PINPOINT TEST AA: DTC P185C:00

AA1 OPERATE THE ELD INDICATOR USING THE TCCM
REAR LOCKING DIFF LAMP OUTPUT CONTROL
OPTIONAL (DIFF_LAMP_OS) PID
DataLogger — TCCM . GO to AA5 .
z Command the DIFF_LAMP_OS PID on.
z Does the ELD indicator in the MSS illuminate? No
GO to AA2 .
AA2 CHECK THE ELD INDICATOR CIRCUIT FOR A
SHORT TO VOLTAGE
z Ignition OFF. Yes
z Disconnect: TCCM C2371A. REPAIR circuit CCF33 (GY/YE).
z Disconnect: MSS . CLEAR the DTCs. TEST the system
z Ignition ON. for normal operation.
z Measure the voltage between TCCM C2371A-20,
circuit CCF33 (GY/YE), harness side and ground. No

GO to AA3 .

AA3 CHECK FOR VOLTAGE TO THE MSS
z Measure and record the battery voltage at the battery. Yes
GO to AA4 .
No
VERIFY BCM fuse 34 (10A) is OK. If
OK, REPAIR circuit CBP34 (VT/BN). If
CLEAR the DTCs. TEST the system
z Measure the voltage between MSS C284-7, circuit

CBP34 (VT/BN), harness side and ground.
z Does the voltage equal the recorded battery

voltage?
AA4 CHECK THE TCCM GROUND CIRCUIT
z Ignition OFF. Yes
z Disconnect: TCCM C2371B. GO to AA5 .
z Measure the resistance between C2371B-3, circuit
GD123 (BK/GY), harness side and ground. No
REPAIR circuit GD123 (BK/GY).

AA5 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
terminals/pins No
pushed-out pins - install new pins as necessary The system is operating correctly at
z Connect all TCCM connectors. Make sure they are this time. Concern may have been
seated correctly. caused by a loose or corroded
z Operate the system and verify the concern is still connector. ADDRESS the root cause
present. of the connector or pin issues.
Pinpoint Test AB: DTC P185D:00
Normal Operation
z DTC P185D:00 (Differential Lock-up Control Circuit Performance: No Sub Type Information) — The
TCCM sends a signal to the lock up solenoid to lock the differential. After several unsuccessful
attempts, the TCCM sets this DTC alerting the driver the ELD is inoperative. Fault may be due to a
wheel speed condition or due to a mechanical failure within the driveline/axle subsystem.

z ELD field coil
PINPOINT TEST AB: DTC P185D:00

AB1 CHECK THE ABS MODULE WHEEL SPEED SENSOR
PIDs
DataLogger — ABS Module. GO to AB2 .
z While driving the vehicle at 30 km/h (18 mph), monitor the
following wheel speed sensor PIDs: No
Left Front Wheel Speed Sensor (LF_WSPD) VERIFY that the 4 road wheels
Left Rear Wheel Speed Sensor (LR_WSPD) are the same size and have
Right Front Wheel Speed Sensor (RF_WSPD) similar tread depth. CHECK the
Right Rear Wheel Speed Sensor (RR_WSPD) ABS for faults. REFER to Section
z Compare the speedometer reading to the wheel speed 206-09 . TEST the system for
sensor PIDs. normal operation.
z Do the wheel speed sensor PIDs and speedometer
speeds match within 1.5 km/h (1 mph)?
AB2 CHECK RESISTANCE OF THE ELD FIELD COIL
z Ignition OFF. Yes
z Disconnect: ELD Field Coil. GO to AB3 .
z NOTE: If the temperatures are exceptionally high, a higher
than normal resistance reading could result. A lower No
temperature could result in a lower resistance reading. INSTALL a new ELD field coil.
z Measure the resistance between ELD field coil C4359 pins REFER to Section 205-02B .
1 and 2, component side. CLEAR the DTCs. TEST the
z Is the resistance between 2-4 ohms?

AB3 CHECK THE ELD FIELD COIL GROUND
z Measure the resistance between ELD field coil C4359-2, Yes
circuit GD123 (BK/GY), harness side and ground. REFER to Section 205-02B to
repair the rear differential. CLEAR
the DTCs. TEST the system for
normal operation.
No
REPAIR circuit GD123 (BK/GY).
CLEAR the DTCs. TEST the
Pinpoint Test AC: DTC P187C:00 and P187D:00
Normal Operation
differential and decreases to 40% duty cycle once the differential is locked. If the differential lock control
circuit is open or shorted to ground, the TCCM senses a signal is not reaching the differential and sets a
DTC.
z DTC P187C:00 (Differential Lock-Up Control Circuit/Open: No Sub Type Information) — The TCCM
sends a signal to the differential to lock the differential. The TCCM C2371B pin 9 senses that the
differential lock control circuit is open. The ELD differential is not engaged.
z DTC P187D:00 (Differential Lock-Up Control Circuit Low: No Sub Type Information) — The TCCM
sends a signal to lock the differential. The TCCM C2371B pin 9 senses that the differential lock
control circuit is shorted to ground. The ELD differential is not engaged.

z TCCM
PINPOINT TEST AC: DTC P187C:00 AND P187D:00

AC1 CHECK FOR TCCM DTCs
NOTE: Failure to place the MSS in 2H or OFF prior to Yes

carrying out a self-test of the TCCM (to disable the ELD For DTC P187C:00, GO to AC4 .
field coil) results in inaccurate self-test.
For DTC P187D:00, GO to AC2 .
z Ignition ON.
z Set the MSS in 2H ( ESOF or 2 speed-torque-on-demand). For all other DTCs, REFER to the
z Set the MSS in OFF ( 2WD ). TCCM DTC Chart in this section.
z Enter the following diagnostic mode on the scan tool: Self-
Test — TCCM . No
z Are any DTCs present? IDENTIFY the customer concern
and GO to Symptom Chart -
Electronic Locking Differential
(ELD) System in this section.
AC2 CHECK FOR TCCM DTCs WITH THE ELD FIELD COIL
DISCONNECTED
z Ignition OFF. Yes
z Disconnect: ELD Field Coil. GO to AC3 .
z Ignition ON.
z Set the MSS in 2H ( ESOF or 2 speed-torque-on-demand). No
z Set the MSS in OFF ( 2WD ). INSTALL a new field coil. REFER
z Enter the following diagnostic mode on the scan tool: Self- to Section 205-02B . CLEAR the
Test — TCCM . DTCs. TEST the system for
z CLEAR the DTCs. REPEAT the self-test. Does DTC normal operation.
P187D:00 return?
AC3 CHECK THE ELD DIFFERENTIAL LOCK CONTROL

z Ignition OFF. Yes
z Disconnect: TCCM C2371B. GO to AC4 .
z Measure the resistance between TCCM C2371B-9, circuit
CCF31 (BN/VT), harness side and ground. No
REPAIR circuit CCF31 (BN/VT).

AC4 CHECK THE ELD DIFFERENTIAL LOCK CONTROL
CIRCUIT FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: TCCM C2371B. GO to AC5 .
z Disconnect: ELD Field Coil.
z Measure the resistance between TCCM C2371B-9, circuit No
CCF31 (BN/VT), harness side and ELD field coil C4359-1, REPAIR circuit CCF31 (BN/VT).
circuit CCF31 (BN/VT), harness side. CLEAR the DTCs. TEST the

AC5 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
the root cause of the connector or
pin issues.
Pinpoint Test AD: Rear Wheels Binding When Turning Corners With the ELD OFF
Normal Operation
z DTC P187E:00 (Differential Lock-Up Control Circuit High: No Sub Type Information) — The TCCM
sends a signal to lock the differential. This DTC sets when the TCCM C2371B-9 senses that the
differential lock control circuit is shorted to battery voltage. The differential is constantly engaged.

z ELD field coil
z TCCM
PINPOINT TEST AD: REAR WHEELS BINDING WHEN TURNING CORNERS WITH THE ELD OFF

AD1 CHECK FOR VOLTAGE TO THE ELD FIELD COIL
z Ignition OFF. Yes
z Disconnect: ELD Field Coil. GO to AD2 .
z Ignition ON.
z Set the MSS in 2H ( ESOF or 2 speed-torque-on- No
demand). REFER to Section 205-02B to repair the
z Set the MSS in OFF ( 2WD ). rear differential. CLEAR the DTCs.
z Measure the voltage between ELD field coil C4359-1, TEST the system for normal operation.
circuit CCF31 (BN/VT), harness side and ground.

AD2 CHECK THE ELD FIELD COIL CIRCUIT FOR A
SHORT TO VOLTAGE
Yes
z Ignition OFF. REPAIR circuit CCF31 (BN/VT).

z Disconnect: TCCM C2371B. CLEAR the DTCs. TEST the system for
z Ignition ON. normal operation.
z Measure the voltage between field coil C4359-1,
circuit CCF31 (BN/VT), harness side and ground. No
GO to AD3 .

AD3 CHECK THE TCCM REAR LOCKING
DIFFERENTIAL PWM OUTPUT CONTROL
(DIFF_PWM_OS) PID
z Ignition OFF. Yes
z Connect: ELD Field Coil. GO to AD4 .
z Connect: TCCM C2371B.
z Ignition ON. No
z Enter the following diagnostic mode on the scan tool: INSTALL a new MSS . REFER to Mode
DataLogger — TCCM . Select Switch (MSS) in this section.
z With the MSS in 2H or OFF (depending upon vehicle CLEAR the DTCs. TEST the system for
option content), monitor the DIFF_PWM_OS PID. normal operation.
z Does the DIFF_PWM_OS PID read OFF?
AD4 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
terminals/pins No
necessary time. Concern may have been caused
z Connect all TCCM connectors. Make sure they are by a loose or corroded connector.
present.
Pinpoint Test AE: DTC U0100:00
Normal Operation
z DTC U0100:00 (Lost Communication With ECM/PCM "A": No Sub-Type Information) — sets in
continuous memory in the TCCM if data messages received from the PCM over the HS-CAN are
missing for 5 seconds or longer with ignition in RUN and battery voltage in range. For a complete list
of all network messages, refer to Section 418-00 .
z PCM
z TCCM
PINPOINT TEST AE: DTC U0100:00

AE1 CHECK THE TCCM CONTINUOUS
MEMORY DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode GO to AE2 .
on the scan tool: TCCM Self-Test.
z Clear the DTCs. No
z Wait 10 seconds. The system is operating correctly at this time. The DTC
z Repeat the TCCM self-test. may have been set due to high network traffic or an
z Is DTC U0100:00 retrieved again? intermittent fault condition.
AE2 RETRIEVE THE RECORDED DTCs
FROM THE PCM KOEO SELF-TEST
PCM KOEO self-test. REFER to Section 414-00 .
z Is DTC P0562:00 or P0563:00
recorded? No
GO to AE3 .
AE3 RETRIEVE THE RECORDED DTCs
FROM THE TCCM SELF-TEST
TCCM self-test. REFER to GO to Pinpoint Test M .
z Is DTC P0562:00 or P0563:00
recorded? No
GO to AE4 .
AE4 CHECK FOR DTC U0100:00 SET IN
OTHER MODULES
z Ignition ON. Yes
z Enter the following diagnostic mode INSTALL a new PCM. REFER to Section 303-14 . TEST
on the scan tool: Self-Test — All the system for normal operation.
CMDTCs .
z Retrieve the continuous memory No
DTCs from all modules. INSTALL a new TCCM . REFER to Transfer Case
z Is DTC U0100:00 in the RCM , or Control Module (TCCM) in this section. TEST the system
DTC U0100:87 in the BCM ? for normal operation.
Pinpoint Test AF: DTC U0121:00
Normal Operation
z DTC U0121:00 (Lost Communication With Anti-Lock Brake System (ABS) Control Module: No Sub-
Type Information) — sets in continuous memory in the TCCM if data messages received from the
ABS module over the HS-CAN are missing for 5 seconds or longer with ignition in RUN and battery
voltage in range. For a complete list of all network messages, refer to Section 418-00 .
z ABS module
z TCCM
PINPOINT TEST AF: DTC U0121:00

AF1 VERIFY THE CUSTOMER CONCERN
z Ignition ON. Yes
z Verify there is an observable symptom GO to AF2 .
present.
AF2 CHECK THE COMMUNICATION
NETWORK
z Ignition ON. Yes
z Enter the following diagnostic mode on GO to AF3 .
the scan tool: Network Test.
z Carry out the network test. No
z Does the ABS module pass the REFER to Section 418-00 .
network test?
AF3 RETRIEVE THE RECORDED DTCs
FROM THE ABS MODULE SELF-TEST
ABS module self-test. REFER to Section 206-09 .
z Is DTC B11E8:16 (B1318) or DTC
B11E8:17 (B1317) recorded? No
GO to AF4 .
AF4 RETRIEVE THE RECORDED DTCs
FROM THE TCCM SELF-TEST
TCCM self-test. GO to Pinpoint Test M .
z Is DTC P0562:00 or P0563:00
recorded? No
GO to AF5 .
AF5 RECHECK THE TCCM DTCs
NOTE: If new modules were installed Yes

prior to the DTC being set, the module INSTALL a new ABS module. REFER to Section 206-
configuration may be incorrectly set 09 . CLEAR the DTCs. REPEAT the TCCM self-test. If
during the PMI or the PMI may not DTC U0121:00 is still present, INSTALL a new
have been carried out. TCCM . REFER to Transfer Case Control Module
(TCCM) in this section. TEST the system for normal
z Clear the DTCs. operation.
z Wait 10 seconds.
z Repeat the TCCM self-test. No
z Is DTC U0121:00 still present? The system is operating correctly at this time. The
Pinpoint Test AG: DTC U0140:00
Normal Operation
z DTC U0140:00 (Lost Communication With Body Control Module: No Sub-Type Information) — sets in
continuous memory in the TCCM if data messages received from the BCM over the HS-CAN are
missing for 5 seconds or longer with ignition in RUN and battery voltage in range. For a complete list
of all network messages, refer to Section 418-00 .
z BCM
z TCCM
PINPOINT TEST AG: DTC U0140:00

AG1 VERIFY THE CUSTOMER CONCERN
z Ignition ON. Yes
z Verify there is an observable symptom present. GO to AG2 .
z Is an observable symptom present?
No
The system is operating normally at this
time. The DTC may have been set due to
high network traffic or an intermittent fault
condition.
AG2 CHECK THE COMMUNICATION NETWORK
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan GO to AG3 .
tool: Network Test.
z Carry out the network test. No
z Does the pass the network test? REFER to Section 418-00 .
AG3 RETRIEVE THE RECORDED DTCs FROM THE
BCM SELF-TEST
z Check for recorded DTCs from the BCM self-test. Yes
z Is DTC U3003:16 or DTC U3003:17 recorded? Section 419-10 .
No
GO to AG4 .
AG4 RETRIEVE THE RECORDED DTCs FROM THE
TCCM SELF-TEST
z Check for recorded DTCs from the TCCM self-test. Yes
z Is DTC P0562:00 or P0563:00 recorded? GO to Pinpoint Test M .
No
GO to AG5 .
AG5 RECHECK THE TCCM DTCs
Yes
NOTE: If new modules were installed prior to the
GO to AG6 .
DTC being set, the module configuration may be
incorrectly set during the or the may not have been
No
carried out. The system is operating correctly at this

z Clear the DTCs. time. The DTC may have been set due to
z Wait 10 seconds. high network traffic or an intermittent fault
z Repeat the TCCM self-test. condition.
z Is DTC U0140:00 still present?
AG6 CHECK FOR DTC U0140 OR DTC U0140:00 SET
IN OTHER MODULES
z Clear all DTCs. Yes
z Ignition OFF. INSTALL a new BCM . REFER to Section
z Ignition ON. 419-10 . TEST the system for normal
z Wait 10 seconds. operation.
tool: Self-Test — All CMDTCs . No
z Retrieve the continuous memory DTCs from all INSTALL a new TCCM . REFER to
modules. Transfer Case Control Module (TCCM) in
z Is DTC U0140 or U0140:00 set in more than one this section. TEST the system for normal
module? operation.
Pinpoint Test AH: Neutral Flat Tow Functional Test
Refer to Wiring Diagrams Cell 34 , Four-Wheel Drive System for schematic and connector information.
Normal Operation
Neutral flat tow operates by shifting the transfer case shift motor into the NEUTRAL position, locking the
transfer case in NEUTRAL. The TCCM sends the transfer case shift motor NEUTRAL position status to the
IPC over the HS-CAN .

z IPC
z TCCM
z TR sensor from PCM
z Ignition switch
PINPOINT TEST AH: NEUTRAL FLAT TOW FUNCTIONAL TEST
NOTICE: 2WD vehicles cannot be towed with any wheels on the ground as vehicle or transmission
damage may occur.
NOTICE: Failing to put the transfer case in its NEUTRAL position will damage vehicle components.
NOTE: 4WD vehicles can only be flat towed with all wheels on the ground by placing the transfer case in its
NEUTRAL position.

AH1 CHECK NEUTRAL FLAT TOW
ACTIVATION AND DEACTIVATION
z Activate neutral flat tow. Refer to Yes
Neutral Flat Tow Activation and RETURN the vehicle to the customer. ADVISE the
Deactivation in this section. customer about the correct Neutral Flat Tow Activation
z Does the IPC indicate neutral flat and Deactivation procedure.
tow is activated?
No
GO to AH2 .
AH2 CHECK NEUTRAL FLAT TOW
ACTIVATION WHILE MONITORING THE
TCCM 4WD MODES (4WD_MODES) PID
z Ignition ON. Yes
z Enter the following diagnostic mode REFER to Section 413-01 to diagnose IPC faults. After
on the scan tool: DataLogger — the repair is complete, CLEAR the DTCs. TEST the
TCCM . system for normal operation.
z Monitor the 4WD_MODES PID.
z Does the PID indicate NEUTRAL? No
GO to AH3 .
AH3 CHECK FOR TCCM DTCs
on the scan tool: Self-Test — REFER to the TCCM DTC Chart in this section. After the
TCCM . repair is complete, CLEAR the DTCs. TEST the system
z Are any DTCs present? for normal operation.
No
GO to AH4 .
AH4 CHECK TCCM BRAKE ON/OFF
(4X4_BOO) PID
on the scan tool: DataLogger — GO to AH5 .
TCCM .
z Monitor the 4X4_BOO PID while No
pressing the brake pedal. REFER to Section 417-01 to diagnose stoplamp system
z Does the PID agree with the faults. After the repair is complete, CLEAR the DTCs.
brake pedal position? TEST the system for normal operation.
AH5 CHECK THE TCCM IGNITION
POSITION (KEY_POS_4X4) PID
on the scan tool: DataLogger — GO to AH6 .
TCCM .
z Monitor the KEY_POS_4X4 PID No
with the ignition in the ON position. REFER to Section 211-05 for further diagnosis of the
z Does the PID indicate Ignition ignition switch.
On?
AH6 CHECK THE TCCM NEUTRAL
INDICATOR (NEUTRAL) PID
For vehicles equipped with the ESOF system, GO to
on the scan tool: DataLogger — Pinpoint Test B to diagnose the transfer case shift motor.
TCCM . For vehicles equipped with the 2-speed torque-on-
z Monitor the NEUTRAL PID with the demand system, GO to Pinpoint Test P to diagnose the
gear selector in neutral position. transfer case shift motor.
z Does the PID indicate TRUE?
No
REFER to Section 307-01 for diagnosis of the TR sensor.
Four Wheel Drive (4WD) Systems — 2-Speed Torque-On-Demand
Special Tool(s)
Flex Probe Kit
equivalent


The 2-speed torque-on-demand system is an automatic electronic-shift system that allows the operator to
choose between 2-Wheel Drive (2WD) and 3 different Four-Wheel Drive (4WD) modes. The operator can
switch between 2WD (2H) mode, 4X4 AUTO (4A) mode or 4X4 (4H) mode at any speed or at a stop. To
engage or disengage 4X4 LOW (4L) mode, the vehicle speed must be less than 5 km/h (3 mph) and the
transmission must be in NEUTRAL.
Wheel slip is sensed by monitoring the average front and rear wheel speeds. Based on steering wheel
angle, Accelerator Pedal Position (APP) and wheel slip, a Pulse-Width Modulation (PWM) signal is
transmitted to the transfer case as torque is required.
The Transfer Case Control Module (TCCM) will provide the ABS with current clutch duty cycle and whether
or not ABS may command the clutch duty cycle.
The brake subsystem sends the following information signals to the 4WD system over the High Speed
Controller Area Network (HS-CAN):
z Occurrences of brake events and failures. Refer to Section 206-09 .

z Steering wheel angle status. Refer to Section 206-09 .
z Wheel speeds. Refer to Section 206-09 .
A concern with any of the above listed brake system signals HS-CAN will affect operation of the 4WD
system.
The APP output signal is provided to the TCCM from the PCM. This signal is used by the TCCM in
controlling the transfer case clutch.
The shift motor sense plate, an integral part of the shift motor assembly, informs the TCCM of the transfer
case position.
The electric shift motor is mounted externally to the transfer case. It drives a rotary cam which moves the
range fork within the transfer case between the HIGH range (2H, 4A and 4H) and LOW range (4L) positions.
The shift motor only moves during a shift to/from 4L on the 2 speed torque on demand system; it
does not move during any other mode shift.
The TCCM sends a duty cycle command to the clutch coil which activates the clutch within the transfer case.
The TCCM varies the torque sent to the front driveline by controlling the transfer case clutch. At rest and
under cruising conditions, the TCCM activates the transfer case clutch a minimum duty cycle (percentage of
time the clutch is turned on), which allows for the slight difference between the front and rear driveshafts
which normally occurs when negotiating a corner on dry pavement. Under any of the following conditions,
the TCCM will increase the duty cycle in order to prevent or control slip:
z Slip is detected
z Heavy acceleration (throttle position)
z Straight-ahead steering wheel angle
Feature inputs:
z MSS
z Steering wheel angle (from the ABS module)
z TR position (from the PCM)
z Transmission output torque (from the PCM)
z Wheel speed signal (transmitted from the ABS module)
z APP (from the PCM)
z Transfer case shift motor contact plate position inputs A, B, C, D
Feature outputs:
z PWM signal to the transfer case clutch

z 4WD message center indicators
z Transfer case shift motor outputs
Shifts between 4X4 AUTO (4A) and 4X4 (4H) modes can be made at any speed. Listed below are the inputs
and outputs needed by the to execute a change between any of these modes.
Feature inputs:
z Wheel speed signal

z MSS
Feature outputs:

When shifting into or out of 4X4 LOW (4L) mode, TCCM the requires that the vehicle speed is less than 5
km/h (3 mph) and the transmission is in NEUTRAL.
Feature inputs:

z MSS
z Transfer case shift motor encoder contact plate position inputs A, B, C, D
z Wheel speed signal (transmitted from ABS module)
Feature outputs:

z Halfshafts z BJB fuses:
z IWEs 20 (20A)
z Driveshaft and U-joints 29 (10A)
z Vacuum leaks 54 (5A)
z Fluid leaks 68 (25A)
z Matching tire sizes z BCM fuse 34 (10A) (vehicles with ELD only)
z Transfer case z Wiring, terminals or connectors
z MSS
z Synchronization clutch
z IWE solenoid
z Transfer case shift motor



418-00 .
(CMDTCs).
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Four-Wheel Drive System or
GO to Symptom Chart - NVH .
DTC Charts
Transfer Case Control Module (TCCM) DTC Chart
code provides information about specific fault conditions such as opens or shorts to ground. Continuous
Memory Diagnostic Trouble Codes (CMDTCs) have an additional 2-character DTC status code suffix to
assist in determining DTC history.

C1979:11 IWE Solenoid Circuit Failure: Circuit GO to Pinpoint Test N .
Short To Ground
Short To Battery
Open
P0562:00 System Voltage Low: No Sub Type GO to Pinpoint Test M .
Information
P0563:00 System Voltage High: No Sub Type GO to Pinpoint Test M .
Information
P1812:00 4-Wheel Drive Mode Select Circuit GO to Pinpoint Test X .
Failure: No Sub Type Information
P1815:00 4-Wheel Drive Mode Select Short To GO to Pinpoint Test X .
Ground: No Sub Type Information
P1825:00 4-Wheel Drive Clutch Relay Open GO to Pinpoint Test Q .
Circuit: No Sub Type Information

P1826:00 4-Wheel Drive Low Clutch Relay Circuit GO to Pinpoint Test Q .
To Battery: No Sub Type Information
P1827:00 4-Wheel Drive Low Clutch Relay Circuit GO to Pinpoint Test Q .
To Ground: No Sub Type Information
P1839:00 Transfer Case Shift Motor Open Circuit: GO to Pinpoint Test P .
No Sub Type Information
P1840:00 Transfer Case Shift Motor Short Circuit GO to Pinpoint Test P .
To Battery: No Sub Type Information
P1841:00 Transfer Case Shift Motor Short Circuit GO to Pinpoint Test P .
To Ground: No Sub Type Information
P1849:00 Transfer Case Contact Plate 'A' Short GO to Pinpoint Test P .
Circuit To Ground: No Sub Type
Information
P184B:00 Transfer Case Unable To Transition GO to Pinpoint Test P .
Between 4H and 4L: No Sub Type
Information
P1853:00 Transfer Case Contact Plate 'B' Short GO to Pinpoint Test P .
Information
P1857:00 Transfer Case Contact Plate 'C' Short GO to Pinpoint Test P .
Information
P185A:00 Differential Lock-Up Input Switch Circuit Go to Pinpoint Test Y in Electronic Locking
High: No Sub Type Information Differential (ELD) System, Diagnosis and Testing,
Section 308-07A .
P185B:00 Differential Lock-Up Indicator Circuit Go to Pinpoint Test Z in Electronic Locking
Low: No Sub Type Information Differential (ELD) System, Diagnosis and Testing,
Section 308-07A .
P185C:00 Differential Lock-Up Indicator Circuit Go to Pinpoint Test AA in Electronic Locking
Section 308-07A .
P185D:00 Differential Lock-Up Control Circuit Go to Pinpoint Test AB in Electronic Locking
Performance: No Sub Type Information Differential (ELD) System, Diagnosis and Testing,
Section 308-07A .
P1861:00 Transfer Case Contact Plate 'D' Short GO to Pinpoint Test P .
Information
P1867:00 Transfer Case Contact Plate General GO to Pinpoint Test P .
Circuit Failure: No Sub Type
Information
P187C:00 Differential Lock-Up Control Go to Pinpoint Test AC in Electronic Locking
Circuit/Open: No Sub Type Information Differential (ELD) System, Diagnosis and Testing,
Section 308-07A .
P187D:00 Differential Lock-Up Control Circuit Go to Pinpoint Test AC in Electronic Locking
Low: No Sub Type Information Differential (ELD) System, Diagnosis and Testing,
Section 308-07A .
P187E:00 Differential Lock-Up Control Circuit Go to Pinpoint Test AD in Electronic Locking
Section 308-07A .
P1886:00 4X4 Initialization Failure: No Sub Type CLEAR the DTC. REPEAT the self-test. If the DTC
Information still reports, CONFIRM the TCCM part number is
correct for the vehicle.
P1891:00 Transfer Case Contact Plate Ground GO to Pinpoint Test P .
Return Open Circuit: No Sub Type
Information
U0100:00 Lost Communication With ECM/PCM Go to Pinpoint Test AB in Electronic Locking
"A": No Sub Type Information Differential (ELD) System, Diagnosis and Testing,
Section 308-07A .
U0121:00 Lost Communication With Anti-Lock Go to Pinpoint Test AF in Electronic Locking
Brake System (ABS) Control Module: Differential (ELD) System, Diagnosis and Testing,
No Sub Type Information Section 308-07A .
U0418:00 Invalid Data Received From Brake REFER to Section 206-09 to diagnose the wheel
System Control Module: No Sub Type speed sensor concern.
Information
U3000:04 Control Module: System Internal Failure CLEAR the DTC. REPEAT the self-test. If DTC
U3000:04 is retrieved, INSTALL a new TCCM .
REFER to Transfer Case Control Module (TCCM) in
this section.
U3000:41 Control Module: General Checksum CLEAR the DTC. REPEAT the self-test. If DTC
Failure U3000:41 is retrieved, INSTALL a new TCCM .
this section.
U3000:46 Control Module: Calibration / Parameter CLEAR the DTC. REPEAT the self-test. If DTC
Memory Failure U3000:46 is retrieved, INSTALL a new TCCM .
this section.
U3000:49 Control Module: Internal Electronic CLEAR the DTC. REPEAT the self-test. If DTC
Failure U3000:49 is retrieved, INSTALL a new TCCM .
this section.
U300D:11 Ignition Input On/Start: Circuit Short To GO to Pinpoint Test L .
Ground
Symptom Chart — Four-Wheel Drive System
Symptom Chart —
z No communication with the z Scan tool z REFER to Section 418-
TCCM z DLC 00 .
z TCCM
z Wiring, terminals
or connectors
z The 4X4 mode indicators z Instrument Panel z GO to Pinpoint Test V .
do not operate correctly/do Cluster (IPC)
not operate z 4WD system fault
z HS-CAN
z TCCM
z The vehicle does not shift z Wiring, terminals z GO to Pinpoint Test X .
between 2H (2WD) and or connectors
4X4 modes correctly z MSS
z Transfer case
z TCCM
z The vehicle does not shift z MSS z GO to Pinpoint Test O .
between 4A (4X4 AUTO) z IWEs
and 4H (4X4) modes z IWE solenoid
correctly z Transfer case
z Vacuum leaks
z Front axle
assembly
z TCCM
z Wiring, terminals
or connectors
z Vehicle has no torque or z Transfer case and z CARRY OUT the 4WD
inadequate torque at front related System Functional Test.
wheels in 4A (4X4 AUTO) components GO to Pinpoint Test U .
mode z IWEs and related
components
z Wheel/tire
assemblies
z The vehicle does not shift z Wiring, terminals z GO to Pinpoint Test P .
between 4H (4X4) and 4L or connectors
(4X4 LOW) modes correctly z Transfer case
z TR
z ABS wheel speed
inputs
z IWEs
z TCCM
z Transmission drag
torque
z 4WD does not engage at z Transfer case z GO to Pinpoint Test Q .
speed correctly synchronization
clutch
z Transfer case
z TCCM
z Front axle
assembly
z Wiring, terminals
or connectors
z The front axle does not z MSS z GO to Pinpoint Test N .
engage/disengage correctly z IWEs
z IWE solenoid
z Transfer case
z Vacuum leaks
z Front axle
assembly
z TCCM
z Wiring, terminals
or connectors
z Fuses
z The 4WD system jumps out z IWE vent line(s) z GO to Pinpoint Test R .
of gear z MSS
z Transfer case
z Unable to duplicate z 4WD system z CARRY OUT the 4WD
customer concern and/or related System Functional Test.
components GO to Pinpoint Test U .
z Unable to achieve flat tow z Wiring, terminals z Go to Pinpoint Test AH in
(neutral tow) mode or connectors Electronic Locking
z HS-CAN Differential (ELD)
z IPC System, Diagnosis and
z TCCM Testing, Section 308-
z Door ajar switch 07A .
z Ignition switch
NOTE: NVH symptoms should be identified using the diagnostic tools that are available. For a list of these
tools, an explanation of their uses and a glossary of common terms, refer to Section 100-04 . Since it is
possible any one of multiple systems may be the cause of a symptom, it may be necessary to use a process
of elimination type of diagnostic approach to pinpoint the responsible system. If this is not the causal system
for the symptom, refer back to Section 100-04 for the next likely system and continue diagnosis.

z Grinding noise z Front halfshaft z GO to Pinpoint Test N .
during 4WD speeds not turning
system at the same speed
engagement, z Synchronization
especially at high clutch
speeds
z Vehicle Pulsates z Unequal tire z GO to Pinpoint Test S .
or Shudders in a inflation pressures
Straight Line z Unmatched tire
(Straightline and wheel size
Driveline Wind-up) z Unequal amounts
of tire wear
z Unmatched front
and rear axle
ratios
z The front axle z Vacuum leaks z GO to Pinpoint Test T .
makes noise in 2H z Vacuum check
mode only and valve
generally under z Vacuum reservoir
heavy throttle z IWE solenoid
z IWEs
z The transfer case z Tire inflation z MAKE SURE that all tires and
makes noise pressure wheels are the same size and that
z Tire and wheel the inflation pressures are correct.
size
z Tire tread wear z CHECK tire tread wear to see if
there is more than 0.15 mm (0.06
in) difference in tread wear
between front and rear.
INTERCHANGE one front wheel
and one rear wheel. ROAD TEST

again.
z Internal z OPERATE the vehicle in all
components transmission gears. If there is
noise in the transmission in
NEUTRAL, or in some gears and
not in others, REMOVE and
REPAIR the transmission. REFER
to Section 307-01 . If there is
noise in all gears, DISASSEMBLE
the transfer case. REFER to
Section 308-07B . CHECK the
planetary gears, the bearings, the
upper and lower drive sprockets
and drive chain for damage.
INSTALL new parts as necessary.
z Fluid level z FILL with automatic transmission
fluid. REFER to Section 308-07B .
z Transfer case z Incorrect fluid level z CHECK that the transfer case is
whine — noise at or fluid quality filled to the correct level and with
all ranges z Worn oil pump the specified fluid. REFER to
z Under-inflated or Section 308-07B .
oversized tires z DISASSEMBLE the transfer case.
CHECK the oil pump for wear or
damage. REPAIR as necessary.
REFER to Section 308-07B .
z CONFIRM that the tires and
wheels are correct for the vehicle.
CHECK that the tire inflation
pressures are correct.
z Transfer case z Damaged or worn z DISASSEMBLE the transfer case.
growl/rumble — bearings or CHECK the bearings or planetary
noise at all ranges planetary gear gear for wear or damage. REPAIR
as necessary. REFER to Section
308-07B .
z Transfer case z Excessively z DISASSEMBLE the transfer case.
scraping/grating stretched drive CHECK the drive chain for wear or
— noise at all chain hitting the damage. REPAIR as necessary.
ranges case REFER to Section 308-07B .
z Transfer case z Worn or damaged z DISASSEMBLE the transfer case.
howl/hum — noise sun (input) gear, CHECK the gears for wear or
at all ranges or 4H clutch pack damage. REPAIR as necessary.
only (intermediate) gear REFER to Section 308-07B .
or output shaft
gear
z Vehicle binds in a z Unmatched tire z GO to Pinpoint Test W .
turn/resists sizes
turning/pulsates in z Unequal amounts
a straightline in of tire wear
4WD mode z Unequal tire
inflation pressures
z Throttle position
failure
z Transfer case
z TCCM
Pinpoint Tests
Pinpoint Test L: DTC U300D:11
Normal Operation
The TCCM receives ignition switch position status from the hardwired run/start input circuit and the ignition
switch position status message communicated by the BCM over the HS-CAN .
z DTC U300D:11 (Ignition Input On/Start: Circuit Short To Ground) — Fault sets when short to ground
is sensed by TCCM C2371A pin 7. If the ignition switch is not in RUN for the self-test, this code will
set.

z Fuse
z Ignition switch
z HS-CAN
PINPOINT TEST L: U300D:11

L1 CHECK THE TCCM IGNITION
POSITION (KEY_POS_4X4) AND
IGNITION STATUS
(KEY_STATUS_4X4) PIDs
z Enter the following diagnostic Yes
mode on the scan tool: The system is functioning correctly at this time. CLEAR the
DataLogger — TCCM . DTCs. TEST the system for normal operation.
z Monitor the KEY_POS_4X4 and
KEY_STATUS_4X4 PIDs. No
z Do the ignition PIDs match the If the KEY_STATUS_4X4 PID did not match, CHECK BJB
ignition switch positions? fuse 54 (5A). If the fuse is OK, REPAIR circuit CBB54
(VT/OG). If the fuse is not OK, REFER to the Wiring
Diagrams manual to identify the possible causes of the circuit
short. After the fault is repaired, CLEAR the DTCs. TEST the
If the KEY_POS_4X4 PID did not match, REFER to Section

211-05 to diagnose the ignition switch. After the fault is
repaired, CLEAR the DTCs. TEST the system for normal
operation.
Pinpoint Test M: DTC P0562:00 or P0563:00
Normal Operation
If the TCCM observes an overpower or underpower voltage condition, a DTC is set and all TCCM outputs
are turned off ( IWEs engaged).
z DTC P0562:00 (Battery Voltage Low: No Sub Type Information) — Fault sets when the TCCM
detects battery voltage less than 9 volts for 5 seconds or more at TCCM C2371B pin 7.
z DTC P0563:00 (Battery Voltage High: No Sub Type Information) — Fault sets when the TCCM
detects battery voltage greater than 16 volts for 5 seconds or more at TCCM C2371B pin 7.

z Fuses
z TCCM
PINPOINT TEST M: DTC P0562:00 OR P0563:00
NOTE: DTC P0562:00 or P0563:00 can be set if the vehicle has been recently jump started, the battery has
been recently charged or the battery has been discharged. The battery may become discharged due to
excessive load(s) on the charging system from aftermarket accessories or if the battery has been left
unattended with the accessories on.

M1 RETRIEVE ALL CMDTCs IN ALL MODULES
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: Self-Test REFER to Section 414-00 for
— All CMDTCs . diagnosis of the battery and
z Is P0562:00 or P0563:00 present in one or more modules charging system.
AND P0563, P0620, P0625, P0626 or P065B present in the
PCM? No
GO to M2 .
M2 CHECK BATTERY CONDITION
z Ignition OFF. Yes
z Refer to Section 414-01 and carry out the Battery — Condition GO to M3 .
Test.
z Does the battery pass the condition test? No
CHARGE or INSTALL a new
battery. REFER to Section
414-01 . CLEAR all
M3 CHECK THE CHARGING SYSTEM VOLTAGE
NOTE: Do not allow the engine rpm to increase above 2,000 Yes
rpm while performing this step or the generator may self excite For DTC P0562:00, GO to
and result in default charging system output voltage. If engine M4 .
rpm has gone above 2,000 rpm, shut the vehicle OFF and
restart the engine before performing this step. For DTC P0563:00, GO to
M6 .
z Start the engine.

z Measure the voltage of the battery: No
For DTC P0562:00, turn on headlights and HVAC fan on REFER to Section 414-00 to
high and run engine at 1,500 rpm for a minimum of 2 diagnose the charging
minutes. system. CLEAR all CMDTCs .
For DTC P0563:00, turn off all accessories and run the TEST the system for normal
engine at 1,500 rpm for a minimum of 2 minutes. operation.
z Is the battery voltage between 13-15.2 volts?

M4 CHECK VOLTAGE AND GROUND TO THE TCCM
z Ignition OFF. Yes
z Disconnect: TCCM C2371B . GO to M6 .
z Ignition ON.
z Measure the voltage between TCCM C2371B-3, circuit GD123 No
(BK/GY), harness side and TCCM C2371B-7, circuit SBB68 GO to M5 .
(GN/RD), harness side.

M5 CHECK VOLTAGE TO THE TCCM
z Measure the voltage between TCCM C2371B-7, circuit SBB68 Yes
(GN/RD), harness side and ground. REPAIR circuit GD123
(BK/GY). CLEAR all
No
VERIFY BJB fuse 68 (20A) is
OK. If OK, REPAIR circuit
SBB68 (GN/RD). If not OK,
REFER to the Wiring
short. CLEAR all CMDTCs.
z Is the voltage greater than 11 volts? TEST the system for normal
operation.
M6 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
z Disconnect and inspect all TCCM connectors. INSTALL a new TCCM .
z Repair: REFER to Transfer Case
corrosion (install new connector or terminals - clean Control Module (TCCM) in
module pins) this section. TEST the system
damaged or bent pins - install new terminals/pins for normal operation.
pushed-out pins - install new pins as necessary
z Connect all TCCM connectors. Make sure they are seated No
correctly. The system is operating
z Operate the system and verify the concern is still present. correctly at this time. Concern
z Is the concern still present? may have been caused by a
ADDRESS the root cause of
the connector or pin issues.
Pinpoint Test N: The Front Axle Does Not Engage/Disengage Correctly
Locator views for the vacuum lines and vacuum reservoir are located in Description and Operation. Refer to
Section 308-07A .
Normal Operation
In 2H mode, the TCCM supplies a ground path to the IWE solenoid to apply vacuum to the IWEs
(disengaging the front hubs from the front axle). In 4H or 4L modes, the TCCM does not supply the ground
path to the IWE solenoid, vacuum is not applied to IWEs the and an internal spring in the IWEs keeps the
hubs engaged.
z DTC C1979:11 (IWE Solenoid Circuit Failure: Short Circuit To Ground) — Fault sets when TCCM
C2371A pin 6 detects a short to ground. Fault results in IWEs hubs disengaged all the time.
z DTC C1979:12 (IWE Solenoid Circuit Failure: Short Circuit To Battery) — Fault sets when TCCM
C2371A pin 6 detects a short to voltage. Fault results in IWEs hubs engaged all the time.
z DTC C1979:13 (IWE Solenoid Circuit Failure: Circuit Open) — Fault sets when TCCM C2371A pin 6
detects an open circuit. Fault results in IWEs hubs engaged all the time.

z MSS
z IWEs
z IWE solenoid
z Transfer case
z Vacuum leaks
z Front axle assembly
z TCCM
z Fuses
PINPOINT TEST N: THE FRONT AXLE DOES NOT ENGAGE/DISENGAGE CORRECTLY
surface in an area without traffic to prevent a crash. Failure to follow these instructions may result in
personal injury.

N1 CHECK FOR TCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: Self- For DTC C1979:11, GO to N19 .
Test — TCCM .
z Are any DTCs present? For DTC C1979:12, GO to N18 .
For DTC C1979:13, GO to N20 .

TCCM - DTC Chart.
No
GO to N2 .
N2 CHECK FOR GRINDING NOISES AT HIGH SPEEDS
z With the vehicle warm and the MSS in 2H mode, drive the Yes
vehicle at sustained WOT for 5 seconds. GO to Pinpoint Test T .
z Is there a grinding noise from the axle system during
WOT ? No
GO to N3 .
N3 CHECK TCCM OPERATION
z Ignition ON. Yes
z Monitor the 4X4 indicator on the IPC while moving the MSS GO to N4 .
between 2H and 4H modes.
z Does the 4X4 indicator illuminate when the MSS is in No
the 4H position and turn off when the MSS is in the 2H GO to Pinpoint Test X .
position?
N4 CHECK THE IWE DISENGAGEMENT
Yes
NOTE: The engine must be idling during the following steps
GO to N8 .
to supply the vacuum required for the IWEs to engage and
disengage.
No
z With the vehicle in NEUTRAL, position it on a hoist. Refer GO to N5 .
to Section 100-02 .
z Place the MSS in 2H.
z Start the engine.
z Rotate the LH front tire one revolution forward and one
revolution backward while observing the LH front halfshaft.
z Rotate the RH front tire one revolution forward and one
revolution backward while observing the RH front halfshaft.
z Did either front halfshaft rotate?
N5 CHECK THE IWE ENGAGEMENT
z With the vehicle in NEUTRAL, position it on a hoist. Refer Yes
to Section 100-02 . The front axle is operating
z Place the MSS in 4H. properly at this time. CARRY OUT
z Start the engine. the 4WD Functional Test. GO to
z Rotate the LH front tire one revolution forward and one Pinpoint Test U .
z Rotate the RH front tire one revolution forward and one No
revolution backward while observing the RH front halfshaft. GO to N6 .

z Did both front halfshafts rotate?
N6 CHECK THE IWE SOLENOID OUTPUT IN 4H
z Disconnect the output vacuum line at the IWE solenoid. Yes
z Switch the MSS to 4H. The IWE is mechanically stuck in
z With the engine running, measure the vacuum at the output the disengaged position. INSTALL
port of the IWE solenoid. a new IWE on the halfshaft(s) that
z Is the vacuum less than 25 mm (1 in) Hg? did not rotate. REFER to
Integrated Wheel End (IWE) in
this section. TEST the system for
normal operation.
No
GO to N7 .
N7 CHECK THE IWE SOLENOID
z Ignition OFF. Yes
z Disconnect: IWE Solenoid . GO to N20 .
z Start the engine.
z Measure the vacuum at the output port of the IWE solenoid. No
z Is the vacuum less than 25 mm (1 in) Hg? INSTALL a new IWE solenoid.
operation.
N8 CHECK THE IWE SOLENOID OUTPUT VACUUM IN 2H
z With the engine running and the MSS in 2H, measure the GO to N11 .
vacuum at the output port of the IWE solenoid.
z Is the vacuum greater than 254 mm (10 in) Hg? No
GO to N9 .
N9 CHECK THE IWE SOLENOID INPUT VACUUM
z Disconnect the supply vacuum line at the IWE solenoid. Yes
z With the engine running, measure the supply line vacuum GO to N20 .
to the IWE solenoid.
GO to N10 .
N10 CHECK THE VACUUM RESERVOIR
z Ignition OFF. Yes
z With the source vacuum line still disconnected, connect a REPAIR or INSTALL new vacuum
vacuum pump to the vacuum port on the vacuum reservoir lines or INSTALL a check valve.
and apply 508 mm (20 in) Hg of vacuum. TEST the system for normal
z Does the vacuum maintain or drop less than 25 mm (1 operation.
in) Hg per minute?
No
INSTALL a new vacuum reservoir.
operation.
N11 CHECK THE IWE VACUUM LINES
z Ignition OFF. Yes
z Disconnect the output vacuum line from the IWE solenoid. GO to N14 .
z Disconnect and plug the LH and RH IWE vacuum lines at
the IWEs . No
z Connect a vacuum pump to the IWE output vacuum circuit GO to N12 .
at the IWE solenoid connection. Apply 508 mm (20 in) Hg
of vacuum and observe the vacuum reading.
z Does the vacuum drop more than 25 mm (1 in) Hg per

minute?
N12 CHECK THE LH IWE VACUUM LINE FOR AN
OBSTRUCTION
z REMOVE the plug from the vacuum line at the LH IWE . Yes
z Connect a hand vacuum pump to the LH IWE vacuum line INSTALL a new vacuum line.
and attempt to draw a vacuum on the line. CLEAR the DTCs. TEST the
z Did the vacuum pump draw a vacuum on the LH IWE system for normal operation.
vacuum line?
No
GO to N13 .
N13 CHECK THE RH IWE VACUUM LINE FOR AN
OBSTRUCTION
z REMOVE the plug from the vacuum line at the RH IWE . Yes
z Connect a vacuum pump to the RH IWE vacuum line and INSTALL a new vacuum line.
attempt to draw a vacuum on the line. CLEAR the DTCs. TEST the
z Did the vacuum pump draw a vacuum on the RH IWE system for normal operation.
vacuum line?
No
GO to N14 .
N14 CHECK THE RH IWE LEAK RATE
z Apply 508 mm (20 in) Hg of vacuum to the RH IWE port Yes
and observe vacuum reading. GO to N15 .
z Does the vacuum maintain or drop less than 25 mm (1
in) Hg per minute? No
INSTALL a new RH IWE . REFER
to Integrated Wheel End (IWE) in
normal operation.
N15 CHECK THE RH IWE OPERATION
z Connect a vacuum pump with gauge to the larger port of Yes
the RH IWE . CONNECT the vacuum line to the
z Observe the RH halfshaft while rotating the RH front tire. RH IWE . GO to N16 .
Apply between 152 and 203 mm (6 to 8 in) Hg of vacuum
and release the vacuum to manually disengage and No
engage the RH IWE . INSTALL a new RH IWE . REFER
z Did the RH IWE disengage between 152 and 203 mm (6 to Integrated Wheel End (IWE) in
to 8 in) Hg and engage when the vacuum is released? this section. TEST the system for
normal operation.
N16 CHECK THE LH IWE LEAK RATE
z Disconnect the vacuum line from the larger port at the LH Yes
IWE . GO to N17 .
z Apply 508 mm (20 in) Hg of vacuum to the LH IWE port and
observe vacuum reading. No
z Does the vacuum maintain or drop less than 25 mm (1 INSTALL a new LH IWE . REFER
in) Hg per minute? to Integrated Wheel End (IWE) in
normal operation.
N17 CHECK THE LH IWE OPERATION
the LH IWE . CONNECT the vacuum line to the
z Observe the LH halfshaft while rotating the LH front tire. LH IWE . GO to N18 .

engage the LH IWE . INSTALL a new LH IWE . REFER
z Did the LH IWE disengage between 152 and 203 mm (6 to Integrated Wheel End (IWE) in
to 8 in) Hg and engage when the vacuum is released? this section. CLEAR the DTCs.
operation.
N18 CHECK THE IWE SOLENOID CONTROL CIRCUIT FOR A
SHORT TO VOLTAGE
z Ignition OFF. Yes
z Disconnect: IWE Solenoid . REPAIR circuit CCF05 (BN/BU).
z Disconnect: TCCM C2371A . CLEAR the DTCs. TEST the
z Ignition ON. system for normal operation.
z Measure the voltage between IWE solenoid C1291-2,
circuit CCF05 (BN/BU), harness side and ground. No
GO to N19 .

N19 CHECK THE IWE SOLENOID CONTROL CIRCUIT FOR A
SHORT TO GROUND
z Ignition OFF. Yes
z Disconnect: TCCM C2371A .
z Measure the resistance between solenoid C1291-2, circuit No
CCF05 (BN/BU), harness side and ground. REPAIR circuit CCF05 (BN/BU).

N20 CHECK THE IWE SOLENOID RESISTANCE
NOTE: If the temperatures (either ambient or in the engine Yes

compartment) are exceptionally high, a higher than normal GO to N21 .
resistance reading could result. A lower temperature could
result in a lower resistance reading. No
INSTALL a new IWE solenoid.
z Measure the resistance between IWE solenoid C1291 pins CLEAR the DTCs. TEST the
1 and 2, component side. system for normal operation.

N21 CHECK FOR VOLTAGE TO THE IWE SOLENOID
z Measure the voltage between IWE solenoid C1291-1, Yes
circuit SBB29 (GY/RD), harness side and ground. GO to N22 .
No
CHECK BJB fuse 29 (10A). If OK,
REPAIR circuit SBB29 (GY/RD). If
short. CLEAR the DTCs. TEST

N22 CHECK THE IWE SOLENOID CONTROL CIRCUIT FOR
AN OPEN
z Ignition OFF. Yes
z Measure the resistance between IWE solenoid C1291-2, No
circuit CCF05 (BN/BU), harness side and TCCM C2371A-6, REPAIR circuit CCF05 (BN/BU).
circuit CCF05 (BN/BU), harness side. CLEAR the DTCs. TEST the

N23 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes

pin issues.
Pinpoint Test O: The Vehicle Does Not Shift Between 4A (4X4 AUTO) and 4H (4X4) Modes Correctly
Normal Operation
(disengaging the front hubs from the front axle). In AUTO, 4H and 4L modes, the TCCM does not supply the
ground path to the IWE solenoid, vacuum is not applied to the IWEs and an internal spring keeps the hubs
engaged. Systematically check the necessary inputs and outputs at the TCCM , internal components of the
transfer case, MSS , IWE components and drive axles.

z MSS
z IWEs
z IWE solenoid
z Transfer case
z Vacuum leaks
z TCCM
PINPOINT TEST O: THE VEHICLE DOES NOT SHIFT BETWEEN 4A (4X4 AUTO) AND 4H (4X4) MODES
CORRECTLY

O1 CHECK FOR TCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: Self-Test REFER to the TCCM DTC
— TCCM . Chart in this section.
z Are DTCs retrieved?
No
GO to O2 .
O2 CHECK THE 4H INDICATOR
z Select 4H mode and observe the IPC . Yes
z Does the IPC indicator lamp indicate 4H (4X4) mode? GO to O8 .
No
GO to O3 .
O3 CHECK THE TCCM IGNITION POSITION (KEY_POS_4X4) PID
DataLogger — TCCM . GO to O4 .
z Monitor the KEY_POS_4X4 PID while cycling through each
position: No
z Does the ignition position PID match the ignition switch REFER to Section 211-05 to
positions? diagnose the ignition switch
concern.
O4 CHECK THE TCCM 4WD SWITCH STATUS (4X4_SW) PID
z Monitor 4X4_SW PID while cycling the MSS through each Yes
position. GO to O7 .
MSS Position PID Status No

GO to O5 .
2H 2-W Drive
4A A4WD
4H 4W Auto/Hi
4L 4W Low
z Does each PID status agree with each MSS position?

O5 CHECK THE MSS RESISTANCE VALUES
z Ignition OFF. Yes
z Disconnect: MSS . GO to O6 .
z Measure the resistance between C284 pin 2 and pin 3,
component side. Refer to the following chart: No
INSTALL a new MSS .
MSS Position Resistance (±1%) REFER to Mode Select
Switch (MSS) in this section.
2H 619 ohms CLEAR the DTCs. TEST the
4A 270 ohms
4H 130 ohms
4L 62 ohms
z Are the resistance values within specification?

O6 CHECK THE MSS CONTROL AND RETURN CIRCUITS FOR
AN OPEN
z Disconnect: TCCM C2371A . Yes
z Measure the resistance between MSS C284-2, circuit CCF13 GO to O19 .
(WH/BU), harness side and TCCM C2371A-16, circuit CCF13
(WH/BU), harness side. No
(s). CLEAR the DTCs. TEST

operation.
z Measure the resistance between MSS C284-3, circuit RCF13

(WH/BN), harness side and TCCM C2371A-14, circuit RCF13
(WH/BN), harness side.

O7 CHECK THE TCCM 4WD PWM CLUTCH STATUS
(4WD_CLTCH_OUT) PID IN 4H
z Switch the MSS to 4H mode. Yes
z Monitor the 4WD_CLTCH_OUT PID. GO to O19 .
z Does the PID read 2 to 10% at closed throttle?
No
DIAGNOSE the PCM. REFER
to PC/ED manual and the HS-
CAN . REFER to Section 418-
00 . CLEAR the DTCs. TEST
operation.
O8 CHECK FOR WIND-UP IN 4H MODE
z Drive the vehicle on a dry, hard surface in turns while applying GO to O13 .
the throttle.
z Is wind-up present in turns? No
GO to O9 .
(4WD_CLTCH_OUT) PID AT WOT
z Monitor the 4WD_CLTCH_OUT PID at WOT , KOEO .
z Does the 4WD_CLTCH_OUT PID read 98% at WOT ? No
GO to O10 .
O10 CHECK THE TCCM ABSOLUTE THROTTLE POSITION
(TP_TCCM) PID
z NOTE: The TP_TCCM PID is APP as communicated by the Yes
PCM via HS-CAN . GO to O11 .

z Slowly move the accelerator pedal from closed throttle to WOT
and observe the TP_TCCM PID. No
z Does the TP_TCCM PID vary between 0% at closed throttle DIAGNOSE the PCM. REFER
and 100% at WOT ? to PC/ED manual and the HS-
CAN . REFER to Section 418-
00 . CLEAR the DTCs. TEST
operation.
O11 CHECK FOR TRANSFER CASE CLUTCH ENGAGEMENT
WITH THE TCCM 4WD PWM CLUTCH STATUS COMMAND
(4WD_CLTCH_OUT) ACTIVE COMMAND AND 4WD CLUTCH
STATUS (4WD_CLTCH_OUT) PIDs
z Using the 4WD_CLTCH_OUT active command, engage the Yes
transfer case clutch to 100% while monitoring the END the active command.
4WD_CLTCH_OUT PID. CHECK the transfer case.
z Does the 4WD_CLTCH_OUT PID read 100%? REFER to Section 308-07B .
No
END the active command. GO
to O12 .
O12 CHECK THE IPC INDICATOR IN AUTO MODE
z Select 4A mode and observe the IPC . Yes
z Does the message center indicate 4A (4X4 AUTO) mode? GO to O13 .
No
GO to Pinpoint Test V .
O13 CHECK FOR WIND-UP IN AUTO MODE
z Drive the vehicle on a dry, hard surface in turns while applying Yes
the throttle. GO to O14 .
z Is wind-up present in turns?
No
correctly.
(4WD_CLTCH_OUT) PID AT CLOSED THROTTLE
z Monitor the 4WD_CLTCH_OUT PID at closed throttle, KOEO . Yes
z Does the 4WD_CLTCH_OUT PID indicate 2 to 10% clutch GO to O15 .
application at closed throttle?
No
GO to O17 .
O15 CHECK VOLTAGE ON THE CLUTCH CONTROL CIRCUIT
USING THE TCCM 4WD PWM CLUTCH STATUS
(4WD_CLTCH_OUT) ACTIVE COMMAND
z Using the 4WD_CLTCH_OUT active command, command the Yes
transfer case clutch to 4%. END the active command.
z Measure the voltage by carefully back-probing transfer case CHECK the transfer case.
C350-16, circuit CCF03 (GY/BN), component side and ground. REFER to Section 308-07B .
No
GO to O16 .
z Is the voltage approximately 0.2 to 0.4 volt?

O16 CHECK THE CLUTCH CONTROL CIRCUIT FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: Transfer Case . GO to O17 .
z Disconnect: TCCM C2371B .
z Measure the resistance between transfer case C350-16, circuit No
CCF03 (GY/BN), harness side and TCCM C2371B-1, circuit REPAIR circuit CCF03
CCF03 (GY/BN), harness side. (GY/BN). CLEAR the DTCs.
operation.

O17 CHECK THE ABS MODULE WHEEL SPEED SENSOR PIDs
DataLogger — ABS Module . GO to O18 .
z While driving the vehicle at 30 km/h (18 mph), monitor the
following wheel speed sensor PIDs: No
Left Front Wheel Speed Sensor (LF_WSPD) CHECK the ABS for faults.
Left Rear Wheel Speed Sensor (LR_WSPD) REFER to Section 206-09 .
z Compare the speedometer reading to the wheel speed sensor
PIDs.
z Do the wheel speed sensor PIDs and speedometer speeds
match within 1.5 km/h (1 mph)?
O18 CHECK THE TCCM ABSOLUTE THROTTLE POSITION
(TP_TCCM) PID
z NOTE: The TP_TCCM PID is APP as communicated by the
PCM via HS-CAN . No
z Slowly move the accelerator pedal from closed throttle to and DIAGNOSE the PCM. REFER
observe the TP_TCCM PID. to PC/ED manual and the HS-
z Does the TP_TCCM PID vary between 0% at closed throttle CAN . REFER to Section 418-
and 100% at WOT ? 00 . CLEAR the DTCs. TEST
operation.
O19 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
corrosion (install new connector or terminals - clean Control Module (TCCM) in this
module pins) section. TEST the system for
damaged or bent pins - install new terminals/pins normal operation.
z Connect all TCCM connectors. Make sure they are seated No
correctly. The system is operating
z Operate the system and verify the concern is still present. correctly at this time. Concern
z Is the concern still present? may have been caused by a
Pinpoint Test P: The Vehicle Does Not Shift Between 4H (4X4) and 4L (4X4 Low) Modes Correctly
Normal Operation
The high-low shift occurs when the reduction shift fork moves the high-low collar to lock the planetary gear
set to the output shaft. The torque transmitted through the sun gear from the input shaft turns the front
planetary gear set assembly. The front planetary gear set assembly, now engaged, provides transfer case
speed reduction. Certain criteria, such as vehicle speed and TR selection must be met before this shift can
occur. Systematically check the necessary inputs and outputs of the TCCM , components of the transfer
case, IWE components and halfshafts.

z P1839:00 — Transfer Case Fault sets when TCCM C2371B pin 4 or 5 detects an open circuit.
Shift Motor Open Circuit: No Shift motor moves are prevented when this DTC is set.
z P1840:00 — Transfer Case Fault sets when TCCM C2371B pin 4 or 5 detects a short to voltage.
Shift Motor Short Circuit To Shift motor moves are prevented when this DTC is set.
Information
z P1841:00 — Transfer Case Fault sets when TCCM C2371B pin 4 or 5 detects a short to ground.
Ground: No Sub Type
Information
z P1849:00 — Transfer Case Fault sets when TCCM C2371A pin 1 detects a short to ground. Shift
Contact Plate 'A' Short motor moves are prevented when this DTC is set. The TCCM will not
Circuit To Ground: No Sub complete mode change if a change in shift motor position is required.
Type Information
z P184B:00 — Transfer Case Fault sets when target shift motor position is not reached after the
Unable to Transition maximum number of allowed blocked shift retries for 4H to 4L.
Between 4H and 4L: No Requested shift motor position is not reached.
Contact Plate 'B' Short motor moves are prevented when this DTC is set. The TCCM will not
Circuit to Ground: No Sub complete mode change if a change in shift motor position is required.
Type Information
Contact Plate 'C' Short motor moves are prevented when this DTC is set. The TCCM will not
Type Information
Contact Plate 'D' Short motor moves are prevented when this DTC is set. The TCCM will not
Type Information
z P1867:00 — Transfer Case Fault sets when an invalid shift motor position is detected during
Contact Plate General selection of a new 4WD mode or during a motor movement. If the shift
Circuit Failure: No Sub Type motor is not moving, shift motor movement will be prevented. If the
Information shift motor is moving when this DTC sets, the shift motor will move to
the high-side mechanical stop.
z P1891:00 — Transfer Case Fault sets when TCCM C2371A pin 5 detects a short to ground, a
Contact Plate Ground short to voltage or open circuit. The TCCM will not complete mode
Return Open Circuit: No change if a change in shift motor position is required.

z Transfer case
z TR
z ABS wheel speed inputs
z IWEs
z TCCM
z Transmission drag torque
PINPOINT TEST P: THE VEHICLE DOES NOT SHIFT BETWEEN 4H (4X4) AND 4L (4X4 LOW) MODES
CORRECTLY
personal injury.
Result / Action to
Test Step
Take
P1 CHECK FOR TCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: Self-Test — For DTC P184B:00,
TCCM . GO to P2 .
For DTC P1839:00,
GO to P22 .
For DTC P1840:00,

GO to P23 .
For DTC P1841:00,

GO to P24 .
For DTC P1849:00,

P1853:00, P1857:00,
P1861:00, GO to P17 .
For DTC P1867:00,

GO to P7 .
For DTC P1891:00,

GO to P15 .
For all other DTCs,

REFER to the TCCM
DTC Chart in this
section.
No
GO to P2 .
P2 CHECK THE 2H TO 4H SHIFT
z Drive the vehicle and shift MSS from 2H to 4H. Yes
z Does the vehicle shift between 2H and 4H correctly? GO to P3 .
No
GO to Pinpoint Test O .
P3 CHECK THE 4H TO 4L SHIFT
z NOTE: When switching in or out of 4L, the transmission must be in Yes
NEUTRAL and the vehicle stopped or moving less than 5 km/h (3 Transmission neutral
mph). drag is excessive.
z Drive the vehicle and shift MSS from 4H to 4L. REFER to Section 307-
z Does the transfer case shift from 4H to 4L correctly and the 01 for transmission
complaint is related to a clunk noise during the shift? diagnosis.
No
GO to P4 .
P4 CHECK THE NEUTRAL INDICATOR (NEUTRAL) PID
z Enter the following diagnostic mode on the scan tool: DataLogger — Yes
TCCM . GO to P5 .
z Monitor the NEUTRAL TCCM PID while shifting the transmission
through gear ranges. No
z Does the NEUTRAL PID indicate True when the transmission is REFER to Section 307-
shifted to NEUTRAL? 01 for further diagnosis
of the TR sensor.
P5 CHECK THE TCCM AVERAGE FRONT WHEEL SPEED
(FRT_WHL_SPD) AND AVERAGE REAR WHEEL SPEED
(REAR_WHL_SPD) PIDs
z Ignition OFF. Yes
z Connect: TCCM C2371A . GO to P6 .
z Connect: MSS .
z Ignition ON. No
z Switch the MSS to 2H. REFER to Section 206-
z Enter the following diagnostic mode on the scan tool: DataLogger — 09 to diagnose the
TCCM . wheel speed concern.
z Monitor the FRT_WHL_SPD and REAR_WHL_SPD PIDs with the After the repair is
vehicle stopped and while driving. complete, CLEAR the
z Do the FRT_WHL_SPD and REAR_WHL_SPD PIDs match with the DTCs. TEST the
vehicle stopped and at all speeds? system for normal
operation.
P6 CHECK THE ABS MODULE WHEEL SPEED PIDs
ABS Module . GO to P7 .
z Monitor the wheel speed PIDs:
Left Front Wheel Speed Sensor (LF_WSPD) No
Left Rear Wheel Speed Sensor (LR_WSPD) REFER to Section 206-
Right Front Wheel Speed Sensor (RF_WSPD) 09 for further diagnosis
Right Rear Wheel Speed Sensor (RR_WSPD) of the ABS system.
z Do the wheel speed PIDs indicate 0 km/h (0 mph)?
P7 CHECK THE TCCM 4WD MODES (4WD_MODES) PID WITH THE
MSS IN 4H
z Switch the MSS to 4H. GO to P10 .
z Monitor the 4WD_MODES PID.
z Does the 4WD_MODES PID indicate 4WD High? No
GO to P8 .
P8 CHECK FOR 4H WIND-UP
z Switch the MSS to 4H. Yes
z Drive the vehicle on a dry, hard surface in turns. GO to P11 .
No
GO to P9 .
P9 CHECK FOR TRANSFER CASE ENGAGEMENT
z With the vehicle in NEUTRAL, position it on a hoist. Refer to Section Yes
100-02 . GO to P10 .
z Rotate the rear driveshaft.
z Observe the front driveshaft. No
z Did the front driveshaft rotate? GO to P14 .
P10 CHECK FOR IWE ENGAGEMENT
100-02 . GO to P12 .
z Switch the MSS to 4H.
z NOTE: The engine must be idling during the following steps to supply GO to Pinpoint Test N .
the vacuum required for the IWEs to engage and disengage.
z Rotate the LH front tire one revolution forward and one revolution
backward while observing the LH front halfshaft and U-joint.
z Rotate the RH front tire one revolution forward and one revolution
backward while observing the RH front halfshaft and U-joint.
z Did both front halfshafts rotate?
P11 CHECK THE TRANSFER CASE SHIFT TO 2H
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: DataLogger — GO to P12 .
TCCM .
z Command the Transfer Case Contact Plate Power (PLATE_PWR_OS) No
PID to energize the transfer case gearmotor encoder assembly. GO to P15 .
z Monitor the Transfer Case Contact Plate Switch A (PLATE_A), B
(PLATE_B), C (PLATE_C) and D (PLATE_D) PIDs for the contact
plate position with the MSS in the 2H position.
Contact Plate Position

MSS Position PLATE_A PLATE_B PLATE_C PLATE_D
2H/4A/4H Mode CLOSED OPEN CLOSED CLOSED
4L Mode OPEN CLOSED OPEN CLOSED
z Do the PIDs and message center indicate that vehicle shifted into
2H (4X2 displayed in message center for approximately 4
seconds)?
P12 CHECK FOR IWE DISENGAGEMENT
100-02 . GO to Pinpoint Test N .
backward while observing the LH front halfshaft and U-joint.
z Rotate the RH front tire one revolution forward and one revolution No
backward while observing the RH front halfshaft and U-joint. GO to P13 .
z Did either of the front halfshafts rotate?
P13 CHECK FOR TRANSFER CASE DISENGAGEMENT
z Rotate the rear driveshaft while observing the front driveshaft. Yes
z Does the front driveshaft rotate? The system is
functioning correctly.
CARRY OUT the
Functional Test. GO to
Pinpoint Test u .
No
GO to P14 .
P14 CHECK THE TCCM TRANSFER CASE CONTACT PLATE POSITION
PIDs
TCCM . GO to P25 .
z Command the Transfer Case Contact Plate Power (PLATE_PWR_OS)
PID to energize the transfer case gearmotor encoder assembly. No
z Monitor the Transfer Case Contact Plate Switch A (PLATE_A), B GO to P15 .
(PLATE_B), C (PLATE C) and D (PLATE_D) PIDs for the contact plate
position with the MSS in the 4H position.

2H/4A/4H Mode CLOSED OPEN CLOSED CLOSED
z Did the PIDs and message center indicate that the vehicle shifted
into 4H (4X4 HIGH)?
P15 CHECK THE TRANSFER CASE SHIFT MOTOR OPERATION
z Remove the transfer case shift motor from the transfer case, leaving Yes
the wiring connector connected. GO to P25 .
z Observe the transfer case shift motor while switching the MSS from
2H to 4H. No
z Does the transfer case shift motor rotate from the 2H position to GO to P16 .
the 4H position?
P16 CHECK TRANSFER PLATE CONTACT PLATE CIRCUITS FOR A
SHORT TO VOLTAGE
z Ignition ON. Yes
z Measure the voltage between the following circuits at C2371A, REPAIR the affected
harness side and ground: circuit(s). CLEAR the
DTCs. TEST the
Circuit C2371A Pin system for normal
operation.
CCF14 (WH) 1
No
CCF15 (BN/YE) 2
GO to P17 .
CCF16 (VT/GN) 3
CCF17 (WH/OG) 4
RCF09 (BN/WH) 5

P17 CHECK TRANSFER PLATE CONTACT PLATE CIRCUITS FOR A
SHORT TO GROUND
z Ignition OFF. Yes
z Disconnect: Transfer Case (if not previously disconnected) . GO to P18 .
z Disconnect: TCCM C2371A (if not previously disconnected) .
z Measure the resistance between the following circuits at C2371A, No
harness side and ground: REPAIR the affected
circuit(s). CLEAR the
Circuit C2371A Pin DTCs. TEST the
system for normal
CCF14 (WH) 1 operation.
CCF15 (BN/YE) 2
CCF16 (VT/GN) 3
CCF17 (WH/OG) 4
RCF09 (BN/WH) 5

P18 CHECK THE TRANSFER PLATE CONTACT PLATE CIRCUITS FOR
AN OPEN
z Ignition OFF. Yes
z Disconnect: Transfer Case . GO to P19 .
z Measure the resistance of the following circuits between TCCM No
C2371A, harness side and transfer case C350, harness side: REPAIR the affected
Circuit C2371A Pin C350 Pin DTCs. TEST the
system for normal
CCF14 (GN/OG) 1 5 operation.
CCF15 (BN/YE) 2 1
CCF16 (VT/GN) 3 9
CCF17 (WH/OG) 4 13
RCF09 (BN/WH) 5 10

P19 CHECK THE SHIFT MOTOR FOR AN INTERNAL SHORT TO
GROUND
z Measure the resistance between transfer case C350 pins 1, 5, 9, 10 Yes
and 13, component side and ground. GO to P20 .
No
INSTALL a new
transfer case shift
motor. REFER to
Transfer Case Shift
Motor in this section.
CLEAR the DTCs.

If the concern is still
present, GO to P26 .

P20 CHECK THE SHIFT MOTOR CIRCUITS FOR POWER WHILE
COMMANDING THE TCCM CW RELAY (CW_SMD_OS) AND CCW
RELAY (CCW_SMD_OS) PIDs ON
z Connect: TCCM C2371A . Yes
z Ignition ON. GO to P25 .
z Enter the following diagnostic mode on the scan tool: DataLogger —
TCCM . No
z Command the CW_SMD_OS PID ON and OFF while measuring the GO to P21 .
voltage between transfer case C350-14, circuit CCF08 (GY/OG),
harness side and ground. Then command the CCW_SMD_OS PID
ON and OFF while measuring the voltage between transfer case
C350-15, circuit CCF07 (BN/GN), harness side and ground.
z Are the voltages 10 volts or greater on the circuits when

commanding the PIDs ON?
P21 CHECK THE TCCM VOLTAGE CIRCUIT
z Ignition OFF. Yes
z Disconnect: TCCM C2371B . GO to P22 .
z Measure the voltage between TCCM C2371B-6, circuit SBB20
(GN/RD), harness side and ground. No
VERIFY BJB fuse 20
(20A) is OK. If OK,
REPAIR circuit SBB20
(GN/RD). If not OK,
REFER to the Wiring
Diagrams manual to
identify possible
causes of the circuit
short. CLEAR the
DTCs. TEST the
system for normal
operation.
P22 CHECK THE TRANSFER CASE SHIFT MOTOR CIRCUITS FOR AN

OPEN
z Ignition OFF. Yes
z Disconnect: TCCM C2371B . GO to P23 .
z Disconnect: Transfer Case .
z Measure the resistance between transfer case C350, harness side No
and TCCM C2371B, harness side. Refer to the following chart. REPAIR the affected
Transfer Case Circuit TCCM DTCs. TEST the
system for normal
C350-14 CCF08 (GY/OG) C2371B-5 operation.
C350-15 CCF07 (BN/GN) C2371B-4

P23 CHECK THE TRANSFER CASE SHIFT MOTOR CIRCUITS FOR
SHORT TO VOLTAGE
z Ignition OFF. Yes
z Disconnect: TCCM C2371B (if not previously disconnected) . REPAIR the affected
z Disconnect: Transfer Case (if not previously disconnected) . circuit(s). CLEAR the
z Measure the voltage between transfer case C350-14, circuit CCF08 DTCs. TEST the
(GY/OG), harness side and ground; and between transfer case C350- system for normal
15, circuit CCF07 (BN/GN), harness side and ground. operation.
No
GO to P24 .

P24 CHECK THE TRANSFER CASE SHIFT MOTOR CIRCUITS FOR
SHORT TO GROUND
z Ignition OFF. Yes
z Disconnect: TCCM C2371B (if not previously disconnected) . GO to P25 .
z Disconnect: Transfer Case (if not previously disconnected) .
z Measure the resistance between transfer case C350-14, circuit CCF08 No
(GY/OG), harness side and ground; and between the transfer case REPAIR the affected
C350-15, circuit CCF07 (BN/GN), harness side and ground. circuit(s). CLEAR the
DTCs. TEST the

system for normal
operation.

P25 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
z Disconnect and inspect all TCCM connectors. INSTALL a new
z Repair: TCCM . REFER to
corrosion (install new connector or terminals - clean module Transfer Case Control
pins) Module (TCCM) in this
damaged or bent pins - install new terminals/pins section. TEST the
pushed-out pins - install new pins as necessary system for normal
z Connect all TCCM connectors. Make sure they are seated correctly. operation.
z Operate the system and verify the concern is still present.
The system is
operating correctly at
this time. Concern may
have been caused by a
loose or corroded
connector. ADDRESS
the root cause of the
connector or pin
issues.
P26 SHIFT THE TRANSFER CASE TO 4H MANUALLY
z Remove the transfer case shift motor from the transfer case. Yes
z Using a wrench, rotate the shift cam to the 4H position. GO to P27 .
z Rotate the rear driveshaft and watch the front driveshaft.
z Does the transfer case shift to 4H and the front driveshaft No
rotates? REPAIR the transfer
case. REFER to
Section 308-07B .
P27 CHECK THE TORQUE REQUIRED TO SHIFT THE TRANSFER
CASE
z Rotate the shift cam by hand through 4L, 4H and 2H positions. Yes
z Measure the torque required to perform the shift. GO to P28 .
z Is the torque required to shift 45 Nm (33 lb-ft) or less?
No
REPAIR the transfer
case. REFER to
Section 308-07B .
P28 SHIFT THE TRANSFER CASE TO 2H MANUALLY
z Rotate the shift cam to the 2H position. Yes
z Rotate the rear driveshaft and watch the front driveshaft. GO to P29 .
z Does the transfer case shift to 2H and the front driveshaft does
not rotate? No
REPAIR the transfer

case. REFER to
Section 308-07B .
P29 SHIFT THE TRANSFER CASE TO 4L MANUALLY
z Rotate the shift cam by hand to the 4L position. Yes
z Rotate the rear driveshaft and watch the front driveshaft. INSTALL a new
z Does the transfer case shift to 4L and the front driveshaft transfer case shift
rotates? motor. REFER to
Transfer Case Shift
Motor in this section.
CLEAR the DTCs.
TEST the system for
normal operation.
No
REPAIR the transfer
case. REFER to
Section 308-07B .
Pinpoint Test Q: Four-Wheel Drive (4WD) Does Not Engage at Speed Correctly
Refer to Wiring Diagrams Cell 34 , Four-Wheel Drive System for schematic and connector information.
Normal Operation
When the operator selects a transfer case mode from 2H mode, the TCCM engages a clutch for
approximately 5 seconds to synchronize the front and rear driveshafts allowing a mechanical engagement of
the transfer case. The TCCM also removes the ground path from the IWE solenoid, which removes vacuum
from the IWEs , allowing them to engage the front axle shaft. Systematically check the necessary inputs and
outputs at the TCCM , internal components of the transfer case, IWE components and drive axles.
z DTC P1825:00 (4-Wheel Drive Clutch Relay Open Circuit: No Sub Type Information) — Fault sets
when TCCM C2371B pin 1 detects an open circuit. The TCCM disables transfer case synchronization
clutch operation.
z DTC P1826:00 (4-Wheel Drive Low Clutch Relay Circuit To Battery: No Sub Type Information) —
Fault sets when TCCM C2371B pin 1 detects a short to voltage. Transfer case synchronization clutch
operation, though disabled by the TCCM , is fully engaged when this DTC is present.
z DTC P1827:00 (4-Wheel Drive Low Clutch Relay Circuit To Ground) — Fault sets when TCCM
C2371B pin 1 detects a short to ground. The TCCM disables transfer case synchronization clutch
operation.

z Transfer case synchronization clutch
z Transfer case
z TCCM
PINPOINT TEST Q: 4WD DOES NOT ENGAGE AT SPEED CORRECTLY
Q1 RETRIEVE TCCM DTCs

z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: Self- For DTC P1825:00, GO to Q11 .
Test — TCCM .
z Are any DTCs retrieved? For DTC P1826:00, GO to Q13 .
For DTC P1827:00, GO to Q10 .
For all other DTCs, GO to the

TCCM DTC Chart in this section.
No
GO to Q2 .
Q2 CHECK 4X4 MODE ENGAGEMENT AT REST
z Switch the Mode Select Switch (MSS) from 4X2 mode to Yes
4X4 mode. GO to Q3 .
z Does 4X4 mode engage at rest correctly?
No
GO to Pinpoint Test N .
Q3 CHECK 4X2 MODE TO 4X4 MODE SHIFT AT SPEED
z Switch the MSS to 4X2 mode. Yes
z Drive the vehicle and carry out a 4X2 mode to 4X4 mode GO to Pinpoint Test U .
shift while driving at approximately 16 km/h (10 mph).
z Stop the vehicle, shift to 4X2 mode, drive the vehicle and No
carry out a 4X2 mode to 4X4 mode shift while driving at GO to Q4 .
approximately 64 km/h (40 mph).
z Does 4X4 mode engage correctly at 16 km/h (10 mph)
and at 64 km/h (40 mph)?
Q4 CHECK THE TCCM AVERAGE FRONT WHEEL SPEED
(REAR_WHL_SPD)
DataLogger — TCCM . GO to Q5 .
z Monitor the FRT_WHL_SPD and REAR_WHL_SPD PIDs
while driving in a straight line. No
z Do the FRT_WHL_SPD and REAR_WHL_SPD PIDs REFER to Section 206-09 to
match? diagnose the wheel speed sensor
concern.
Q5 CHECK THE TRANSFER CASE CLUTCH LOCKUP
USING TCCM 4WD PWM CLUTCH STATUS (4WD
CLTCH_OUT) PID ACTIVE COMMAND
to Section 100-02 . GO to Q6 .
DataLogger — TCCM . No
z Switch the MSS to AUTO mode. GO to Q9 .
z Using the 4WD CLTCH_OUT active command, command
the PID to 98%.
z Rotate the rear driveshaft while observing the front
driveshaft.
z Does the front driveshaft rotate when the rear
driveshaft is rotated?
Q6 CHECK THE TRANSFER CASE CLUTCH RELEASE

USING TCCM 4WD PWM CLUTCH STATUS (4WD
CLTCH_OUT) PID ACTIVE COMMAND

z With the vehicle still in NEUTRAL and on a hoist, using Yes
the 4WD_CLTCH_OUT active command, command the GO to Q15 .
transfer case clutch to 0%.
z Rotate the rear driveshaft while observing the front No
driveshaft. End the active command. GO to
z Does the front driveshaft rotate when the rear Q7 .
driveshaft is rotated?
Q7 CHECK THE TRANSFER CASE ENGAGEMENT (ON A
HOIST)
z Start the engine, switch the MSS to 4X2 mode. Yes
z Place the transmission in DRIVE and increase speed to GO to Q8 .
between 16 km/h (10 mph) and 24 km/h (15 mph).
z While observing the front driveshaft, switch the MSS to No
4X4 mode. GO to Q15 .
z Did the front driveshaft start to spin?
Q8 CHECK THE TRANSFER CASE DISENGAGEMENT
z Switch the MSS to 4X2 mode while observing the front Yes
driveshaft. GO to Q15 .
z Does the front driveshaft rotate?
No
GO to Pinpoint Test N .
Q9 CHECK CLUTCH CONTROL CIRCUIT FOR VOLTAGE
z Using the 4WD_CLTCH_OUT active command, Yes
command the transfer case clutch to 98%. END the active command. INSTALL
z Measure the voltage by carefully back-probing transfer a new transfer case synchronization
case C350-16, circuit CCF03 (GY/BN), component side clutch. REFER to Section 308-07B .
and the transfer case housing. CLEAR the DTCs. TEST the
No
GO to Q10 .

Q10 CHECK THE TRANSFER CASE-TO-CHASSIS GROUND
z Using the 4WD_CLTCH_OUT active command, Yes
command the transfer case clutch to 98%. END the active command. REPAIR
z Measure the voltage by carefully back-probing transfer the transfer case ground connection
case C350-16, circuit CCF03 (GY/BN), component side between the transfer case and the
and chassis ground. chassis. CLEAR the DTCs. TEST
No
GO to Q11 .

Q11 CHECK CLUTCH CONTROL CIRCUIT FOR A SHORT
TO GROUND
z Ignition OFF. Yes
z Disconnect: Transfer Case . GO to Q12 .
z Disconnect: TCCM C2371B .
z Measure the resistance between transfer case C350-16, No
circuit CCF03 (GY/BN), harness side and ground. REPAIR circuit CCF03 (GY/BN).

Q12 CHECK CLUTCH CONTROL CIRCUIT FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: Transfer Case (if not previously GO to Q13 .
disconnected) .
z Disconnect: TCCM C2371B (if not previously No
disconnected) . REPAIR circuit CCF03 (GY/BN).
z Measure the resistance between transfer case C350-16, CLEAR the DTCs. TEST the
circuit CCF03 (GY/BN), harness side and TCCM C2371B- system for normal operation.
1, circuit CCF03 (GY/BN), harness side.
Q13 CHECK CLUTCH CONTROL CIRCUIT FOR VOLTAGE

(4WD_CLTCH_OUT) PID ACTIVE COMMAND

z Connect: Transfer Case . Yes
z Connect: TCCM C2371B . END the active command. GO to
z Ignition ON. Q14 .
DataLogger — TCCM . No
z Using the 4WD_CLTCH_OUT active command, END the active command. INSTALL
command the transfer case clutch to greater than 10%. a new transfer case synchronization
z Measure the voltage by carefully back-probing transfer clutch. REFER to Section 308-07B .
case C350-16, circuit CCF03 (GY/BN), component side CLEAR the DTCs. TEST the
and ground. system for normal operation.

Q14 CHECK CLUTCH CONTROL CIRCUIT FOR A SHORT
TO VOLTAGE USING THE TCCM 4WD PWM CLUTCH
STATUS (4WD_CLTCH_OUT) ACTIVE COMMAND
DataLogger — TCCM . REPAIR circuit CCF03 (GY/BN).
z Using the 4WD_CLTCH_OUT active command, CLEAR the DTCs. TEST the
command the transfer case clutch to 0%. system for normal operation.
z Measure the voltage by carefully back-probing transfer
case C350-16, circuit CCF03 (GY/BN), component side No
and ground. GO to Q15 .

Q15 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
z Repair: Transfer Case Control Module
corrosion (install new connector or terminals - (TCCM) in this section. TEST the
clean module pins) system for normal operation.
z Connect all TCCM connectors. Make sure they are seated The system is operating correctly at
correctly. this time. Concern may have been

z Operate the system and verify the concern is still present. caused by a loose or corroded
z Is the concern still present? connector. ADDRESS the root
cause of connector or pin issue.
Pinpoint Test R: The Four-Wheel Drive (4WD) System Jumps Out of Gear
Section 308-07A .
Normal Operation
When the 4WD system engages the user selected mode, that mode should be maintained. If the 4WD
system does not stay in the selected mode, systematically check the 4WD system components.

z IWE vent line(s)
z MSS
z Transfer case
PINPOINT TEST R: THE 4WD SYSTEM JUMPS OUT OF GEAR

R1 CHECK FOR OBSTRUCTED IWE VENT
LINES
z With the vehicle in NEUTRAL, position Yes
it on a hoist. Refer to Section 100-02 . INSTALL new IWE vent lines as necessary. TEST the
z NOTE: The IWE vent port is the smaller system for normal operation.
of the 2 vacuum ports.
z Disconnect the LH IWE line from the No
vent port. GO to R2 .
z Attach a hand vacuum pump to the
IWE vent line.
z Attempt to draw and hold a vacuum.
z Connect the LH IWE line.
z Disconnect the RH IWE line from the
vent port.
z Attempt to draw and hold a vacuum.
z Can a vacuum be held on either IWE
vent line?
R2 CHECK THE TCCM 4WD SWITCH
STATUS (4X4_SW) PID
z Ignition ON. Yes
z Enter the following diagnostic mode on GO to R3 .
the scan tool: DataLogger — TCCM .
z Drive the vehicle. No
z Monitor the 4X4_SW PID while driving GO to Pinpoint Test N .
the vehicle in each MSS position.
MSS Position PID Status
2H 2-W Drive
4A A4WD
4H 4W Auto/Hi
4L 4W Low
z Does the PID always agree with the

MSS position?
R3 CHECK THE 4WD INDICATORS
z Stop the vehicle. Yes
z Shift the transmission into the GO to Pinpoint Test N .
NEUTRAL position.
z NOTE: 2H is indicated by the absence No
of 4X4 AUTO, 4H or 4L mode GO to R4 .
indicators in the IPC message center.
z Observe the 4WD indicators in the IPC
while cycling through each MSS
position.
z Do the 4WD indicators match MSS
switch positions?
R4 CHECK FOR TCCM DTCs
z Shift the transmission into the PARK Yes
position. REFER to the TCCM DTC Chart in this section for
z Enter the following diagnostic mode on diagnosis.
the scan tool: Self-Test — TCCM .
z Are DTCs present? No
CHECK the transfer case fluid level. REFER to
Section 308-07B . If the fluid level is OK, CHECK for
internal transfer case faults. REFER to Section 308-
07B . TEST the system for normal operation.
Pinpoint Test S: Vehicle Pulsates or Shudders in a Straight Line (Straightline Driveline Wind-up)
Normal Operation
In order for the 4WD system to function correctly, tires and wheels must be the same size, be in good
condition and the front and rear axle ratios must match.

z Unmatched tire sizes
z Unequal amounts of tire wear
z Unequal tire inflation pressures
z Unmatched front and rear axle ratios
PINPOINT TEST S: VEHICLE PULSATES OR SHUDDERS IN A STRAIGHT LINE (STRAIGHTLINE

DRIVELINE WIND-UP)
NOTE: 4X4 is not intended for driving on hard/dry surfaces; using 4X4 mode while driving on these surfaces
may produce noises like intermittent clunking, but will not damage driveline components.

S1 VERIFY THE CONCERN
z Drive the vehicle and shift from 2H mode to 4H Yes
mode. There should be minimal wind-up in 4H GO to S2 .
mode during straightline maneuvers (wind-up in
turns is normal; 4H/4L is not intended for driving No
on hard/dry surfaces). RETURN the vehicle to the customer.
z Is excessive wind-up present? ADVISE about correct 4WD system operation
and normal vehicle behavior.
S2 CHECK FOR MATCHING WHEEL AND TIRE
SIZES
z Check the wheel and tire sizes. Yes
z Do the 4 wheels and tire sizes match? GO to S3 .
No
ADVISE the customer that 4WD systems
require 4 matched, correctly inflated, correctly
maintained tires to operate correctly.
S3 CHECK TIRE WEAR
z Check each of the 4 tires for wear. Yes
z Are the 4 tires worn evenly? GO to S4 .
No
rotated tires to operate correctly.
S4 CHECK TIRE INFLATION PRESSURE
z Check the inflation pressure in each tire. Refer Yes
to the Safety Certification Label on driver door GO to S5 .
or door pillar.
z Are the tire inflation pressures correct? No
ADJUST the tire pressure as necessary.
TEST the vehicle for normal operation.
S5 CHECK THE FRONT AND REAR AXLE RATIOS
z Check that front and rear axle ratios match. Yes
Refer to Section 205-00 . RETURN the vehicle to the customer and
z Do the front and rear axle ratios match? ADVISE about correct 4WD system usage
and normal vehicle behavior.
No
CHECK the VC label. INSTALL the correct
axle(s). REFER to Section 205-02A or
Section 205-02B or Section 205-03 . TEST
Pinpoint Test T: The Front Axle Makes Noise in 2H Mode Only and Generally Under Heavy Throttle
Section 308-07A .
Normal Operation
In 2H mode, the TCCM provides a ground path to the IWE solenoid to supply vacuum to each IWE
(disengaging the front hubs from the front axle). During certain conditions such as WOT maneuvers,
manifold vacuum is lower than desired. To maintain uninterrupted IWE function in 2H, stored engine vacuum
is sourced from the vacuum reservoir. A one-way check valve is implemented between the vacuum reservoir
and the IWE solenoid to prevent the stored vacuum from escaping into the manifold during low engine
vacuum conditions. For noise-free IWE operation under all conditions, the check valve must be operating
correctly.

z Vacuum leaks
z Vacuum check valve
z Vacuum reservoir
z IWE solenoid
z IWE
PINPOINT TEST T: THE FRONT AXLE MAKES NOISE IN 2H MODE ONLY AND GENERALLY UNDER
HEAVY THROTTLE

T1 CHECK FOR GRINDING NOISES AT HIGH SPEEDS
Yes
GO to T2 .
part of this test, drive the vehicle on a hard surface in
an area without traffic to prevent a crash. Failure to No
follow these instructions may result in personal injury. IDENTIFY the customer concern
and GO to the Symptom Charts
z With the vehicle warm and the MSS in 2H mode, drive the in this section.
vehicle at sustained WOT for 5 seconds.
WOT ?
T2 CHECK THE IWE SOLENOID OUTPUT VACUUM IN 2H
z NOTE: The engine must be idling during the following steps Yes
to supply vacuum to the IWE solenoid. GO to T7 .
z Start the engine.
z Disconnect the output vacuum line at the IWE solenoid No
while having the vacuum supply attached to the solenoid. GO to T3 .
z With the engine running and the in 2H mode, measure the
vacuum at the output port of the solenoid.
z Is the vacuum greater than 254 mm (10 in) Hg?
T3 CHECK THE IWE SOLENOID INPUT VACUUM
z With the engine still running, measure the supply line INSTALL a new IWE solenoid.
vacuum to the IWE solenoid. TEST the system for normal
z Is the vacuum greater than 254 mm (10 in) Hg? operation.
No
GO to T4 .
T4 CHECK SOURCE VACUUM TO THE VACUUM RESERVOIR

z Disconnect the source vacuum line from the vacuum Yes
reservoir. GO to T5 .
z With the engine still running, measure the source vacuum
being supplied to the vacuum reservoir. No
z Is the vacuum greater than 254 mm (10 in) Hg? REPAIR or INSTALL a new
source vacuum line. TEST the
T5 CHECK THE VACUUM RESERVOIR
z Ignition OFF. Yes
z Disconnect the vacuum line from the vacuum reservoir. GO to T6 .
z Connect a hand vacuum pump to the source vacuum port
on the vacuum reservoir and apply 508 mm (20 in) Hg of No
vacuum. INSTALL a new vacuum
z Does the vacuum maintain or drop less than 25 mm (1 reservoir. TEST the system for
in) Hg per minute? normal operation.
T6 CHECK THE ONE-WAY VACUUM CHECK VALVE
z NOTE: The check valve is between the IWE solenoid and Yes
the vacuum reservoir. Concern not present at this time.
z Connect the vacuum lines to the IWE solenoid. CARRY OUT the Four-Wheel
z Connect a hand vacuum pump to the IWE solenoid vacuum Drive (4WD) System Functional
line at the vacuum reservoir and apply 508 mm (20 in) Hg of Test. GO to Pinpoint Test u .
vacuum.
z Does the vacuum maintain or drop less than 25 mm (1 No
in) Hg per minute? REPAIR or INSTALL new
vacuum lines or INSTALL a new
one-way check valve. TEST the
T7 CHECK THE IWE VACUUM SYSTEM
z Ignition OFF. Yes
z Disconnect both vacuum lines from the IWE solenoid. CONNECT the vacuum lines to
z Using a hand vacuum pump, apply 508 mm (20 in) Hg of the solenoid. GO to T11 .
vacuum to the IWE system through the apply vacuum
circuit. No
z Observe the vacuum reading. GO to T8 .
in) Hg per minute?
T8 CHECK THE RH IWE LEAK RATE
z With the vehicle in NEUTRAL, position it on a hoist. Refer to Yes
Section 100-02 . GO to T9 .
z Disconnect the vacuum line from the larger port on the RH
IWE . No
z Apply 508 mm (20 in) Hg of vacuum to the RH port and INSTALL a new RH IWE .
observe vacuum reading. REFER to Integrated Wheel End
z Does the vacuum maintain or drop less than 25 mm (1 (IWE) in this section. TEST the
in) Hg per minute? system for normal operation.
T9 CHECK THE LH IWE LEAK RATE
IWE . GO to T10 .
z Apply 508 mm (20 in) Hg of vacuum to the LH port and

normal operation.
T10 CHECK THE IWE VACUUM SUPPLY TUBE
z Disconnect both vacuum lines from the IWE solenoid. Yes
z Plug both LH and RH IWE vacuum lines. Apply 508 mm (20 GO to T11 .
in) Hg of vacuum to the IWE apply vacuum circuit and
observe the vacuum reading. No
z Does the vacuum maintain or drop less than 25 mm (1 INSTALL new vacuum lines as
in) Hg per minute? necessary. TEST the system for
normal operation.
T11 CHECK THE IWE VACUUM SUPPLY AT EACH IWE IN 2H
z Connect a hand-held vacuum gauge to the LH vacuum Yes
supply tube. GO to T12 .
z NOTE: The engine must be idling during the following steps
to supply the vacuum required for the IWE to engage and No
disengage. INSTALL new vacuum lines as
z Start the engine. necessary. TEST the system for
z Switch the to 2H mode while observing the vacuum gauge. normal operation.
z Repeat these steps for the RH IWE .
z Are the vacuum readings greater than 254 mm (10 in)
Hg?
T12 CHECK THE LH IWE VACUUM LINE FOR AN
OBSTRUCTION
z Ignition OFF. Yes
z Disconnect both vacuum lines from the IWE solenoid. INSTALL a new vacuum line.
z With the vehicle in NEUTRAL, position it on a hoist. Refer to TEST the system for normal
Section 100-02 . operation.
z Disconnect the vacuum line at the LH IWE .
z Connect a hand vacuum pump to the LH IWE vacuum line No
and attempt to draw a vacuum on the line. CONNECT the vacuum line to the
z Did the hand vacuum pump draw a vacuum on the LH LH IWE . GO to T13 .
IWE vacuum line?
T13 CHECK THE RH IWE VACUUM LINE FOR AN
OBSTRUCTION
z Disconnect the larger vacuum line at the RH IWE . Yes
z Connect a hand vacuum pump to the RH IWE vacuum line INSTALL a new vacuum line.
and attempt to draw a vacuum on the line. TEST the system for normal
z Did the hand vacuum pump draw a vacuum on the RH operation.
IWE vacuum line?
No
CONNECT the vacuum line to the
RH IWE . GO to T14 .
T14 CHECK THE LH IWE OPERATION
z Ignition OFF. Yes
z Connect a hand vacuum pump with gauge to the larger port GO to T15 .
of the LH IWE .
z Observe the LH halfshaft while rotating the LH front tire. No
Apply between 152 and 203 mm (6 to 8 in) Hg of vacuum INSTALL a new LH IWE . REFER
and release the vacuum to manually disengage and engage to Integrated Wheel End (IWE) in
the LH IWE . this section. TEST the system for
z Did the LH IWE disengage between 152 and 203 mm (6 normal operation.
to 8 in) Hg and engage when the vacuum is released?
T15 CHECK THE RH IWE OPERATION
z Connect a hand vacuum pump with gauge to the larger port Yes
of the RH IWE . GO to Pinpoint Test U .
z Observe the RH halfshaft while rotating the RH front tire.
Apply between 152 and 203 mm (6 to 8 in) Hg of vacuum No
and release the vacuum to manually disengage and engage INSTALL a new RH IWE .
the RH IWE . REFER to Integrated Wheel End
z Did the RH IWE disengage between 152 and 203 mm (6 (IWE) in this section. TEST the
to 8 in) Hg and engage when the vacuum is released? system for normal operation.
Pinpoint Test U: Four-Wheel Drive (4WD) System Functional Test
Section 308-07A .
Normal Operation
When operating in 4WD modes, the transfer case clutch is energized and both IWEs are locked. When in 4L
mode, the transfer case low range gear set provides an additional 2.64 gear reduction. When operating in
2H mode, the transfer case clutch is de-energized and both IWEs are unlocked.

z Transfer case and related components
z IWEs and related components
z Wheel/tire assemblies
PINPOINT TEST U: FOUR-WHEEL DRIVE (4WD) SYSTEM FUNCTIONAL TEST
NOTE: 4X4 High and 4X4 Low are not intended for driving on hard/dry surfaces; using these modes while
driving on these surfaces may produce noises like intermittent clunking, but will not damage driveline
components.

U1 CHECK 2H MODE OPERATION
z Shift the transmission into the NEUTRAL Yes
position. GO to U2 .
z Switch the MSS to 2H mode.
z Are there any 4WD mode indicators No
present in the IPC message center? GO to U4 .
U2 CHECK FOR TCCM DTCs
z Shift the transmission into the PARK position. Yes
z Ignition ON. REFER to the TCCM DTC Chart in this section
z Enter the following diagnostic mode on the for diagnosis.
scan tool: Self-Test — TCCM .
z Are DTCs retrieved? No
GO to U3 .
U3 CHECK FOR WIND-UP IN 2H MODE
z Drive the vehicle on a dry, hard surface while Yes
executing turns. GO to Pinpoint Test P .

No
U4 CHECK AUTO MODE OPERATION
z Switch the MSS to 4A mode. Yes
z Is the 4X4 auto (4A) mode indicator on in GO to U7 .
the IPC message center?
No
GO to U5 .
z Ignition ON. Yes
z Enter the following diagnostic mode on the REFER to the TCCM DTC Chart in this section
scan tool: Self-Test — TCCM . for diagnosis.
z Are DTCs present?
No
GO to U6 .
U6 CHECK FOR WIND-UP IN 4A MODE
z Drive the vehicle on a dry, hard surface, Yes
executing turns while applying the throttle. GO to U7 .
No
GO to U8 .
U7 CHECK THE TCCM 4WD PWM CLUTCH
STATUS (4WD_CLTCH_OUT) PID
scan tool: DataLogger — TCCM . GO to U8 .
z Monitor the 4WD_CLTCH_OUT PID.
z Does the PID indicate 2 to 10% clutch No
application at closed throttle? GO to U9 .
U8 CHECK FOR WIND-UP IN 4A MODE WITH
100% CLUTCH USING THE TCCM 4WD PWM
CLUTCH STATUS (4WD_CLTCH_OUT) ACTIVE
COMMAND
z Command the 4WD_CLTCH_OUT to 100%.
z Drive the vehicle on a dry, hard surface, No
executing turns. CHECK the transfer case. REFER to Section
z Is wind-up present in turns? 308-07B .
U9 CHECK THE TCCM AVERAGE FRONT
WHEEL SPEED (FRT_WHL_SPD) AND AVERAGE
REAR WHEEL SPEED (REAR_WHL_SPD) PIDs
z Monitor the FRT_WHL_SPD and
REAR_WHL_SPD PIDs. No
z Drive the vehicle 30 km/h (18 mph). VERIFY all 4 tires are the same size and brand.
z Record and compare the FRT_WHL_SPD and INSTALL new tires as necessary. If the tires
REAR_WHL_SPD PIDs. are OK, CHECK the ABS. REFER to Section
z Do the FRT_WHL_SPD and 206-09 and VERIFY that the 4 road tire sizes
REAR_WHL_SPD PID values match within match. TEST the system for normal operation.
1.5 km/h (1 mph)?
U10 CHECK THE TCCM ABSOLUTE THROTTLE

POSITION (TP_TCCM) PID
z Ignition ON.
z Monitor the TP_TCCM PID. No
z NOTE: The TP_TCCM PID is APP as CHECK the APP sensor and/or the PCM.
communicated by the PCM via HS-CAN . REFER to the Powertrain Control/Emissions
z Slowly move throttle from closed throttle to Diagnosis (PC/ED) manual.
WOT and observe the TP_TCCM PID.
z Does the TP_TCCM PID value vary between
0% at closed throttle and 100% at WOT ?
U11 CHECK 4H MODE OPERATION
z Does the 4X4 (4H) indicator illuminate in GO to U14 .
the IPC message center correctly?
No
GO to U12 .
No
GO to U13 .
executing turns. GO to Pinpoint Test Q .
No
U14 CHECK FOR STRAIGHTLINE WIND-UP IN
4H MODE
z Drive the vehicle on a dry, hard surface. Yes
z Is straightline wind-up present? GO to Pinpoint Test S .
No
GO to U15 .
U15 CHECK WIND-UP IN TURNS IN 4H MODE
z Drive the vehicle in 4H mode while turning. Yes
z Is wind-up present in turns? GO to U16 .
No
U16 CHECK 4L MODE OPERATION
z Bring the vehicle to a stop with the Yes
transmission in NEUTRAL, switch the MSS to GO to U19 .
4L mode.
z Does the 4WD LOW (4L) indicator in the No
IPC message center illuminate correctly? GO to U17 .

No
GO to U18 .
U18 CHECK FOR WIND-UP IN 4L MODE
executing turns. GO to Pinpoint Test V .
No
GO to Pinpoint Test P .
U19 CHECK FOR WIND-UP IN TURNS IN 4L
MODE
executing turns. GO to U20 .
z Is wind-up present and 4L mode
functioning? No
CHECK for DTCs. REFER to the Inspection
and Verification procedure in this section. If no
DTCs are present, GO to Pinpoint Test P .
U20 CHECK 4L MODE TO 2H MODE SHIFT
z With the vehicle at a stop and transmission in Yes
NEUTRAL, switch the MSS from 4L mode to GO to U21 .
2H mode.
z Are there any 4WD mode indicators No
present in the message center? GO to U23 .
z Release the brake pedal. REFER to the TCCM DTC Chart in this section
z Enter the following diagnostic mode on the for diagnosis.
z Are DTCs retrieved? No
GO to U22 .
executing turns. GO to Pinpoint Test P .
No
U23 CHECK FOR TRANSFER CASE
DISENGAGEMENT
z With the vehicle in NEUTRAL, position it on a Yes
hoist. Refer to Section 100-02 . REFER to Section 308-07B .
z Rotate the rear driveshaft while observing the
front driveshaft. No
z Does the front driveshaft rotate? GO to U24 .
U24 CHECK FOR LH AND RH DISENGAGEMENT
NOTE: The engine must be at idle during the Yes

following steps to supply vacuum for IWE GO to Pinpoint Test N .
engagement/disengagement.
No
z Start the engine and allow to idle. GO to U25 .

z Rotate the LF tire one revolution forward and
one revolution backward while observing the
LF halfshaft and U-joint.
z Rotate the RF tire one revolution forward and
one revolution backward while observing the
RF halfshaft and U-joint.
z Does the LH or RH front halfshaft rotate?
U25 CHECK FOR VACUUM LEAKS
z Ignition OFF. Yes
z Disconnect both vacuum lines from the IWE CHECK the IWE and related components for
solenoid. leaks. GO to Pinpoint Test N .
z Using a hand vacuum pump, apply 508 mm
(20 in) Hg of vacuum to the IWE apply No
vacuum circuit. GO to U26 .
z Observe the vacuum reading.
z Did the vacuum drop more than 25 mm (1
in) Hg per minute?
U26 CHECK 2H MODE TO 4H MODE SHIFT AT
SPEED ABOVE 32 KM/H (20 MPH)
z Drive the vehicle on the road and shift from 2H The 4WD system is functioning correctly.
mode to 4H mode while driving above 32 km/h
(20 mph). No
z Does the transfer case shift to 4H mode GO to Pinpoint Test Q .
satisfactorily?
Pinpoint Test V: The 4X4 Mode Indicators Do Not Operate Correctly/Do Not Operate
Normal Operation
The 4WD system status is transmitted to the IPC from the TCCM through the HS-CAN to the 4WD indicator.
A steady indicator displays if the vehicle is in 4X4 auto (4A), 4X4 (4H) or 4X4 low (4L). When in 2WD , the
message center will display 4X2 for approximately 4 seconds, then the message center will no longer
provide 4WD system indication until another shift mode is attained. A system fault condition will illuminate
the powertrain malfunction indicator. The powertrain malfunction indicator includes other general powertrain
system failures. For information about HS-CAN , refer to Section 418-00 .

z IPC
z 4WD system fault
z HS-CAN circuits
z TCCM
PINPOINT TEST V: THE 4X4 MODE INDICATORS DO NOT OPERATE CORRECTLY/DO NOT OPERATE

V1 CHECK FOR TCCM DTCs
z Ignition ON. Yes

z Enter the following diagnostic mode on the scan REFER to the TCCM DTC Chart in this
tool: Self-Test — TCCM . section for diagnosis.
z Are DTCs present?
No
GO to V2 .
V2 CHECK FOR IPC DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan REFER to Section 413-01 .
tool: Self-Test — IPC .
z Are DTCs present? No
GO to V3 .
V3 CHECK 4WD SYSTEM OPERATION
z Test drive the vehicle and operate the 4WD Yes
system. REFER to Section 413-01 .
z Does the 4WD system operate correctly?
No
GO to Symptom Chart - Four Wheel Drive
(4WD) in this section.
Pinpoint Test W: Vehicle Binds in a Turn/Resists Turning/Pulsates in a Straightline in 4WD Mode
Normal Operation
When the vehicle is operating in 4WD modes, all 4 wheels receive the same amount of torque and rotate at
the same speed. The amount of traction the vehicle can achieve depends on the amount of traction each tire
can establish with the road surface. In order for the 4WD system to function correctly, each tire must be in
good condition and the front and rear axle ratios must match.

z Unmatched tire sizes
z Throttle position failure
z Transfer case
z TCCM
PINPOINT TEST W: VEHICLE BINDS IN A TURN/RESISTS TURNING/PULSATES IN A STRAIGHTLINE

IN 4WD MODE
NOTE: 4X4 is not intended for driving on hard/dry surfaces; using 4X4 mode while driving on these surfaces
may produce noises like intermittent clunking, but will not damage driveline components.

W1 VERIFY THE CONCERN
z Test drive the vehicle on a straight stretch of Yes
road in 4A mode. If the problem occurs in 4A mode, GO to W2 ; If
z Drive the vehicle through turns and parking 4H mode or 4L mode, binding is a normal
lot maneuvers. condition.
z Does the vehicle bind, pulsate or

shudder? No
GO to Pinpoint Test S .
W2 CHECK THE 4H AND 4L INDICATORS
z Review the test drive notes. Yes
z Did the 4X4 (4H) or 4X4 LOW (4L) or If the powertrain malfunction indicator (wrench
powertrain malfunction indicator (wrench light) illuminated, GO to W4 .
light) illuminate in the IPC message
center? If the 4H mode or 4L mode indicators illuminated,
GO to W3 .
No
GO to W5 .
W3 VERIFY THE FAULT
z Review the test drive notes. Yes
z Was 4H mode or 4L mode selected when The system is functioning correctly.
the 4H or 4L indicators were illuminated
in the IPC message center? No
The fault may have been caused by an
intermittent, uncommanded or autolock shift.
TEST the system for normal operation. GO to
Pinpoint Test S .
W4 CHECK FOR TCCM DTCs
scan tool: Self-Test — TCCM . REFER to the TCCM DTC Chart for diagnosis.
No
GO to W5 .
W5 VERIFY THE CONCERN WITH TRANSFER
CASE CONNECTOR DISCONNECTED
z Disconnect: Transfer Case . Yes
z Test drive the vehicle on a straight stretch of INSPECT the driveline components for damage
road and in turns, and shift the transfer case or wear. REFER to Inspection and Verification in
through each mode. Record any fault this section. TEST the system for normal
conditions. operation.
z Is the concern present?
No
GO to W6 .
W6 CHECK THE TCCM 4WD PWM CLUTCH
STATUS (4WD_CLTCH_OUT) PID
z Connect: Transfer Case . Yes
z Using the scan tool, clear the DTCs. GO to W7 .
z Enter the following diagnostic mode on the
scan tool: DataLogger — TCCM . No
z Monitor the 4WD_CLTCH_OUT PID at CHECK the transfer case. REFER to Section
closed throttle, KOEO . 308-07B . TEST the system for normal operation.
z Select 4H mode.
z Does the PID indicate 2 to 10% clutch
application at closed throttle?
W7 CHECK THE ABS MODULE WHEEL SPEED
SENSOR PIDs
scan tool: DataLogger — ABS Module . GO to W8 .
z While driving the vehicle at 30 km/h (18

mph), monitor the following wheel speed No
sensor PIDs: VERIFY that the 4 road wheels are the same size
Left Front Wheel Speed Sensor and have similar tread depth. CHECK the ABS
(LF_WSPD) for faults. REFER to Section 206-09 . TEST the
Left Rear Wheel Speed Sensor system for normal operation.
(LR_WSPD)
Right Front Wheel Speed Sensor
(RF_WSPD)
Right Rear Wheel Speed Sensor
(RR_WSPD)
z Compare the speedometer reading to the
wheel speed sensor PIDs.
z Do the wheel speed sensor PIDs and
speedometer speeds match within 1.5
km/h (1 mph)?
W8 CHECK THE TCCM ABSOLUTE THROTTLE
POSITION (TP_TCCM) PID
scan tool: DataLogger — TCCM . GO to W9 .
z NOTE: The TP_TCCM PID is APP as
communicated by the PCM via HS-CAN . No
z Slowly move accelerator pedal from closed DIAGNOSE the PCM. REFER to the Powertrain
throttle to and observe the TP_TCCM PID. Control/Emissions Diagnosis (PC/ED) manual.
z Does the TP_TCCM PID value vary TEST the system for normal operation.
between 0% at closed throttle and 100%
at WOT ?
W9 CHECK THE TRANSFER CASE FRONT
DRIVESHAFT OUTPUT
z With the vehicle in NEUTRAL, position it on Yes
a hoist. Refer to Section 100-02 . GO to W10 .
z Rotate the front driveshaft by hand.
z Does the front driveshaft rotate freely No
(does it require less than 45 Nm [33 lb-ft] CHECK the transfer case. REFER to Section
to rotate)? 308-07B . TEST the system for normal operation.
W10 CHECK FOR CORRECT TCCM
OPERATION
z Ignition OFF. Yes
z Disconnect and inspect all TCCM INSTALL a new TCCM . REFER to Transfer
connectors. Case Control Module (TCCM) in this section.
z Repair: TEST the system for normal operation.
corrosion (install new connector or
terminals - clean module pins) No
damaged or bent pins - install new The system is operating correctly at this time.
terminals/pins Concern may have been caused by a loose or
pushed-out pins - install new pins as corroded connector. ADDRESS the root cause of
necessary the connector or pin issues.
z Connect all TCCM connectors. Make sure
they are seated correctly.
z Operate the system and verify the concern
is still present.
Pinpoint Test X: The Vehicle Does Not Shift Between 2H (2WD) and 4X4 Modes Correctly
Normal Operation
The MSS communicates the operator's choice to the TCCM . The TCCM then controls the transfer case
synchronization clutch, transfer case motor and IWEs as necessary. If the vehicle is not responding as
intended, systematically check the necessary inputs and outputs of the TCCM , components of the transfer
case, IWE components and halfshafts. Check all circuits for opens and shorts to power or ground.

z P1812:00 — 4-Wheel Drive Mode Select Fault sets when TCCM C2371A pin 16 senses an
Circuit Failure: No Sub Type Information open circuit. 4WD system mode cannot be changed.
z P1815:00 — 4-Wheel Drive Mode Select Fault sets when TCCM C2371A pin 16 detects a
Short To Ground: No Sub Type Information short to ground. 4WD system mode cannot be
changed.

z MSS
z Transfer case
z TCCM
PINPOINT TEST X: THE VEHICLE DOES NOT SHIFT BETWEEN 2H (2WD) AND 4X4 MODES
CORRECTLY
personal injury.

X1 CHECK FOR TCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan For DTC P1812:00, GO to X5 .
tool: Self-Test — TCCM .
z Are any DTCs present? For DTC P1815:00, GO to X7 .
For all other DTCs, REFER to the DTC

Chart in this section.
No
GO to X2 .
X2 CHECK THE TCCM IGNITION POSITION
(KEY_POS_4X4) AND IGNITION STATUS
(KEY_STATUS_4X4) PIDs
tool: DataLogger — TCCM . GO to X3 .
z Monitor the KEY_POS_4X4 and
KEY_STATUS_4X4 PIDs while cycling through No

each position. If the KEY_STATUS_4X4 PID did not
z Do the ignition PIDs match the ignition switch match, CHECK BJB fuse 54 (5A). If the
positions? fuse is OK, REPAIR circuit CBB54
(VT/OG). If the fuse is not OK, REFER to
the Wiring Diagrams manual to identify
the possible causes of the circuit short.
After the fault is repaired, CLEAR the
DTCs. TEST the system for normal
operation.
If the KEY_POS_4X4 PID did not match,

REFER to Section 211-05 to diagnose
the ignition switch. After the fault is
repaired, CLEAR the DTCs. TEST the
X3 CHECK THE TCCM MODULE SUPPLY VOLTAGE
(VBAT_4X4) PID
z Enter the following diagnostic mode on the scan GO to X4 .
tool: DataLogger — TCCM .
z Monitor the VBAT_4X4 PID. No
z Is the VBAT_4X4 PID greater than 12 volts? REFER to Section 414-00 to DIAGNOSE
the low battery voltage and/or charging
system concern. CLEAR the DTCs. TEST
X4 CHECK THE MSS POSITION MONITORING THE
TCCM 4WD SWITCH STATUS (4X4_SW) PID
tool: DataLogger — TCCM . GO to X10 .
z Monitor the 4X4_SW PID while switching to each
MSS position. No
z Does the PID match the MSS position? GO to X5 .
X5 CHECK THE MSS RESISTANCE VALUES
z Ignition OFF. Yes
z Disconnect: MSS . GO to X6 .
z Measure the resistance between MSS C284 pins 2
and 3, component side, while rotating the MSS No
through all positions. Refer to the following chart. INSTALL a new MSS . REFER to Mode
Select Switch (MSS) in this section.
MSS Position Resistance (±1%) CLEAR the DTCs. TEST the system for
normal operation.
2H 619 ohms
4A 270 ohms
4H 130 ohms
4L 62 ohms

X6 CHECK THE MSS CONTROL AND RETURN
CIRCUITS FOR SHORT TO VOLTAGE
z Ignition ON. REPAIR the affected circuit(s). CLEAR
z Measure the voltage between MSS C284-3, circuit the DTCs. TEST the system for normal
RCF13 (WH/BN), harness side and ground; and operation.
between MSS C284-2, circuit CCF13 (WH/BU),
harness side and ground. No
GO to X7 .

CIRCUITS FOR SHORT TO GROUND
z Ignition OFF. Yes
z Disconnect: TCCM C2371A . GO to X8 .
z Disconnect: MSS .
z Measure the resistance between MSS C284-3, No
circuit RCF13 (WH/BN), harness side and ground; REPAIR the affected circuit(s). CLEAR
and between MSS C284-2, circuit CCF13 (WH/BU), the DTCs. TEST the system for normal
harness side and ground. operation.

z Measure the resistance between MSS C284, and GO to X9 .
TCCM C2371A, harness side. Refer to the following
chart. No
MSS Circuit TCCM the DTCs. TEST the system for normal
operation.
C284-3 RCF13 (WH/BN) C2371A-14
C284-2 CCF13 (WH/BU) C2371A-16

z Ignition OFF. Yes
z Measure the resistance between MSS C284-3, GO to X10 .
circuit RCF13 (WH/BN), harness side and MSS
C284-2, circuit CCF13 (WH/BU), harness side. No
the DTCs.

X10 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
z Repair: Transfer Case Control Module (TCCM) in
corrosion (install new connector or terminals this section. TEST the system for normal
- clean module pins) operation.
terminals/pins No
necessary time. Concern may have been caused by
z Connect all TCCM connectors. Make sure they are a loose or corroded connector.

present.
Four Wheel Drive (4WD) Systems — Electronic Shift
Special Tool(s)
Flex Probe Kit

Test Light
SGT27000 or equivalent 250-300
mA incandescent bulb test light

The Electronic Shift-On-The-Fly (ESOF) system has 3 modes of operation: 2H (4X2), 4H (4X4 HIGH) and 4L
(4X4 LOW). Integrated Wheel Ends (IWEs) are used at each front wheel to reduce rolling resistance when
2H is selected. The Transfer Case Control Module (TCCM) sends a duty cycle command to the
synchronization coil which activates the clutch within the transfer case. Refer to Section 308-07B .
Engagement and disengagement of the front wheels is done by the IWEs . The IWEs are normally engaged
(no vacuum). Vacuum is supplied to the IWEs by actuation of the IWE solenoid when commanded by the
TCCM . When actuated, the IWE solenoid allows manifold vacuum to pass through to each IWE . The IWEs
disengage and allow the front wheel hubs to be turned freely from the front axle.
The electric shift motor is mounted externally to the transfer case. It drives a rotary cam which moves the 2
shift forks in the transfer case to change between the 2H and 4H modes and between the 4H and 4L modes.
For information on transfer case mechanical operation, refer to Section 308-07B . The TCCM directly
controls the electric shift motor and can reverse motor polarity to reverse rotary cam/shift fork direction. The
shift motor sense plate, an integral part of the shift motor assembly, informs the TCCM of the transfer case
position.
clutch is used to synchronize the speed of the front driveline with the rear driveline during 2H to 4H shifts.
When the Mode Select Switch (MSS) is switched between 2H and 4H modes, the TCCM energizes the
synchronization clutch. When the transfer case front and rear output shafts are synchronized, the spring-
loaded lockup collar mechanically engages (4H) or disengages (2H) the mainshaft hub to the drive sprocket.
Finally, the front axle IWEs are engaged (4H) or disengaged (2H) and the synchronization clutch is
deactivated.
Shifts from 2H mode to 4H mode can be made at any speed. The synchronization clutch is applied to
equalize output shaft speeds before 4H mode is engaged. The following are the inputs and outputs needed
by the TCCM to execute a change between these modes.
Feature inputs:
z Ambient air temperature from the PCM

z MSS
z Wheel speed signal from ABS module
z APP from PCM
z Transfer case shift motor contact plate position inputs A, B, C and D
Feature outputs:
z Transfer case electric shift motor outputs

z PWM signal to transfer case clutch
z 4WD message center and indicators
When shifting into or out of 4L mode, the TCCM requires the vehicle speed to be less than 5 km/h (3 mph)
and the transmission in NEUTRAL. The following are the inputs and outputs needed by the TCCM to
execute a change into or out of 4L mode.
Feature inputs:
z MSS
z Wheel speed signal from ABS module
z TR position from PCM
z Transfer case shift motor contact plate position inputs A, B, C and D
Feature outputs:
z Transfer case electric shift motor outputs

z PWM signal to transfer case clutch
z 4WD message center and indicators
Off-Road Mode
NOTE: Off-road mode is specifically calibrated for off-road driving conditions and should never be used on
pavement.
The SVT Raptor comes equipped with a special off-road function. An off-road button is located on the floor
console. A light on the button will illuminate when this feature is activated.
Off-road mode affects 4 vehicle functions:
z It allows unique transmission shifting that optimizes off-road performance. Off-road mode shifting
differs from standard on-road shifting in several ways:
Transmission upshifts are delayed and occur less frequently. This ensures the best possible
vehicle response and acceleration if the driver needs to briefly lift off the throttle to negotiate an
obstacle or corner.
Transmission downshifts occur more quickly improving vehicle response.
Sixth gear (overdrive) will not engage. This prevents engine lugging (6.2L equipped vehicles
only).
z Off-road mode provides optimized throttle response tailored for off-road performance driving.
z When off-road mode is engaged, the standard vehicle speed thresholds for the ELD are lifted and the
ELD will remain locked until the operator manually disengages it with the control knob. If the operator
disengages off-road mode and exceeds the standard ELD speed thresholds, the ELD will disengage.
z When off-road mode is engaged, the AdvanceTrac settings are altered for optimized off-road
performance.
To engage off-road mode, slow the vehicle to a speed of 5 km/h (3 mph) or less. Release the accelerator
pedal then press and release the off-road mode button. The message center will display OFF ROAD MODE
ENABLED once off-road mode has been enabled. If any of the above conditions are not met, off-road mode
will not enable and the message center will display information guiding the driver through the proper off-road
mode enabling procedures. To disable off-road mode, press and release the off-road mode button. The
message center will display EXITING OFF ROAD MODE.
The operator can engage the ELD per the following table:

2H (off-road off) a 31 km/h (19 mph) 42 km/h (25 mph) 31 km/h (19 mph) a
2H (off-road on) unlimited unlimited unlimited
4H (off-road on) unlimited unlimited unlimited
4L (off-road on) unlimited unlimited unlimited
a The 4WD system engages/re-engages at or below the speed noted.
z Halfshafts z BJB fuses:

z IWEs 20 (20A)
z Driveshaft and U-joints 29 (10A)
z Vacuum leaks 54 (5A)
z Fluid leaks 68 (25A)
z Matching tire sizes z BCM fuse 34 (10A) (vehicles with ELD only)
z Transfer case z Wiring, terminals or connectors
z MSS
z Synchronization clutch
z IWE solenoid
z Transfer case shift motor
5. NOTE: The VCM LED prove out confirms power and ground from the DLC are provided to the VCM .



418-00 .
10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Four-Wheel Drive (4WD)
System or GO to Symptom Chart - NVH .
DTC Charts
Transfer Case Control Module (TCCM) DTC Chart
code provides information about specific fault conditions such as opens or shorts to ground. have an
additional 2-character DTC status code suffix to assist in determining DTC history.

B12E0:11 Off Road Indicator: Circuit GO to Pinpoint Test J .
Short To Ground
Short To Battery
Open
B12E5:00 Off Road Mode Select GO to Pinpoint Test K .
Switch: No Sub Type
Information
B12E5:11 Off Road Mode Select GO to Pinpoint Test K .
Switch: Circuit Short To
Ground
C1979:11 IWE Solenoid Circuit GO to Pinpoint Test D .
Failure: Circuit Short To
Ground
Failure: Circuit Short To
Battery
Failure: Circuit Open
P0562:00 System Voltage Low: No Go to Pinpoint Test M in 2-Speed Torque-On-Demand, Diagnosis
Sub Type Information and Testing, Section 308-07A .
P0563:00 System Voltage High: No Go to Pinpoint Test M in 2-Speed Torque-On-Demand, Diagnosis
Sub Type Information and Testing, Section 308-07A .
P1812:00 4-Wheel Drive Mode GO to Pinpoint Test B .
Select Circuit Failure: No
P1815:00 4-Wheel Drive Mode GO to Pinpoint Test B .
Select Short To Ground:
P1825:00 4-Wheel Drive Clutch GO to Pinpoint Test G .
Relay Open Circuit: No
P1826:00 4-Wheel Drive Low Clutch GO to Pinpoint Test G .
Relay Circuit To Battery:
P1827:00 4-Wheel Drive Low Clutch GO to Pinpoint Test G .
Relay Circuit To Ground:
P1839:00 Transfer Case Shift Motor GO to Pinpoint Test B .
Open Circuit: No Sub
Type Information
Short Circuit To Battery:
Short Circuit To Ground:
P1849:00 Transfer Case Contact GO to Pinpoint Test B .
Plate 'A' Short Circuit To
Ground: No Sub Type

Information
P184A:00 Transfer Case Unable To GO to Pinpoint Test B .
Transition Between 4x2
and 4x4 Mode: No Sub
Type Information
P184B:00 Transfer Case Unable To GO to Pinpoint Test C .
Transition Between 4x4
High and 4x4 Low Range:
Plate 'B' Short Circuit To
Ground: No Sub Type
Information
Plate 'C' Short Circuit To
Ground: No Sub Type
Information
P185A:00 Differential Lock-Up Input Go to Pinpoint Test Y in Electronic Locking Differential (ELD)
Switch Circuit High: No System, Diagnosis and Testing, Section 308-07A .
P185B:00 Differential Lock-Up Go to Pinpoint Test Z in Electronic Locking Differential (ELD)
Indicator Circuit Low: No System, Diagnosis and Testing, Section 308-07A .
P185C:00 Differential Lock-Up Go to Pinpoint Test AA in Electronic Locking Differential (ELD)
Indicator Circuit High: No System, Diagnosis and Testing, Section 308-07A .
P185D:00 Differential Lock-Up Go to Pinpoint Test AB in Electronic Locking Differential (ELD)
Control Circuit System, Diagnosis and Testing, Section 308-07A .
Performance: No Sub
Type Information
Plate 'D' Short Circuit To
Ground: No Sub Type
Information
Plate General Circuit
Failure: No Sub Type
Information
P187C:00 Differential Lock-Up Go to Pinpoint Test AC in Electronic Locking Differential (ELD)
Control Circuit/Open: No System, Diagnosis and Testing, Section 308-07A .
P187D:00 Differential Lock-Up Go to Pinpoint Test AC in Electronic Locking Differential (ELD)
Control Circuit Low: No System, Diagnosis and Testing, Section 308-07A .
P187E:00 Differential Lock-Up Go to Pinpoint Test AD in Electronic Locking Differential (ELD)
Control Circuit High: No System, Diagnosis and Testing, Section 308-07A .
Plate Ground Return
Open Circuit: No Sub
Type Information
U0100:00 Lost Communication With Go to Pinpoint Test AE in Electronic Locking Differential (ELD)
ECM/PCM "A": No Sub System, Diagnosis and Testing, Section 308-07A .
Type Information
U0121:00 Lost Communication With Go to Pinpoint Test AF in Electronic Locking Differential (ELD)
Anti-Lock Brake System System, Diagnosis and Testing, Section 308-07A .
(ABS) Control Module: No
U0140:00 Lost Communication With Go to Pinpoint Test AG in Electronic Locking Differential (ELD)
Body Control Module System, Diagnosis and Testing, Section 308-07A .
(BCM): No Sub Type
Information
U0418:00 Invalid Data Received REFER to Section 206-09 to diagnose the wheel speed sensor
From Brake System concern.
Control Module: No Sub
Type Information
U2300:54 Central Configuration: This DTC can set if one or more expected configuration data
Missing Calibration identifications is missing (gearbox type, axle ratio, tire
circumference) from the BCM . CARRY OUT a self-test of the
BCM . If BCM DTCs are present, REFER to Section 419-10 . If no
BCM DTCs are present, CLEAR the DTCs. CARRY OUT a TCCM
self-test. If U2300:54 returns, INSTALL a new TCCM . REFER to
Transfer Case Control Module (TCCM) in this section.
U2300:55 Central Configuration: Not This DTC can set upon TCCM power up only until all expected
Configured configuration data parameters (gearbox type, axle ratio, tire
circumference) is received from the BCM . CARRY OUT a self-test
of the BCM . If BCM DTCs are present, REFER to Section 419-10 .
If no BCM DTCs are present, CLEAR the DTCs. CARRY OUT
TCCM self-test. If U2300:55 returns, INSTALL a new TCCM .
REFER to Transfer Case Control Module (TCCM) in this section.
U2300:56 Central Configuration: This DTC can set if one expected configuration data parameter is
Invalid / Incompatible out of range (gearbox type, axle ratio, tire circumference) from the
Configuration BCM . CARRY OUT a self-test of the BCM . If DTCs are present,
REFER to Section 419-10 . If no BCM DTCs are present, CLEAR
the DTCs. CARRY OUT a TCCM self-test. If U2300:56 returns,
INSTALL a new TCCM . REFER to Transfer Case Control Module
(TCCM) in this section.
U2300:64 Central Configuration: This DTC can set if the expected axle ratio or tire circumference is
Signal Plausibility Failure out of range from the BCM . CARRY OUT a self-test of the BCM . If
BCM DTCs are present, REFER to Section 419-10 . If no BCM
DTCs are present, CLEAR the DTCs. CARRY OUT a TCCM self-
test. If U2300:64 returns, INSTALL a new TCCM . REFER to
Transfer Case Control Module (TCCM) in this section.
U3000:04 Control Module: System CLEAR the DTC. REPEAT the self-test. If DTC U3000:04 is
Internal Failure retrieved, INSTALL a new TCCM . REFER to Transfer Case
U3000:41 Control Module: General CLEAR the DTC. REPEAT the self-test. If DTC U3000:41 is
Checksum Failure retrieved, INSTALL a new TCCM . REFER to Transfer Case
U3000:46 Control Module: CLEAR the DTC. REPEAT the self-test. If DTC U3000:46 is
Calibration / Parameter retrieved, INSTALL a new TCCM . REFER to Transfer Case
Memory Failure Control Module (TCCM) in this section.
U3000:49 Control Module: Internal CLEAR the DTC. REPEAT the self-test. If DTC U3000:49 is
Electronic Failure retrieved, INSTALL a new TCCM . REFER to Transfer Case

U300D:11 Ignition Input On/Start: GO to Pinpoint Test B .
Symptom Chart — Four-Wheel Drive (4WD) System
Symptom Chart — System

z No communication with z Scan tool z REFER to Section 418-
the TCCM z DLC 00 .
z TCCM
connectors
z The 4WD indicators do not z Wiring, terminals or z GO to Pinpoint Test A .
operate correctly connectors
z 4WD system fault
z IPC
z TCCM
z The vehicle does not shift z Wiring, terminals or z GO to Pinpoint Test B .
between 2H and 4H connectors
modes correctly z MSS
z Transfer case
z Transfer case
synchronization
clutch
z IWEs
z IWE solenoid
z TCCM
z Front axle
assembly
z The vehicle does not shift z TR z GO to Pinpoint Test C .
between 4H and 4L z Transmission drag
modes correctly torque
z ABS wheel speed
inputs
z HS-CAN
z The 4WD does not z Transfer case z GO to Pinpoint Test G .
engage at speed correctly synchronization
clutch
z Transfer case
z TCCM
z Front axle
assembly
connectors
z The front axle does not z MSS z GO to Pinpoint Test D .
engage/disengage z IWEs
correctly z IWE solenoid
z Transfer case
z Vacuum leaks
z Front axle
assembly
z TCCM
connectors
z Fuses
z The transfer case jumps z IWE vent line(s) z GO to Pinpoint Test E .
out of gear z MSS
z Transfer case
z Unable to duplicate z 4WD system z CARRY OUT the ESOF
customer concern and/or related Functional Test. GO to
components Pinpoint Test I .
z Rear wheels binding when z Wiring, terminals or z Go to Pinpoint Test AD in
turning corners with the connectors Electronic Locking
MSS in 2WD or OFF z ELD field coil Differential (ELD) System,
z Differential Diagnosis and Testing,
Section 308-07A .
z Off-road mode is z Wiring, terminals or z GO to Pinpoint Test K .
inoperative connectors
z Off-road mode
switch
z TCCM
z Off-road mode switch z Wiring, terminals or z GO to Pinpoint Test J .
indicator is inoperative connectors
z Off-road mode
switch
z TCCM
z Unable to achieve flat tow z Wiring, terminals or z Go to Pinpoint Test AH in
(neutral tow) mode connectors Electronic Locking
z HS-CAN Differential (ELD) System,
z IPC Diagnosis and Testing,
z TCCM Section 308-07A .
z Door ajar switch
z Ignition switch
symptom, refer back to for the next likely system and continue diagnosis.
z Grinding noise z Front halfshaft z GO to Pinpoint Test B .
during 4WD speeds not turning
engagement, at the same speed
especially at high z Synchronization
speeds clutch
z Vehicle pulsates z Unequal tire z GO to Pinpoint Test H .

or shudders in a inflation pressures
straight line z Unmatched tire
(straightline and wheel size
driveline wind-up) z Unequal amounts
of tire wear
z Unmatched front
and rear axle
ratios
z The front axle z Vacuum leaks z GO to Pinpoint Test F .
makes noise in 2H z Vacuum check
mode only and valve
generally under z Vacuum reservoir
heavy throttle z IWE solenoid
z IWEs
z The transfer case z Tire inflation z MAKE SURE that all tires and
makes noise pressure wheels are the same size and that
z Tire and wheel the inflation pressures are correct.
size
z Tire tread wear z CHECK tire tread wear to see if
there is more than 0.15 mm (0.06
in) difference in tread wear
between front and rear.
INTERCHANGE one front wheel
and one rear wheel. ROAD TEST
again.
z Internal z OPERATE the vehicle in all
components transmission gears. If there is
noise in the transmission in
NEUTRAL, or in some gears and
not in others, REMOVE and
REPAIR the transmission. REFER
to Section 307-01 . If there is
noise in all gears, DISASSEMBLE
the transfer case. REFER to
Section 308-07B . CHECK the
planetary gears, the bearings, the
upper and lower drive sprockets
and drive chain for damage.
INSTALL new parts as necessary.
z Fluid level z FILL with transfer case fluid.
z Transfer case z Incorrect fluid level z CHECK that the transfer case is
whine — noise at or fluid quality filled to the correct level and with
all ranges z Worn oil pump the specified fluid. REFER to
z Under-inflated or Section 308-07B .
oversized tires z DISASSEMBLE the transfer case.
CHECK the oil pump for wear or
damage. REPAIR as necessary.
z CONFIRM that the tires and
wheels are correct for the vehicle.
CHECK that the tire inflation
pressures are correct.
z Transfer case z Damaged or worn z DISASSEMBLE the transfer case.
growl/rumble — bearings or CHECK the bearings or planetary
noise at all ranges planetary gear gear for wear or damage. REPAIR
as necessary. REFER to Section
308-07B .
z Transfer case z Excessively z DISASSEMBLE the transfer case.
scraping/grating stretched drive CHECK the drive chain for wear or
— noise at all chain hitting the damage. REPAIR as necessary.
ranges case REFER to Section 308-07B .
z Transfer case z Worn or damaged z DISASSEMBLE the transfer case.
howl/hum — noise sun (input) gear, CHECK the gears for wear or
at all ranges or clutch pack damage. REPAIR as necessary.
4WD only (intermediate) gear REFER to Section 308-07B .
or output shaft
gear
Pinpoint Tests
Pinpoint Test A: The 4WD Indicators Do Not Operate Correctly
Refer to Wiring Diagrams Cell 34 , Four Wheel Drive System for schematic and connector information.
Normal Operation
Indicator status of the 4WD system is transmitted to the Instrument Panel Cluster (IPC) from the TCCM
through the HS-CAN then displayed in the message center of the IPC . The message center displays 4X4
HIGH when in 4H and 4X4 LOW in 4L. When in 2H, the message center will display 4X2 for approximately 4
seconds then no longer provides 4WD system indication until another shift mode is attained. For information
about HS-CAN , refer to Section 418-00 .

z 4WD system fault
z IPC
z TCCM
PINPOINT TEST A: THE 4WD INDICATORS DO NOT OPERATE CORRECTLY

A1 CHECK FOR IPC DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: Self-Test If DTC U0102:00 is retrieved,
— IPC . REFER to Section 418-00 to
z Are any DTCs present? diagnose lost communication
with TCCM . For all other IPC
DTCs, REFER to Section
413-01 .
No
GO to A2 .
A2 CHECK FOR TCCM DTCs

z Enter the following diagnostic mode on the scan tool: Self-Test Yes
— TCCM . REFER to the TCCM DTC
z Are any DTCs present? Chart in this section for
diagnosis.
No
GO to A3 .
A3 CHECK THE TCCM IGNITION POSITION (KEY_POS_4X4) AND
IGNITION STATUS (KEY_STATUS_4X4) PIDs
DataLogger — TCCM . GO to A4 .
z Monitor the KEY_POS_4X4 and KEY_STATUS_4X4 PIDs while
cycling through each position. No
z Do the ignition PIDs match the ignition switch positions? If the KEY_STATUS_4X4
PID did not match, CHECK
BJB fuse 54 (5A). If the fuse
is OK, REPAIR circuit CBB54
(VT/OG). If the fuse is not
OK, REFER to the Wiring
the possible causes of the
circuit short.
If the KEY_POS_4X4 PID did

not match, REFER to Section
211-05 to diagnose the
ignition switch.
A4 CHECK THE 4WD SYSTEM INDICATION IN 2H
z Switch the MSS to 2H while monitoring the message center. Yes
z Does 4X2 display in the message center for approximately GO to A5 .
4 seconds?
No
GO to A6 .
A5 CHECK THE 4WD SYSTEM INDICATION IN 4H
z Switch the MSS to 4H while monitoring the message center. Yes
z Does 4X4 HIGH display in the message center? GO to A8 .
No
GO to A9 .
A6 CHECK THE MSS USING THE TCCM 4WD SWITCH STATUS
(4X4_SW) PID
DataLogger — TCCM . GO to A7 .
z Monitor the 4X4_SW PID while switching to each MSS position.
z Does the 4X4_SW PID match the MSS position? No
INSTALL a new MSS .
REFER to Mode Select
Switch (MSS) in this section.
operation.
A7 CHECK THE TCCM PIDs IN 2H
DataLogger — TCCM . END the active command.

z Command the Transfer Case Shift Motor Position Sense CHECK the IPC for faults.
Contact Plate Power Circuit Status (PLATE_PWR_OS) PID to REFER to Section 413-01 .
energize the transfer case gearmotor encoder assembly.
z Monitor the Integrated Wheel Ends Output Control (IWE_OS) No
PID and the Transfer Case Contact Plate Switch A (PLATE_A), END the active command.
B (PLATE_B), C (PLATE_C) and D (PLATE_D) PIDs with the GO to Pinpoint Test B .
MSS in the 2H position.

2H Mode CLOSED OPEN CLOSED CLOSED
4H Mode OPEN CLOSED CLOSED OPEN
z Do the PIDs indicate the IWE solenoid is energized (PID

status No) and that the shift motor is in 2H position?
A8 CHECK THE 4WD SYSTEM INDICATION IN 4L
z NOTE: When shifting in or out of 4L, the transmission must be Yes
in NEUTRAL and the vehicle stopped or moving less than 5 The 4WD indicators are
km/h (3 mph). operating correctly. CARRY
z With the vehicle at a stop and transmission in NEUTRAL, switch OUT the ESOF Functional
the MSS to 4L while monitoring the message center. Test. GO to Pinpoint Test I .
z Does the message center display 4X4 LOW ?
No
GO to A10 .
A9 CHECK THE TCCM PIDs IN 4H
z Enter the following diagnostic mode on the scan tool: END the active command.
DataLogger — TCCM . CHECK the IPC for faults.
z Command the Transfer Case Shift Motor Position Sense REFER to Section 413-01 .
Contact Plate Power Circuit Status (PLATE_PWR_OS) PID to
energize the transfer case gearmotor encoder assembly. No
z Monitor the Integrated Wheel Ends Output Control (IWE_OS) END the active command.
PID and the Transfer Case Contact Plate Switch A (PLATE_A), GO to Pinpoint Test B .
B (PLATE_B), C (PLATE_C) and D (PLATE_D) PIDs with the
MSS in the 4H position.

z Do the PIDs indicate the IWE solenoid is de-energized (PID

status Yes) and that the shift motor is in 4H position?
A10 CHECK THE TCCM PIDs IN 4L
DataLogger — TCCM . CHECK the IPC for faults.
z Command the Transfer Case Shift Motor Position Sense REFER to Section 413-01 .
Contact Plate Power Circuit Status (PLATE_PWR_OS) PID to

energize the transfer case gearmotor encoder assembly. No
z Monitor the Integrated Wheel Ends Output Control (IWE_OS) END the active command.
PID and the Transfer Case Contact Plate Switch A (PLATE_A), GO to Pinpoint Test C .
B (PLATE_B), C (PLATE_C) and D (PLATE_D) PIDs with the
MSS in the 4L position.

z Do the PIDs indicate the IWE solenoid is de-energized (PID

status Yes) and that the shift motor is in 4L position?
Pinpoint Test B: The Vehicle Does Not Shift Between 2H and 4H Correctly and/or Grinding Noise
Heard During 4WD Engagement at High Speeds
Normal Operation
The MSS communicates the operator's choice to the TCCM . The TCCM then controls the transfer case
synchronization clutch, transfer case motor and IWEs as necessary. If the vehicle is not responding to the
operator's intentions, systematically check the necessary inputs and outputs of the TCCM , components of
the transfer case, IWE components and halfshafts. Check all circuits for opens and shorts to power or
ground.

z P1812:00 — 4-Wheel Drive Fault sets when TCCM C2371A pin 16 detects an open circuit or
Mode Select Circuit Failure: short to battery. Four-Wheel Drive (4WD) system mode cannot be
No Sub Type Information changed.
z P1815:00 — 4-Wheel Drive Fault sets when TCCM C2371A pin 16 detects a short to ground.
Mode Select Short Circuit 4WD system mode cannot be changed.
To Ground: No Sub Type
Information
z P1839:00 — Transfer Case Fault sets when TCCM C2371B pin 4 or 5 detects an open circuit.
Shift Motor Open Circuit: No Shift motor moves are prevented when this DTC is set.
z P1840:00 — Transfer Case Fault sets when TCCM C2371B pin 4 or 5 detects a short to voltage.
Information
z P1841:00 — Transfer Case Fault sets when TCCM C2371B pin 4 or 5 detects a short to ground.
Ground: No Sub Type
Information
Contact Plate 'A' Short motor moves are prevented when this DTC is set. The TCCM will not
Circuit To Ground: No Sub complete mode change if a change in shift motor position is required.
Type Information
z P184A:00 — Transfer Case Fault sets when target shift motor position is not reached after the
Unable To Transition maximum number of allowed blocked shift retries for 2H to 4H or 4H
Between 4x2 and 4x4 Mode: to 2H. Requested shift motor position is not reached.
Contact Plate 'B' Short motor moves are prevented when this DTC is set. The TCCM will not
Type Information
Contact Plate 'C' Short motor moves are prevented when this DTC is set. The TCCM will not
Type Information
Contact Plate 'D' Short motor moves are prevented when this DTC is set. The TCCM will not
Type Information
z P1867:00 — Transfer Case Fault sets when an invalid shift motor position is detected during
Contact Plate General selection of a new 4WD mode or during a motor movement. If the
Circuit Failure: No Sub Type shift motor is not moving, shift motor movement will be prevented. If
Information the shift motor is moving when this DTC sets, the shift motor will
move to the high-side or low-side mechanical stop position.
z P1891:00 — Transfer Case Fault sets when TCCM C2371A pin 5 detects a short to ground, a
Contact Plate Ground short to voltage or open circuit. The TCCM will not complete mode
Return Open Circuit: No Sub change if a change in shift motor position is required.
Type Information
z U300D:11 — Ignition Input Fault sets when TCCM C2371A pin 7 detects a short to ground.
On/Start: Circuit Short To
Ground

z MSS
z Transfer case
z IWEs
z IWE solenoid
z TCCM
PINPOINT TEST B: THE VEHICLE DOES NOT SHIFT BETWEEN 2H AND 4H CORRECTLY AND/OR
GRINDING NOISE HEARD DURING 4WD ENGAGEMENT AT HIGH SPEEDS
personal injury.

B1 CHECK FOR TCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: Self-Test For DTC P184A:00, GO to
— TCCM . B19 .
For DTC P1812:00, GO to
B5 .

B7 .

B28 .

B26 .

B27 .
For DTC P1849:00, DTC

P1853:00, DTC P1857:00,
DTC P1861:00, GO to B21 .

B4 .

B20 .
For DTC U300D:11, GO to

B2 .
For all other DTCs, REFER

to the DTC Chart in this
section.
No
GO to B2 .
B2 CHECK THE TCCM IGNITION POSITION (KEY_POS_4X4) AND
IGNITION STATUS (KEY_STATUS_4X4) PIDs
z Enter the following diagnostic mode on the scan tool: DataLogger Yes
— TCCM . GO to B3 .
z Monitor the KEY_POS_4X4 and KEY_STATUS_4X4 PIDs while
cycling through each ignition switch position. No
z Do the ignition PIDs match the ignition switch positions? If the KEY_STATUS_4X4
PID did not match, CHECK
BJB fuse 54 (5A). If the fuse
is OK, REPAIR circuit
CBB54 (VT/OG). If the fuse
is not OK, REFER to the
Wiring Diagrams manual to
identify the possible causes
of the circuit short. After the
fault is repaired, CLEAR the
normal operation.
If the KEY_POS_4X4 PID

did not match, REFER to
Section 211-05 to diagnose
the ignition switch. After the
fault is repaired, CLEAR the
normal operation.
B3 CHECK THE TCCM MODULE SUPPLY VOLTAGE (VBAT_4X4)
PID
z Start the engine and monitor the VBAT_4X4 PID.
z Is the VBAT_4X4 PID greater than 12 volts? No
DIAGNOSE the low battery
voltage and/or charging
system concern. After the
repair is complete, CLEAR
the DTCs. TEST the system
B4 CHECK THE MSS POSITION MONITORING THE TCCM 4WD
SWITCH STATUS (4X4_SW) PID
z Monitor the 4X4_SW PID while switching to each MSS position.
z Does the 4X4_SW PID match the MSS position? No
GO to B5 .
B5 CHECK THE MSS RESISTANCE VALUES
z Ignition OFF. Yes
z Disconnect: MSS . GO to B6 .
z Measure the resistance between MSS C284 pins 2 and 3,
component side, while rotating the MSS through all positions. No
Refer to the following chart. INSTALL a new MSS .
REFER to Mode Select
MSS Position Resistance Switch (MSS) in this section.
2H 606 - 632 ohms system for normal operation.
4H 265 - 275 ohms
4L 127 - 133 ohms

B6 CHECK THE MSS CONTROL AND RETURN CIRCUITS FOR
SHORT TO VOLTAGE
z Ignition OFF. Yes
z Disconnect: TCCM C2371A . REPAIR the affected circuit
z Ignition ON. (s). CLEAR the DTCs. TEST
z Measure the voltage between MSS C284-2, circuit RCF13 the system for normal
(WH/BN), harness side and ground; and between MSS C284-3, operation.
circuit CCF13 (WH/BU), harness side and ground.
No
GO to B7 .

B7 CHECK THE MSS CONTROL AND RETURN CIRCUITS FOR
SHORT TO GROUND
z Ignition OFF. Yes
z Measure the resistance between MSS C284-2, circuit RCF13 GO to B8 .
(WH/BN), harness side and ground; and between MSS C284-3,
circuit CCF13 (WH/BU), harness side and ground. No
operation.

B8 CHECK THE MSS CONTROL AND RETURN CIRCUITS FOR AN
OPEN
z Measure the resistance between MSS C284 and TCCM C2371A Yes
as shown below: GO to B9 .
MSS Circuit TCCM No

C284-2 RCF13 (WH/BN) C2371A-14 (s). CLEAR the DTCs. TEST
C284-3 CCF13 (WH/BU) C2371A-16
operation.

B9 CHECK THE MSS CONTROL AND RETURN CIRCUITS FOR A
SHORT TOGETHER
z Ignition OFF. Yes
z Measure the resistance between MSS C284-2, circuit RCF13 GO to B10 .
(WH/BN), harness side and MSS C284-3, circuit CCF13
(WH/BU), harness side. No

B10 CHECK THE TCCM AVERAGE FRONT WHEEL SPEED
(REAR_WHL_SPD) PIDs
z Connect: MSS . GO to B11 .
z Ignition ON.
z Set the MSS to 2H. No
z Enter the following diagnostic mode on the scan tool: DataLogger REFER to Section 206-09 to
— TCCM . diagnose the wheel speed
z Monitor the FRT_WHL_SPD and REAR_WHL_SPD PIDs with concern. After the repair is
the vehicle stopped and while driving. complete, CLEAR the DTCs.
z Do the FRT_WHL_SPD and REAR_WHL_SPD PIDs match TEST the system for normal
with the vehicle stopped and at all speeds? operation.
B11 CHECK THE TCCM 4WD MODES (4WD_MODES) PID WITH
THE MSS IN 4H
z Enter the following diagnostic mode on the scan tool: DataLogger GO to B14 .
— TCCM .
z Set the MSS to 4H. No
z Monitor the 4WD_MODES PID. GO to B12 .
z Does the 4WD_MODES PID indicate 4WD High?
B12 CHECK FOR 4H WIND-UP
z Drive the vehicle on a dry, hard surface in turns. GO to B15 .

No
GO to B13 .
B13 CHECK FOR TRANSFER CASE ENGAGEMENT
Section 100-02 . GO to B14 .
z Rotate the rear driveshaft.
z Observe the front driveshaft. No
z Did the front driveshaft rotate? GO to B18 .
B14 CHECK FOR IWE ENGAGEMENT
z NOTE: The engine must be idling during the following steps to Yes
supply the vacuum required for the IWEs to engage and CHECK that all driveline
disengage. fasteners are present and
z Start the engine. tightened to specification.
z Rotate the LH front tire one revolution forward and one revolution REFER to Section 205-00
backward while observing the LH front halfshaft and U-joint. for further diagnosis of the
z Rotate the RH front tire one revolution forward and one front axle.
revolution backward while observing the RH front halfshaft and
U-joint. No
z Did both front halfshafts rotate? GO to Pinpoint Test D .
B15 CHECK THE TRANSFER CASE SHIFT TO 2H
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: DataLogger GO to B16 .
— TCCM .
z Command the Transfer Case Contact Plate Power No
(PLATE_PWR_OS) PID to energize the transfer case gearmotor GO to B20 .
encoder assembly.
(PLATE_B), C (PLATE_C) and D (PLATE_D) PIDs for the
contact plate position with the MSS in the 2H position.

z Do the PIDs and message center indicate that vehicle shifted

into 2H (4X2) displayed in message center for approximately
4 seconds)?
B16 CHECK FOR IWE DISENGAGEMENT
Section 100-02 . GO to Pinpoint Test D .
backward while observing the LH front halfshaft and U-joint. No
z Rotate the RH front tire one revolution forward and one GO to B17 .
revolution backward while observing the RH front halfshaft and
U-joint.
z Did either of the front halfshafts rotate?
B17 CHECK FOR TRANSFER CASE DISENGAGEMENT
z Rotate the rear driveshaft while observing the front driveshaft. Yes
z Does the front driveshaft rotate? The system is functioning

correctly. CARRY OUT the
ESOF Functional Test. GO
to Pinpoint Test I .
No
GO to B18 .
B18 CHECK THE TRANSFER CASE CONTACT PLATE POSITION
PIDs
z Command the Transfer Case Contact Plate Power
(PLATE_PWR_OS) PID to energize the transfer case gearmotor No
encoder assembly. GO to B19 .
(PLATE_B), C (PLATE C) and D (PLATE_D) PIDs for the contact
plate position with the MSS in the 4H position.

z Do the transfer case contact plate PIDs indicate 4H?

B19 CHECK THE TRANSFER CASE SHIFT MOTOR OPERATION
z Remove the transfer case shift motor from the transfer case, Yes
leaving the wiring connector connected. GO to B29 .
z Observe the transfer case shift motor while switching the MSS
from 2H to 4H. No
z Does the transfer case shift motor rotate from the 2H GO to B20 .
position to the 4H position?
B20 CHECK TRANSFER CASE CONTACT PLATE CIRCUITS FOR
A SHORT TO VOLTAGE
z Ignition OFF. Yes
z Disconnect: Transfer Case . REPAIR the affected circuit
z Disconnect: TCCM C2371A . (s). CLEAR the DTCs. TEST
z Ignition ON. the system for normal
z Measure the voltage between the following circuits at TCCM operation.
C2371A, harness side and ground:
No
Circuit C2371A Pin GO to B21 .
CCF14 (GN/OG) 1
CCF15 (BN/YE) 2
CCF16 (VT/GN) 3
CCF17 (WH/OG) 4
RCF09 (BN/WH) 5

B21 CHECK TRANSFER CASE CONTACT PLATE CIRCUITS FOR
A SHORT TO GROUND
z Ignition OFF. Yes
z Disconnect: Transfer Case . GO to B22 .
z Measure the resistance between the following circuits at TCCM No
C2371A, harness side and ground: REPAIR the affected circuit
Circuit C2371A Pin the system for normal
operation.
CCF14 (GN/OG) 1
CCF15 (BN/YE) 2
CCF16 (VT/GN) 3
CCF17 (WH/OG) 4
RCF09 (BN/WH) 5

B22 CHECK THE TRANSFER CASE CONTACT PLATE CIRCUITS
FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: Transfer Case . GO to B23 .
z Measure the resistance of the following circuits between TCCM No
C2371A, harness side and transfer case C350, harness side: REPAIR the affected circuit
C2371A Pin Circuit C350 Pin the system for normal
operation.
1 CCF14 (GN/OG) 5
2 CCF15 (BN/YE) 1
3 CCF16 (VT/GN) 9
4 CCF17 (WH/OG) 13
5 RCF09 (BN/WH) 10

B23 CHECK THE SHIFT MOTOR FOR AN INTERNAL SHORT TO
GROUND
z Measure the resistance between transfer case C350 pins 1, 5, 9, Yes
10 and 13, component side and ground. GO to B24 .
No
INSTALL a new transfer
case shift motor. REFER to
Transfer Case Shift Motor in
this section. CLEAR the
DTCs. REPEAT the self-
test, if the concern is still
present, GO to B30 .

B24 CHECK THE SHIFT MOTOR CIRCUITS FOR POWER WHILE
COMMANDING THE TCCM CW RELAY (CW_SMD_OS) AND CCW
RELAY (CCW_SMD_OS) PIDs ON
z Ignition ON. Yes
z Connect: TCCM C2371A . GO to B29 .
z Enter the following diagnostic mode on the scan tool: DataLogger
— TCCM . No
z Command the CW_SMD_OS PID ON and OFF while measuring GO to B25 .
the voltage between transfer case C350-14, circuit CCF08
(GY/OG), harness side and ground. Then command the
CCW_SMD_OS PID ON and OFF while measuring the voltage
between transfer case C350-15, circuit CCF07 (BN/GN), harness
side and ground.
z Are the voltages 9 volts or greater on the circuits when

commanding the PIDs ON?
B25 CHECK THE TCCM VOLTAGE CIRCUIT
z Ignition OFF. Yes
z Disconnect: TCCM C2371B . GO to B26 .
z Measure the voltage between TCCM C2371B-6, circuit SBB20
(GN/RD), harness side and ground. No
VERIFY BJB fuse 20 (20A)
is OK. If OK, REPAIR circuit
SBB20 (GN/RD). If not OK,
REFER to the Wiring
short. CLEAR the DTCs.
operation.

B26 CHECK THE TRANSFER CASE SHIFT MOTOR CIRCUITS FOR
SHORT TO VOLTAGE
z Ignition ON. Yes
z Disconnect: TCCM C2371B . REPAIR the affected circuit
z Disconnect: Transfer Case . (s). CLEAR the DTCs. TEST
z Measure the voltage between transfer case C350-14, circuit the system for normal
CCF08 (GY/OG), harness side and ground; and between transfer operation.
case C350-15, circuit CCF07 (BN/GN), harness side and ground.
No
GO to B27 .

SHORT TO GROUND
z Ignition OFF. Yes

CCF08 (GY/OG), harness side and ground; and between the REPAIR the affected circuit
transfer case C350-15, circuit CCF07 (BN/GN), harness side and (s). CLEAR the DTCs. TEST
ground. the system for normal
operation.

AN OPEN
z Ignition OFF. Yes
z Measure the resistance between transfer case C350 and TCCM No
C2371B as shown below: REPAIR the affected circuit.
Transfer Case Circuit TCCM system for normal operation.
C350-14 CCF08 (GY/OG) C2371B-5

C350-15 CCF07 (BN/GN) C2371B-4

B29 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
module pins) this section. TEST the
damaged or bent pins - install new terminals/pins system for normal operation.
z Connect all TCCM connectors. Make sure they are seated
correctly. No
z Operate the system and verify the concern is still present. The system is operating
z Is the concern still present? correctly at this time.
Concern may have been
corroded connector.
B30 SHIFT THE TRANSFER CASE TO 4H MANUALLY
z Remove the transfer case shift motor from the transfer case. Yes
z Using a wrench, rotate the shift cam to the 4H position. GO to B31 .
z Rotate the rear driveshaft and watch the front driveshaft.
z Does the transfer case shift to 4H and the front driveshaft No
rotates? REPAIR the transfer case.
B31 CHECK THE TORQUE REQUIRED TO SHIFT THE TRANSFER
CASE
z Rotate the shift cam by hand through 4L, 4H and 2H positions. Yes
z Measure the torque required to perform the shift. GO to B32 .
z Is the torque required to shift 45 Nm (33 lb-ft) or less?
No
REPAIR the transfer case.
B32 SHIFT THE TRANSFER CASE TO 2H MANUALLY
z Rotate the shift cam to the 2H position. Yes
z Rotate the rear driveshaft and watch the front driveshaft. GO to B33 .
z Does the transfer case shift to 2H and the front driveshaft
does not rotate? No
B33 SHIFT THE TRANSFER CASE TO 4L MANUALLY
z Rotate the shift cam by hand to the 4L position. Yes
z Rotate the rear driveshaft and watch the front driveshaft. INSTALL a new transfer
z Does the transfer case shift to 4L and the front driveshaft case shift motor. REFER to
rotates? Transfer Case Shift Motor in
this section. CLEAR the
normal operation.
No
Pinpoint Test C: The Vehicle Does Not Shift Between 4H and 4L Modes Correctly
Normal Operation
The high-low shift occurs when the reduction shift fork moves the high-low collar to lock the planetary gear
set to the output shaft. The torque transmitted through the sun gear from the input shaft turns the front
planetary gear set assembly. The front planetary gear set assembly, now engaged, provides transfer case
speed reduction. Certain criteria, such as vehicle speed and TR selection must be met before this shift can
occur. Systematically check the necessary inputs and outputs of the TCCM , components of the transfer
case, IWE components and halfshafts.
z DTC P184B:00 (Transfer Case Unable To Transition Between 4x4 High and 4x4 Low Range) — Fault
sets when target shift motor position is not reached after the maximum number of allowed blocked
shift retries for 4H to 4L. Requested shift motor position is not reached.

z TR
z Transmission drag torque
z ABS wheel speed inputs
z HS-CAN
PINPOINT TEST C: THE VEHICLE DOES NOT SHIFT BETWEEN 4H AND 4L MODES CORRECTLY
personal injury.

C1 CHECK FOR TCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: For DTC P184B:00, GO to C2 .
Self-Test — TCCM .
z Are any DTCs present? For all other DTCs, REFER to the
No
GO to Pinpoint Test B .
C2 CHECK THE 2H TO 4H SHIFT
z Drive the vehicle and shift MSS from 2H to 4H. Yes
z Does the vehicle shift between 2H and 4H GO to C3 .
correctly?
No
C3 CHECK THE 4H TO 4L SHIFT
z NOTE: When shifting in or out of 4L, the transmission Yes
must be in NEUTRAL and the vehicle stopped or Transmission neutral drag is
moving less than 5 km/h (3 mph). excessive. REFER to Section 307-01
z Drive the vehicle and shift MSS from 4H to 4L. for transmission diagnosis.
z Does the transfer case shift from 4H to 4L correctly
and the complaint is related to a clunk noise during No
the shift? GO to C4 .
C4 CHECK THE TCCM NEUTRAL INDICATOR (NEUTRAL)
AND ABS MODULE WHEEL SPEED PIDs
DataLogger — TCCM . If all 5 PIDs are accurate, GO to
z A. Monitor the NEUTRAL PID while shifting the Pinpoint Test B .
transmission through gear ranges.
A. REFER to Section 307-01 for
DataLogger — ABS Module . further diagnosis of the TR sensor.

z B. Monitor the wheel speed PIDs:
Left Front Wheel Speed Sensor (LF_WSPD) B. REFER to Section 206-09 for
Left Rear Wheel Speed Sensor (LR_WSPD) further diagnosis of the ABS system.
z A. Does the NEUTRAL PID indicate True when the
transmission is shifted to NEUTRAL?
B. Do the wheel speed PIDs indicate 0 km/h (0

mph)?
Pinpoint Test D: The Front Axle Does Not Engage/Disengage Correctly
Section 308-07A .
Normal Operation
(disengaging the front hubs from the front axle). In 4H or 4L modes, the TCCM does not supply the ground
path to the IWE solenoid, vacuum is not applied to IWEs the and an internal spring in the IWEs keeps the
hubs engaged.
z DTC C1979:11 (IWE Solenoid Circuit Failure: Short Circuit To Ground) — Fault sets when TCCM
C2371A pin 6 detects a short to ground. Fault results in IWEs hubs disengaged all the time.
z DTC C1979:12 (IWE Solenoid Circuit Failure: Short Circuit To Battery) — Fault sets when TCCM
C2371A pin 6 detects a short to voltage. Fault results in IWEs hubs engaged all the time.
z DTC C1979:13 (IWE Solenoid Circuit Failure: Circuit Open) — Fault sets when TCCM C2371A pin 6
detects an open circuit. Fault results in IWEs hubs engaged all the time.

z MSS
z IWEs
z IWE solenoid
z Transfer case
z Vacuum leaks
z TCCM
z Fuses
PINPOINT TEST D: THE FRONT AXLE DOES NOT ENGAGE/DISENGAGE CORRECTLY
personal injury.

D1 CHECK FOR TCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: Self- For DTC C1979:11, GO to D19 .
Test — TCCM .
z Are any DTCs present? For DTC C1979:12, GO to D18 .
For DTC C1979:13, GO to D20 .

No
GO to D2 .
D2 CHECK FOR GRINDING NOISES AT HIGH SPEEDS
z With the vehicle warm and the MSS in 2H mode, drive the Yes
vehicle at sustained WOT for 5 seconds. GO to Pinpoint Test F .
WOT ? No
GO to D3 .
D3 CHECK TCCM OPERATION
z Ignition ON. Yes
z Monitor the 4X4 indicator on the IPC while moving the MSS GO to D4 .
between 2H and 4H modes.
z Does the 4X4 indicator illuminate when the MSS is in No
the 4H position and turn off when the MSS is in the 2H GO to Pinpoint Test B .
position?
D4 CHECK THE IWE DISENGAGEMENT
NOTE: The engine must be idling during the following steps Yes
to supply the vacuum required for the IWEs to engage and GO to D8 .
disengage.
No
z With the vehicle in NEUTRAL, position it on a hoist. Refer GO to D5 .
to Section 100-02 .
z Place the MSS in 2H.
z Start the engine.
z Rotate the LH front tire one revolution forward and one
revolution backward while observing the RH front halfshaft.
z Did either front halfshaft rotate?
D5 CHECK THE IWE ENGAGEMENT
to Section 100-02 . The front axle is operating
z With the engine running, place the MSS in 4H. properly at this time. CARRY OUT
z Rotate the LH front tire one revolution forward and one the ESOF Functional Test. GO to
revolution backward while observing the LH front halfshaft. Pinpoint Test I .
revolution backward while observing the RH front halfshaft. No
z Did both front halfshafts rotate? GO to D6 .
D6 CHECK THE IWE SOLENOID OUTPUT IN 4H
z With the engine running and the MSS In 4H, measure the The IWE is mechanically stuck in
vacuum at the output port of the IWE solenoid. the disengaged position. INSTALL
z Is the vacuum less than 25 mm (1 in) Hg? a new IWE on the halfshaft(s) that
did not rotate. REFER to
Integrated Wheel End (IWE) in
normal operation.
No
GO to D7 .
D7 CHECK THE IWE SOLENOID
z Ignition OFF. Yes
z Disconnect: IWE Solenoid . GO to D20 .
z Start the engine.
z Measure the vacuum at the output port of the IWE solenoid. No
z Is the vacuum less than 25 mm (1 in) Hg? INSTALL a new IWE solenoid.
operation.
D8 CHECK THE IWE SOLENOID OUTPUT VACUUM IN 2H
z With the engine running and the MSS in 2H, measure the GO to D11 .
vacuum at the output port of the IWE solenoid.
GO to D9 .
D9 CHECK THE IWE SOLENOID INPUT VACUUM
z With the engine running, measure the supply line vacuum GO to D20 .
to the IWE solenoid.
GO to D10 .
D10 CHECK THE VACUUM RESERVOIR
z Ignition OFF. Yes
z With the source vacuum line still disconnected, connect a REPAIR or INSTALL new vacuum
vacuum pump to the vacuum port on the vacuum reservoir lines or INSTALL a check valve.
and apply 508 mm (20 in) Hg of vacuum. TEST the system for normal
z Does the vacuum maintain or drop less than 25 mm (1 operation.
in) Hg per minute?
No
INSTALL a new vacuum reservoir.
operation.
D11 CHECK THE IWE VACUUM LINES
z Ignition OFF. Yes
z Disconnect the output vacuum line from the IWE solenoid. GO to D14 .
z Disconnect and plug the LH and RH IWE vacuum lines at
the IWEs . No
z Connect a vacuum pump to the IWE output vacuum circuit GO to D12 .
at the IWE solenoid connection. Apply 508 mm (20 in) Hg
of vacuum and observe the vacuum reading.
z Does the vacuum drop more than 25 mm (1 in) Hg per
minute?
D12 CHECK THE LH IWE VACUUM LINE FOR AN
OBSTRUCTION
z REMOVE the plug from the vacuum line at the LH IWE . Yes
z Connect a hand vacuum pump to the LH IWE vacuum line INSTALL a new vacuum line.
and attempt to draw a vacuum on the line. CLEAR the DTCs. TEST the
z Did the vacuum pump draw a vacuum on the LH IWE system for normal operation.
vacuum line?
No
GO to D13 .
D13 CHECK THE RH IWE VACUUM LINE FOR AN
OBSTRUCTION
z REMOVE the plug from the vacuum line at the RH IWE . Yes
z Connect a vacuum pump to the RH IWE vacuum line and INSTALL a new vacuum line.
attempt to draw a vacuum on the line. CLEAR the DTCs. TEST the
z Did the vacuum pump draw a vacuum on the RH IWE system for normal operation.
vacuum line?
No
GO to D14 .
D14 CHECK THE RH IWE LEAK RATE
z Apply 508 mm (20 in) Hg of vacuum to the RH IWE port Yes
and observe vacuum reading. GO to D15 .
in) Hg per minute? No
INSTALL a new RH IWE . REFER
to Integrated Wheel End (IWE) in
normal operation.
D15 CHECK THE RH IWE OPERATION
the RH IWE . CONNECT the vacuum line to the
z Observe the RH halfshaft while rotating the RH front tire. RH IWE . GO to D16 .
engage the RH IWE . INSTALL a new RH IWE . REFER
z Did the RH IWE disengage between 152 and 203 mm (6 to Integrated Wheel End (IWE) in
to 8 in) Hg and engage when the vacuum is released? this section. TEST the system for
normal operation.
D16 CHECK THE LH IWE LEAK RATE
IWE . GO to D17 .
z Apply 508 mm (20 in) Hg of vacuum to the LH IWE port and
normal operation.
D17 CHECK THE LH IWE OPERATION
the LH IWE . CONNECT the vacuum line to the
z Observe the LH halfshaft while rotating the LH front tire. LH IWE . GO to D18 .
engage the LH IWE . INSTALL a new LH IWE . REFER
z Did the LH IWE disengage between 152 and 203 mm (6 to Integrated Wheel End (IWE) in
to 8 in) Hg and engage when the vacuum is released? this section. CLEAR the DTCs.
operation.
D18 CHECK THE IWE SOLENOID CONTROL CIRCUIT FOR A

SHORT TO VOLTAGE
z Ignition OFF. Yes
z Disconnect: IWE Solenoid . REPAIR circuit CCF05 (BN/BU).
z Disconnect: TCCM C2371A . CLEAR the DTCs. TEST the
z Ignition ON. system for normal operation.
circuit CCF05 (BN/BU), harness side and ground. No
GO to D19 .

D19 CHECK THE IWE SOLENOID CONTROL CIRCUIT FOR A
SHORT TO GROUND
z Ignition OFF. Yes
z Disconnect: IWE Solenoid C1291 . GO to D20 .
z Measure the resistance between solenoid C1291-2, circuit No
CCF05 (BN/BU), harness side and ground. REPAIR circuit CCF05 (BN/BU).

D20 CHECK THE IWE SOLENOID RESISTANCE
NOTE: If the temperatures (either ambient or in the engine Yes

GO to D21 .
compartment) are exceptionally high, a higher than normal
resistance reading could result. A lower temperature could
No
result in a lower resistance reading.
INSTALL a new IWE solenoid.
z Measure the resistance between IWE solenoid C1291 pins CLEAR the DTCs. TEST the
1 and 2, component side. system for normal operation.

D21 CHECK FOR VOLTAGE TO THE IWE SOLENOID
z Ignition OFF. Yes
circuit SBB29 (GY/RD), harness side and ground. No
CHECK BJB fuse 29 (10A). If OK,
REPAIR circuit SBB29 (GY/RD). If
short. CLEAR the DTCs. TEST

D22 CHECK THE IWE SOLENOID CONTROL CIRCUIT FOR
AN OPEN
z Ignition OFF. Yes
z Measure the resistance between IWE solenoid C1291-2, No
circuit CCF05 (BN/BU), harness side and TCCM C2371A-6, REPAIR circuit CCF05 (BN/BU).
circuit CCF05 (BN/BU), harness side. CLEAR the DTCs. TEST the

D23 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes

pin issues.
Pinpoint Test E: The Transfer Case Jumps Out of Gear
Section 308-07A .
Normal Operation
Once the 4WD system engages the user selected mode, that mode should be maintained. If the 4WD
system does not stay in the selected position systematically check the 4WD system components.

z Integrated Wheel Ends (IWEs) vent line(s)
z MSS
z Transfer case
PINPOINT TEST E: THE TRANSFER CASE JUMPS OUT OF GEAR
personal injury.

E1 CHECK FOR OBSTRUCTED IWE VENT
LINES
z With the vehicle in NEUTRAL, position Yes
it on a hoist. Refer to Section 100-02 . INSTALL new IWE vent lines as necessary. TEST the
z NOTE: The IWE vent port is the smaller system for normal operation.
of the 2 vacuum ports.
z Disconnect the LH IWE line from the No
vent port. GO to E2 .
z Attach a vacuum pump to the IWE vent
line and attempt to hold a vacuum.
z Disconnect the RH IWE line from the
vent port.
z Attach a vacuum pump to the IWE vent
line and attempt to hold a vacuum.
z Can a vacuum be held on either IWE
vent line?
E2 VERIFY THE CONCERN
Yes
z Drive the vehicle and attempt to GO to E5 .

duplicate the concern.
z Is the concern an uncommanded No
range shift (in or out of low range)? GO to E3 .
E3 CHECK THE MSS POSITION
MONITORING THE TCCM 4WD SWITCH
STATUS (4X4_SW) PID
z Ignition ON. Yes
z Enter the following diagnostic mode on GO to E4 .
the scan tool: DataLogger — TCCM .
z Drive the vehicle. No
z Dynamically monitor the 4X4_SW PID GO to Pinpoint Test B .
while driving the vehicle in each shift
position.
z Does the 4X4_SW PID always agree
with the switch position?
E4 CHECK FOR TCCM DTCs
the scan tool: Self-Test — TCCM . REFER to the TCCM DTC Chart in this section.
No
CARRY OUT the ESOF Functional Test. GO to
Pinpoint Test I .
E5 CHECK THE 4WD INDICATORS
z Stop the vehicle. Yes
z Transmission in NEUTRAL. GO to E6 .
z Depress the brake pedal.
z Observe the 4WD indication in the No
message center while cycling through GO to Pinpoint Test A .
each MSS position.
z Does the 4WD indicator(s) match the
MSS ?
E6 CHECK FOR TCCM DTCs
z Transmission in PARK. Yes
z Enter the following diagnostic mode on REFER to the TCCM DTC Chart in this section.
the scan tool: Self-Test — TCCM .
z Are any DTCs present? No
CHECK the transfer case fluid level. REFER to
Section 308-07B . If the fluid level is OK, CHECK for
internal transfer case faults. REFER to Section 308-
07B .
Pinpoint Test F: The Front Axle Makes Noise in 2H Mode Only and Generally Under Heavy Throttle
Section 308-07A .
Normal Operation
In 2H mode, the TCCM provides a ground path to the IWE solenoid to supply vacuum to each IWE
(disengaging the front hubs from the front axle). During certain conditions such as WOT maneuvers,
manifold vacuum is lower than desired. To maintain uninterrupted IWE function in 2H mode, stored engine
vacuum is sourced from the vacuum reservoir. A one-way check valve is implemented between the manifold
and IWE solenoid/vacuum reservoir to prevent the stored vacuum from escaping into the manifold during
low engine vacuum conditions. For noise-free IWE operation under all conditions, the check valve must be
operating correctly.

z Vacuum leaks
z Vacuum check valve
z Vacuum reservoir
z IWE solenoid
z IWEs
PINPOINT TEST F: THE FRONT AXLE MAKES NOISE IN 2H MODE ONLY AND GENERALLY UNDER
HEAVY THROTTLE
personal injury.

F1 CHECK FOR GRINDING NOISES AT HIGH SPEEDS
z With the vehicle warm and the MSS in 2H mode, Yes
drive the vehicle at sustained WOT for 5 seconds. GO to F2 .
z Is there a grinding noise from the axle system
during WOT ? No
IDENTIFY the customer concern and GO
to Symptom Chart - Four-Wheel Drive
(4WD) System or GO to Symptom Chart -
NVH in this section.
F2 CHECK THE IWE SOLENOID OUTPUT VACUUM IN
2H
z NOTE: The engine must be idling during the Yes
following steps to supply the vacuum required for GO to F7 .
the IWEs to engage and disengage.
z Disconnect the output vacuum line at the IWE GO to F3 .
solenoid while having the vacuum supply attached
to the solenoid.
z With the engine running and the transfer case in 2H
mode, measure the vacuum at the output port of the
IWE solenoid.
F3 CHECK THE IWE SOLENOID INPUT VACUUM
z Disconnect the supply vacuum line at the IWE Yes
solenoid. INSTALL a new IWE solenoid. TEST the
z NOTE: The engine must be idling during the system for normal operation.
following steps to supply the vacuum required for
the IWEs to engage and disengage. No
z With the engine still running, measure the supply GO to F4 .
line vacuum to the IWE solenoid.

F4 CHECK SOURCE VACUUM TO THE VACUUM
RESERVOIR
z Disconnect the source vacuum line from the vacuum Yes
reservoir. GO to F5 .
z NOTE: The engine must be idling during the
following steps to supply the vacuum required for No
the IWEs to engage and disengage. REPAIR or INSTALL a new source
z With the engine still running, measure the source vacuum line. TEST the system for normal
vacuum being supplied to the vacuum reservoir. operation.
F5 CHECK THE VACUUM RESERVOIR
z Ignition OFF. Yes
z Disconnect the vacuum line from the vacuum GO to F6 .
reservoir.
z Connect a vacuum pump to the source vacuum port No
on the vacuum reservoir and apply 508 mm (20 in) INSTALL a new vacuum reservoir. TEST
Hg of vacuum. the system for normal operation.
z Does the vacuum maintain or drop less than 25
mm (1 in) Hg per minute?
F6 CHECK THE VACUUM CHECK VALVE
z NOTE: The check valve is between the vacuum Yes
source and the IWE solenoid and vacuum reservoir. Concern not present at this time. CARRY
z Connect the vacuum lines to the IWE solenoid. OUT the ESOF Functional Test. GO to
z Connect a vacuum pump to the IWE solenoid Pinpoint Test I .
vacuum line at the vacuum reservoir and apply 508
mm (20 in) Hg of vacuum. No
z Does the vacuum maintain or drop less than 25 REPAIR or INSTALL new vacuum lines
mm (1 in) Hg per minute? or INSTALL a new check valve. TEST the
F7 CHECK THE IWE VACUUM SYSTEM
z Ignition OFF. Yes
z Disconnect both vacuum lines from the IWE CONNECT the vacuum lines to the IWE
solenoid. solenoid. GO to F11 .
z Using a vacuum pump, apply 508 mm (20 in) Hg of
vacuum to the IWE system through the apply No
vacuum circuit. GO to F8 .
z Does the vacuum maintain or drop less than 25
mm (1 in) Hg per minute?
F8 CHECK THE RH IWE LEAK RATE
z With the vehicle in NEUTRAL, position it on a hoist. Yes
Refer to Section 100-02 . GO to F9 .
z Disconnect the vacuum line from the larger port on
the RH IWE . No
z Apply 508 mm (20 in) Hg of vacuum to the RH IWE INSTALL a new RH IWE . REFER to
port and observe vacuum reading. Integrated Wheel End (IWE) in this
z Does the vacuum maintain or drop less than 25 section. TEST the system for normal
mm (1 in) Hg per minute? operation.
F9 CHECK THE LH IWE LEAK RATE
z Disconnect the vacuum line from the larger port at Yes
the LH IWE . GO to F10 .
z Apply 508 mm (20 in) Hg of vacuum to the LH IWE
port and observe vacuum reading. No

z Does the vacuum maintain or drop less than 25 INSTALL a new LH IWE . REFER to
mm (1 in) Hg per minute? Integrated Wheel End (IWE) in this
operation.
F10 CHECK THE IWE VACUUM SUPPLY TUBE
z Disconnect both vacuum lines from the IWE Yes
solenoid. GO to F11 .
z Plug both LH and RH IWE vacuum lines. Apply 508
mm (20 in) Hg of vacuum to the IWE apply vacuum No
circuit and observe the vacuum reading. INSTALL new vacuum lines as
z Does the vacuum maintain or drop less than 25 necessary. TEST the system for normal
mm (1 in) Hg per minute? operation.
F11 CHECK THE IWE VACUUM SUPPLY AT EACH
IWE IN 2H
z Connect the vacuum lines to the IWE solenoid. Yes
z Connect a hand-held vacuum gauge to the LH IWE GO to F12 .
vacuum supply tube.
z NOTE: The engine must be idling during the No
following steps to supply the vacuum required for INSTALL new vacuum lines as
the IWEs to engage and disengage. necessary. TEST the system for normal
z Start the engine. operation.
z Switch the MSS to 2H mode while observing the
vacuum gauge.
z Repeat these steps for the RH IWE .
z Are the vacuum readings greater than 254 mm
(10 in) Hg?
F12 CHECK THE LH IWE VACUUM LINE FOR AN
OBSTRUCTION
z Ignition OFF. Yes
z Disconnect both vacuum lines from the IWE INSTALL a new vacuum line. TEST the
solenoid. system for normal operation.
z With the vehicle in NEUTRAL, position it on a hoist.
Refer to Section 100-02 . No
z Disconnect the vacuum line at the LH IWE . CONNECT the vacuum line to the LH
z Connect a hand vacuum pump to the LH IWE IWE . GO to F13 .
vacuum line and attempt to draw a vacuum on the
line.
z Did the vacuum pump draw a vacuum on the LH
IWE vacuum line?
F13 CHECK THE RH IWE VACUUM LINE FOR AN
OBSTRUCTION
z Disconnect the larger vacuum line at the RH IWE . Yes
z Connect a vacuum pump to the RH IWE vacuum INSTALL a new vacuum line. TEST the
line and attempt to draw a vacuum on the line. system for normal operation.
z Did the vacuum pump draw a vacuum on the RH
IWE vacuum line? No
CONNECT the vacuum line to the RH
IWE . GO to F14 .
F14 CHECK THE LH IWE OPERATION
z Connect a vacuum pump with gauge to the larger Yes
port of the LH IWE . GO to F15 .
z Observe the LH halfshaft while rotating the LH front
tire. Apply between 152 and 203 mm (6 to 8 in) Hg No
of vacuum and release the vacuum to manually INSTALL a new LH IWE . REFER to
disengage and engage the LH IWE . Integrated Wheel End (IWE) in this
z Did the LH IWE disengage between 152 and 203 section. TEST the system for normal
mm (6 to 8 in) Hg and engage when the vacuum operation.
is released?
F15 CHECK THE RH IWE OPERATION
z Connect a vacuum pump with gauge to the larger Yes
port of the RH IWE . CARRY OUT the ESOF Functional Test.
z Observe the RH halfshaft while rotating the RH front GO to Pinpoint Test I .
tire. Apply between 152 and 203 mm (6 to 8 in) Hg
of vacuum and release the vacuum to manually No
disengage and engage the RH IWE . INSTALL a new RH IWE . REFER to
z Did the RH IWE disengage between 152 and 203 Integrated Wheel End (IWE) in this
mm (6 to 8 in) Hg and engage when the vacuum section. TEST the system for normal
is released? operation.
Pinpoint Test G: The 4WD Does Not Engage at Speed Correctly
Normal Operation
When the operator selects a transfer case mode from 2H mode, the Transfer Case Control Module (TCCM)
engages the synchronization clutch for approximately 5 seconds to synchronize the front and rear
driveshafts allowing a further mechanical engagement of the transfer case. The TCCM also removes the
ground path from the IWE solenoid, which removes vacuum from the IWEs , allowing them to engage.
Systematically check the necessary inputs and outputs at the TCCM , internal components of the transfer
case, IWE components and drive axles.
z DTC P1825:00 (4-Wheel Drive Clutch Relay Open Circuit: No Sub Type Information) — Fault sets
when TCCM C2371B pin 1 detects an open circuit. The TCCM disables transfer case synchronization
clutch operation.
z DTC P1826:00 (4-Wheel Drive Low Clutch Relay Circuit To Battery: No Sub Type Information) —
Fault sets when TCCM C2371B pin 1 detects a short to voltage. Transfer case synchronization clutch
operation, though disabled by the TCCM , is fully engaged when this DTC is present.
z DTC P1827:00 (4-Wheel Drive Low Clutch Relay Circuit To Ground) — Fault sets when TCCM
C2371B pin 1 detects a short to ground. The TCCM disables transfer case synchronization clutch
operation.

z Transfer case
z TCCM
PINPOINT TEST G: THE 4WD DOES NOT ENGAGE AT SPEED CORRECTLY
personal injury.

G1 CHECK FOR TCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: Self-Test — For DTC P1825:00, GO to
TCCM . G7 .
G12 .

G10 .
For all other DTCs, REFER

to the TCCM DTC Chart for
diagnosis.
No
GO to G2 .
G2 CHECK 4H ENGAGEMENT AT REST
z Switch the MSS from 2H to 4H. Yes
z Confirm 4H engagement by driving the vehicle and check for GO to G3 .
wind-up in turns.
z Does 4H engage at rest correctly? No
G3 CHECK 2H TO 4H SHIFT AT SPEED
z Drive the vehicle and carry out a 2H to 4H shift while driving GO to Pinpoint Test D .
approximately at 16 km/h (10 mph).
z Stop the vehicle, shift to 2H, drive the vehicle and carry out a 2H No
to 4H shift while driving at approximately 64 km/h (40 mph). GO to G4 .
z Does 4H engage correctly (or much better) at 16 km/h (10
mph) than at 64 km/h (40 mph)?
G4 CHECK THE TCCM AVERAGE FRONT WHEEL SPEED
(REAR_WHL_SPD) PIDs
— TCCM . GO to G5 .
z Monitor the FRT_WHL_SPD and REAR_WHL_SPD PIDs while
driving in a straight line. No
z Do the FRT_WHL_SPD and REAR_WHL_SPD PIDs match? REFER to Section 206-09
to diagnose the wheel
speed sensor concern.
G5 CHECK THE TRANSFER CASE SYNCHRONIZATION CLUTCH
LOCK-UP USING THE TCCM 4WD PWM CLUTCH STATUS
(4WD_CLTCH_OUT) PID
z Ignition ON. Yes
z Switch the MSS to 4H. GO to G6 .
z Active command the 4WD_CLTCH_OUT PID to 98%.
z With the vehicle in NEUTRAL, position it on a hoist. Refer to No
Section 100-02 . GO to G7 .
z Remove the transfer case shift motor from the transfer case,
leaving the electrical connector connected.
z Using a wrench, shift the transfer case shift cam to 2H.

z Rotate the rear driveshaft while observing the front driveshaft.
z Does the front driveshaft rotate when the rear driveshaft is
rotated?
RELEASE USING THE TCCM 4WD PWM CLUTCH STATUS
(4WD_CLTCH_OUT) PID
z Active command the 4WD_CLTCH_OUT PID to 0%. Yes
z Rotate the rear driveshaft while observing the front driveshaft. GO to G11 .
z Does the front driveshaft rotate when the rear driveshaft is
rotated? No
END the active command.
GO to G7 .
G7 CHECK FOR VOLTAGE TO THE TRANSFER CASE
SYNCHRONIZATION CLUTCH USING THE TCCM 4WD PWM
CLUTCH STATUS (4WD_CLTCH_OUT) PID
Yes
NOTICE: The following step uses a test light to simulate
normal circuit loads. Use only the test light recommended in
the Special Tools table at the beginning of this section. To INSTALL a new transfer
avoid connector terminal damage, use the Flex Probe Kit for case synchronization
the test light probe connection to the vehicle. Do not use the clutch. REFER to Section
test light probe directly on any connector. 308-07B . CLEAR the
z Ignition OFF. normal operation.
z Ignition ON. No
z Enter the following diagnostic mode on the scan tool: DataLogger GO to G8 .
— TCCM .
z Active command the 4WD_CLTCH_OUT PID at 98%.
z Connect a 12-volt incandescent test light between transfer case

C350-16, circuit CCF03 (GY/BN), harness side and the transfer
case housing.
z Does the test light illuminate?
G8 CHECK THE TRANSFER CASE CHASSIS GROUND USING THE
TCCM 4WD PWM CLUTCH STATUS (4WD_CLTCH_OUT) PID
NOTICE: The following step uses a test light to simulate Yes

normal circuit loads. Use only the test light recommended in END the active command.
the Special Tools table at the beginning of this section. To REPAIR the transfer case
avoid connector terminal damage, use the Flex Probe Kit for ground connection between
the transfer case and the
the test light probe connection to the vehicle. Do not use the
chassis. CLEAR the DTCs.
test light probe directly on any connector.
z Active command the 4WD_CLTCH_OUT PID at 98%. operation.
No
GO to G9 .
z Connect a 12-volt incandescent test light between transfer case

C350-16, circuit CCF03 (GY/BN), harness side and chassis
ground.
z Does the test light illuminate?
CONTROL CIRCUIT FOR AN OPEN
z Measure the resistance between transfer case C350-16, circuit Yes
CCF03 (GY/BN), harness side and TCCM C2371B-1, circuit GO to G10 .
CCF03 (GY/BN), harness side.
No
REPAIR circuit CCF03
(GY/BN). CLEAR the DTCs.
operation.

CONTROL CIRCUIT FOR A SHORT TO GROUND
z Ignition OFF. Yes
z Disconnect: TCCM C2371B . GO to G13 .
CCF03 (GY/BN), harness side and ground. REPAIR circuit CCF03
(GY/BN) for a short to
ground. CLEAR the DTCs.
operation.

CONTROL CIRCUIT FOR VOLTAGE USING THE TCCM 4WD PWM
CLUTCH STATUS (4WD_CLTCH_OUT) PID
z Ignition OFF. Yes

z Disconnect: Transfer Case . END the active command.
z Ignition ON. GO to G12 .
z Enter the following diagnostic mode on the scan tool: DataLogger
— TCCM . No
z Active command the 4WD_CLTCH_OUT PID 98%. END the active command.
case synchronization
clutch. REFER to Section
308-07B . CLEAR the
normal operation.
z Measure the voltage between transfer case C350-16, circuit

CCF03 (GY/BN), harness side and ground.
CIRCUIT FOR A SHORT TO VOLTAGE
z Ignition OFF. Yes
z Disconnect: Transfer Case . REPAIR circuit CCF03
z Disconnect: TCCM C2371B . (GY/BN). CLEAR the DTCs.
z Ignition ON. TEST the system for normal
z Measure the voltage between transfer case C350-16, circuit operation.
CCF03 (GY/BN), harness side and ground.
No
GO to G13 .

G13 CHECK TRANSFER CASE SYNCHRONIZATION CLUTCH
z Ignition OFF. Yes
z Measure the resistance between transfer case C350-16, GO to G14 .
component side and the transfer case housing.
z Is the resistance between 1-3 ohms? No
case synchronization
clutch. REFER to Transfer
Case Disassembly and
Assembly in Section 308-
07B . CLEAR the DTCs.
operation.
G14 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes

module pins) this section. TEST the
damaged or bent pins - install new terminals/pins system for normal
pushed-out pins - install new pins as necessary operation.
z Connect all TCCM connectors. Make sure they are seated
correctly. No
correctly at this time.
Concern may have been
corroded connector.
ADDRESS the root cause
of the connector or pin
issues.
Pinpoint Test H: Vehicle Pulsates or Shudders in a Straight Line (Straightline Driveline Wind-up)
Normal Operation
In order for the 4WD system to function correctly, tires and wheels must be the same size, be in good
condition and the front and rear axle ratios must match.

z Unmatched and wheel size
z Unmatched front and rear axle ratios
PINPOINT TEST H: VEHICLE PULSATES OR SHUDDERS IN A STRAIGHT LINE (STRAIGHTLINE

DRIVELINE WIND-UP)
personal injury.
NOTE: 4X4 high/low (4H/4L) is not intended for driving on hard/dry surfaces.

H1 VERIFY THE CONCERN
z Drive the vehicle and shift from 2H to 4H. Yes
There should be minimal wind-up in 4H mode GO to H2 .
during straight line maneuvers (wind-up in
turns is normal; 4X4 high/low is not intended No
for driving on hard/dry surfaces). RETURN the vehicle to the customer. ADVISE
z Is excessive wind-up present? about correct system operation and normal
vehicle behavior.
H2 CHECK FOR MATCHING WHEEL AND TIRE
SIZES
z Check the wheel and tire sizes. Yes
z Do the 4 wheel and tire sizes match? GO to H3 .
No
H3 CHECK TIRE WEAR
z Check each of the 4 tires for wear. Yes
z Are the 4 tires worn evenly? GO to H4 .
No
ADVISE the customer that Four-Wheel Drive
(4WD) systems require 4 matched, correctly
inflated, correctly maintained tires to operate
correctly.
H4 CHECK TIRE INFLATION PRESSURE
z Check the inflation pressure in each tire. Refer Yes
to VC label. GO to H5 .
z Are the tire inflation pressures correct?
No
ADJUST the tire pressure as necessary. TEST
the vehicle for normal operation. ADVISE the
customer that 4WD systems require 4
matched, correctly inflated, correctly
H5 CHECK THE FRONT AND REAR AXLE
RATIOS
z Check that front and rear axle ratios match. Yes
Refer to Section 205-00 . RETURN the vehicle to the customer and
z Do the front and rear axle ratios match? ADVISE about correct 4WD usage and normal
vehicle behavior.
No
CHECK the vehicle VC label. INSTALL the
correct axle(s). REFER to Section 205-00 .
Pinpoint Test I: Electronic Shift-On-The-Fly (ESOF) Functional Test
Section 308-07A .
Normal Operation
When operating in 4H or 4L mode, the transfer case and both IWEs are locked. When in 4L mode, the
transfer case low range gear set provides an additional 2.64 gear reduction. When operating in 2H mode,
the transfer case and both IWEs are unlocked.

z 4WD system and/or related components
PINPOINT TEST I: ESOF FUNCTIONAL TEST
personal injury.
NOTE: 4X4 high/low (4H/4L) is not intended for driving on hard/dry surfaces.

I1 CHECK FOR IPC DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the If DTC U0102:00 is retrieved, REFER to Section
scan tool: Self-Test — IPC . 418-00 to diagnose lost communication with
z Are any DTCs present? TCCM . For all other DTCs, REFER to Section
413-01 .
No
GO to I2 .
I2 CHECK 2H OPERATION
z Switch the MSS to 2H while monitoring the Yes
message center. GO to I5 .
z Does the message center display 4X2 for
approximately 4 seconds? No
GO to I3 .
I3 CHECK FOR TCCM DTCs
scan tool: Self-Test — TCCM . REFER to the TCCM DTC Chart in this section.
No
GO to I4 .
I4 CHECK FOR WIND-UP IN 2H
z Drive the vehicle on a dry, hard surface Yes
while executing turns. GO to Pinpoint Test B .
No
GO to I5 .
I5 CHECK 4H OPERATION
z Switch the MSS to 4H while monitoring the Yes
message center. GO to I8 .
z Does the message center display 4X4
HIGH? No
GO to I6 .
z Enter the following diagnostic mode on the REFER to the TCCM DTC Chart in this section.
GO to I7 .
while executing turns. Go to Pinpoint Test AB in Electronic Locking

z Is wind-up present in turns? Differential (ELD) System, Diagnosis and
Testing, Section 308-07A .
No
Go to Pinpoint Test AC in Electronic Locking
Differential (ELD) System, Diagnosis and
Testing, Section 308-07A .
I8 CHECK FOR STRAIGHT LINE 4H WIND-UP
z Drive the vehicle on a dry, hard surface. Yes
z Is straightline wind-up present? GO to Pinpoint Test H .
No
GO to I9 .
I9 CHECK 4H WIND-UP IN TURNS
z Drive the vehicle in 4H while turning. Yes
z Is wind-up present in turns? GO to I10 .
No
I10 CHECK 4L OPERATION
z Bring the vehicle to a stop with the Yes
transmission in NEUTRAL and switch the GO to I13 .
MSS to 4L.
z Does the 4X4 LOW indicator illuminate No
correctly? GO to I11 .
GO to I12 .
I12 CHECK FOR WIND-UP IN 4L
while executing turns. GO to Pinpoint Test A .
No
GO to Pinpoint Test C .
I13 CHECK FOR 4L WIND-UP IN TURNS
while executing turns. GO to I14 .
z Is wind-up present and 4L functioning?
No
CHECK for TCCM DTCs. REFER to the TCCM
DTC Chart in this section. If no DTCs are
present, GO to Pinpoint Test C .
I14 CHECK 4L TO 2H SHIFT
z With the vehicle at a stop and transmission Yes
in NEUTRAL, switch the MSS from 4L to 2H. GO to I17 .
z Does the message center display 4X2 for
approximately 4 seconds? No
GO to I15 .

GO to I16 .
z Drive the vehicle on a dry, hard surface GO to Pinpoint Test C .
while executing turns.
z Is wind-up present in turns? No
I17 CHECK FOR TRANSFER CASE
DISENGAGEMENT
z With the vehicle in NEUTRAL, position it on Yes
a hoist. Refer to Section 100-02 . REFER to Section 308-07B .
z Rotate the rear driveshaft while observing
the front driveshaft. No
z Does the front driveshaft rotate? GO to I18 .
I18 CHECK FOR LH AND RH IWE
DISENGAGEMENT
NOTE: The engine must be idling during the Yes

following steps to supply the vacuum GO to Pinpoint Test D .
required for the IWEs to engage and
No
disengage.
GO to I19 .
z Start the engine.
z Rotate the LH front tire one revolution
forward and one revolution backward while
observing the LH front halfshaft and U-joint.
z Rotate the RH front tire one revolution
forward and one revolution backward while
observing the RH front halfshaft and U-joint.
z Does the LH or RH front halfshaft rotate?
I19 CHECK FOR IWE VACUUM LEAKS
z Ignition OFF. Yes
z Disconnect both vacuum lines from the IWE CHECK the IWE and related components for
solenoid. leaks. GO to Pinpoint Test D .
z Using a vacuum pump, apply 508 mm (20
in) Hg of vacuum to the IWE apply vacuum No
circuit. GO to I20 .
z Did the vacuum drop more than 25 mm (1
in) Hg per minute?
I20 CHECK 2H TO 4H SHIFT AT SPEED ABOVE
32 KM/H (20 MPH)
z Drive the vehicle on the road and shift from The 4WD system is functioning correctly.
2H to 4H while driving above 32 km/h (20
mph). No
z Does the transfer case shift to 4H GO to Pinpoint Test G .
satisfactorily?
Pinpoint Test J: Off-Road Mode Switch Indicator Is Inoperative
Normal Operation
When the off-road switch is depressed, a signal is sent to the TCCM which alerts other modules along the
HS-CAN that off-road mode is being requested. Other vehicle functions change to accommodate off-road
mode and an indicator illuminates on the off-road mode switch confirming off-road mode.
z DTC B12E0:11 (Off Road Indicator: Circuit Short to Ground) — When in off-road mode, the TCCM
senses the indicator circuit has low voltage and is always illuminated.
z DTC B12E0:12 (Off Road Indicator: Circuit Short to Battery) — When in off-road mode, the TCCM
senses the indicator circuit has high voltage and never illuminates.
z DTC B12E0:13 (Off Road Indicator: Circuit Open) — When in off-road mode, the TCCM senses the
indicator lamp circuit is open and never illuminates.

z TCCM
PINPOINT TEST J: OFF-ROAD MODE SWITCH INDICATOR IS INOPERATIVE

J1 CHECK FOR TCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: For DTC B12E0:11, GO to J3 .
Self-Test — TCCM .
z Are any DTCs present? For DTC B12E0:12, GO to J2 .
For DTC B12E0:13, GO to J4

No
IDENTIFY the customer concern and
GO to Symptom Chart - Four-Wheel
Drive (4WD) System in this section.
J2 CHECK THE OFF-ROAD MODE INDICATOR CIRCUIT
z Ignition OFF. Yes
z Disconnect: TCCM C2371A . REPAIR circuit CCF01 (BN). CLEAR
z Disconnect: Off-Road Mode Switch . the DTCs. TEST the system for
z Ignition ON. normal operation.
z Measure the voltage between TCCM C2371A-8, circuit
CCF01 (BN), harness side and ground. No
GO to J3 .

z Ignition OFF. Yes
z Disconnect: TCCM C2371A . GO to J4 .
z Disconnect: Off-Road Mode Switch .
circuit CCF01 (BN), harness side and ground. REPAIR circuit CCF01 (BN). CLEAR
the DTCs. TEST the system for
normal operation.

FOR AN OPEN
z Ignition OFF. Yes
z Disconnect: TCCM C2371A . GO to J5 .
circuit CCF01 (BN), harness side and off-road mode REPAIR circuit CCF01 (BN). CLEAR
switch C3393-4, circuit CCF01 (BN), harness side. the DTCs. TEST the system for
normal operation.

J5 CHECK THE TCCM OFF-ROAD INPUT SWITCH
STATUS (OFF_RD_SW) PID
z Connect: Off-Road Mode Switch . GO to J6 .

z Ignition ON.
DataLogger — TCCM . INSTALL a new off-road mode switch.
z Monitor the OFF_RD_SW PID. REFER to the Console — Floor
z Does the OFF_RD_SW PID status indicate Not exploded view in Section 501-12 .
Pressed? PRESS the tab on each side of the
switch to remove it from the bezel.
J6 CHECK THE TCCM OFF-ROAD STATUS
(OFF_RD_STAT) PID
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: GO to J7 .
DataLogger — TCCM .
z Press the off-road mode switch button. No
z Monitor the OFF_RD_STAT PID. INSTALL a new off-road mode switch.
z Does the PID status indicate Off-Road Mode? REFER to the Console — Floor
exploded view in Section 501-12 .
PRESS the tab on each side of the
switch to remove it from the bezel.
J7 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
z Connect all TCCM connectors. Make sure they are The system is operating correctly at
seated correctly. this time. Concern may have been
present. connector. ADDRESS the root cause
z Is the concern still present? of the connector or pin issues.
Pinpoint Test K: Off-Road Mode Is Inoperative
Normal Operation
When the off-road switch is depressed, a signal is sent to the TCCM which alerts other modules along the
HS-CAN that off-road mode is being requested. Other vehicle functions change to accommodate off-road
mode and an indicator illuminates on the off-road mode switch confirming off-road mode.
z DTC B12E5:00 (Off Road Mode Select Switch: No Sub Type Information) — When in off-road mode,
the TCCM C2371A-12 senses if the switch is pressed for more than 30 seconds or if a short to
ground on the switch circuit has occurred.
z DTC B12E5:11 (Off Road Mode Select Switch: Circuit Short To Ground) — The TCCM C2371A-12
senses a short to ground on the switch control circuit.

z TCCM
PINPOINT TEST K: OFF-ROAD MODE IS INOPERATIVE

K1 CHECK FOR TCCM DTCs
z Ignition ON. Yes
z Enter the following diagnostic mode on the scan tool: If DTCs B12E5:00 or B12E5:11 are
Self-Test — TCCM . retrieved, GO to K2 .
No
IDENTIFY the customer concern and
GO to Symptom Chart - Four-Wheel
Drive (4WD) System in this section.
K2 CHECK THE OFF-ROAD MODE SWITCH CIRCUIT FOR
A SHORT TO GROUND
z Ignition OFF. Yes
z Disconnect: TCCM C2371A . GO to K3 .
circuit CCF11 (YE/VT), harness side and ground. REPAIR circuit CCF11 (YE/VT).

K3 CHECK THE OFF-ROAD MODE SWITCH CIRCUIT FOR
AN OPEN
z Measure the resistance between TCCM C2371A-12, Yes
circuit CCF11 (YE/VT), harness side and off-road mode GO to K4 .
switch C3393-1, circuit CCF11 (YE/VT), harness side.
No
REPAIR circuit CCF11 (YE/VT).

K4 CHECK THE OFF-ROAD MODE SWITCH
z Measure the resistance between off-road mode switch Yes
C3393-6, circuit CCF11, component side and off-road GO to K5 .
mode switch C3393-1, circuit CCF11, component side.
No
INSTALL a new off-road mode
switch. REFER to the Console —
Floor exploded view in Section 501-
12 . PRESS the tab on each side of
the switch to remove it from the
bezel. CLEAR the DTCs. TEST the

K5 CHECK FOR CORRECT TCCM OPERATION
z Ignition OFF. Yes
z Connect all TCCM connectors. Make sure they are The system is operating correctly at
seated correctly. this time. Concern may have been
present. connector. ADDRESS the root cause
z Is the concern still present? of the connector or pin issues.
Integrated Wheel End (IWE)

1 1131 Dust cap
2 N802827-S Axle nut
3 W520215-S Upper ball joint nut
4 3C247 Integrated Wheel End (IWE)
5 — Vacuum vent and supply tube
6 W710279-S IWE bolts (3 required)
7 W520215-S Tie-rod nut
Removal
2. Remove the front wheel and tire. Refer to Section 204-04 .
3. Remove the dust cap.
4. Remove and discard the axle nut.
5. Disconnect the vacuum tubes from the Integrated Wheel End (IWE).
6. Remove the 3 IWE -to-wheel knuckle retaining bolts.
7. Remove the tie-rod nut and separate the tie rod from the wheel knuckle.
z Discard the tie-rod nut.
8. Remove the wheel speed sensor harness bracket bolt and position the harness aside.
9. Remove the front brake flexible hose bracket bolt and position the brake hose aside.
10. Remove the upper ball joint nut and separate the upper ball joint from the wheel knuckle.
z Discard the upper ball joint nut.
11. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward.
Once clearance is available, remove the halfshaft outboard end from the wheel knuckle hub bearing.
12. Remove the IWE from the halfshaft outboard end.
Installation
1. Compress the IWE and install a vacuum cap on the vacuum port.
2. NOTICE: Do not dislodge the Integrated Wheel End (IWE) seal spring when installing the IWE
on halfshaft outboard end or component damage may occur.
Install the IWE onto the halfshaft outboard end.
3. NOTE: Allow the wheel knuckle to swing outward while keeping the halfshaft pushed inward.
Once clearance is available, install the halfshaft outboard end into the wheel knuckle hub bearing.
4. Connect the upper ball joint and install a new nut.

5. Connect the tie rod and install a new nut.

6. Position the front brake flexible hose bracket and install the bolt.
7. Position the wheel speed sensor harness bracket and install the bolt.
8. Install the 3 IWE -to-wheel knuckle retaining bolts.

9. Remove the IWE vacuum cap and connect the vacuum tubes.
10. NOTICE: Measure the depth of the CV Shaft threaded end to the inner bearing race (shown in
illustration). The minimum depth is 15.5 mm (0.61 in). If the depth is less than 15.5 mm (0.61 in)
rotate the CV shaft to clear a binding condition between the IWE and CV splines. Installing the
axle nut and tightening without the proper depth of protrusion will result in damage to the
IWE .
Install the new axle nut.

12. Install the dust cap.
13. Install the front wheel and tire. Refer to Section 204-04 .
Mode Select Switch (MSS)

1 14B166 Mode Select Switch (MSS)
2 — MSS electrical connector (part of 14401)
1. Carefully pry the Mode Select Switch (MSS) from the instrument panel.
2. Disconnect the MSS harness connector and remove the switch.
Transfer Case Control Module (TCCM)

1 W706287 Screw (2 required)
2 7E453 Transfer Case Control Module (TCCM)
3 — TCCM electrical connectors (part of 12A581)
4 023A98 Central Junction Box (CJB) cover
1. Remove the Central Junction Box (CJB) cover to gain access to the Transfer Case Control Module
(TCCM).
NOTE: The TCCM has slotted mounting holes. It is not necessary to remove the LH TCCM screw when
removing the TCCM .
2. Loosen the LH TCCM screw and remove the RH TCCM screw.

3. Disconnect the 2 electrical connectors.
4. Remove the TCCM .
Transfer Case Shift Motor
Material
Item Specification
Ultra Silicone Sealant —
TA-29
Part
1 — Coil wire (part of 7G361)
2 7G360 Transfer case shift motor
3 N800670-S Transfer case shift motor bolt (3 required)
4 15525 Connector
5 — Connector inner retainer (part of 15525)
6 — Transfer case shift motor nut (part of 7G360) (2
required)
7 7A443 Transfer case shift motor bolt
Removal
02 .
2. Disconnect the harness connector.
3. Remove the coil wire pin from the electrical connector.

1. Remove the inner retainer from the wire connector.
2. Press the release tab and remove the coil wire pin.
4. Remove the transfer case shift motor bracket bolt and the 3 mounting bolts, then remove the transfer
case shift motor.
Installation
1. Apply a small bead of silicone sealant to the transfer case shift motor mating surface.
NOTICE: New shift motor bracket nuts are loose and are tightened last. Failure to follow the steps in
the correct order may result in damage to the component.
2. Install the transfer case shift motor and the 3 bolts.

3. Install the transfer case shift motor bracket bolt.

4. Secure the transfer case shift motor bracket nuts.

5. NOTE: After the wire is inserted into the connector, gently pull the wire back to verify the pin is locked
inside the connector.
Insert the coil wire pin in the electrical connector and install the inner connector retainer.
SECTION 308-07B: Transfer Case 2014 F-150 Workshop Manual

Material
Capacity
Motorcraft® MERCON® LV MERCON® LV 1.4L (2.9
Automatic Transmission Fluid pt) a
XT-10-QLVC
Motorcraft® Transfer Case Fluid ESP-M2C166- 1.4L (2.9
XL-12 H pt) b
Thread Sealant with PTFE WSK-M2G350- —
TA-24 A2
Ultra Silicone Sealant — —
TA-29
a
2-speed torque-on-demand
b Electronic Shift-On-The-Fly (ESOF)
Crossmember bolts 90 66 —
Drain plug 15 — 133
Exhaust support bracket bolt 35 26 —
Fill plug 15 — 133
Mode Indication Switch (MIS) 41 30 —
Shift motor bolts 10 — 89
Shift motor nuts 3 — 27
Transfer case bolts a — — —
Transfer case field coil nuts 10 — 89
Transfer case-to-transmission bolts a — — —
Transmission mount bolts 90 66 —
Transmission mount nuts 103 76 —
a

Transfer Case
Electronic Shift-On-The-Fly (ESOF) System
The ESOF transfer case system consists of the following components:
z Mode Select Switch (MSS), located on the instrument panel

z Transfer Case Control Module (TCCM)
The Borg-Warner 4419 electronic shift transfer case is a 2-piece magnesium design. The unit transfers
engine power from the transmission to the front and rear axles. Vehicles equipped with an ESOF system
allow the operator to choose between 2-Wheel Drive (2WD) (2H) and 2 different 4WD modes. The transfer
case is shifted electronically based on the MSS position. Under normal driving conditions, the transfer case
is in 2WD (2H), but when desired, the operator may shift into 4WD high (4H) or 4WD low (4L). The operator
can shift between 2WD (2H) and 4WD high (4H) at any speed. When shifting into or out of 4WD low (4L)
range, the TCCM requires that the vehicle speed is less than 5 km/h (3 mph) and the transmission in
NEUTRAL.
The transfer case is equipped with an electronically controlled high torque capacity clutch which is located
inside the case. This clutch is used to synchronize the speed of the front driveline with the rear driveline
during 2WD (2H) to 4WD high (4H) shifts. The transfer case is lubricated by a positive displacement fluid
pump that channels fluid flow through holes in the rear output shaft.
2-Speed Torque-On-Demand
The 2-speed torque-on-demand transfer case system consists of the following components:
z MSS , located on the instrument panel

z TCCM
The Borg-Warner 2-speed torque-on-demand transfer case is a 2-piece magnesium design. The transfer
case transfers engine power from the transmission to the front and rear axles. Vehicles equipped with the 2-
speed torque-on-demand system allow the operator to choose between 2WD and 3 different 4WD modes.
The transfer case is shifted electronically based on the MSS position. Under normal driving conditions, the
unit is in 2WD (2H), but when desired, the operator may shift into 4WD high (4H), 4WD low (4L) or 4WD
AUTO (4A). When shifting into or out of 4WD (4L) range, the TCCM requires that the vehicle speed is less
than 5 km/h (3 mph) and the transmission is in NEUTRAL.
The transfer case is equipped with an electronically controlled high torque capacity clutch which is located
inside the case. This clutch is used to synchronize the speed of the front driveline with the rear driveline
during 2WD (2H) to 4WD high (4H) or 4WD AUTO (4A) shifts. The clutch also provides torque to the front
driveline in all 4WD modes. The transfer case is lubricated by a positive displacement fluid pump that
channels fluid flow through holes in the rear output shaft.

Transfer Case Draining and Filling
Special Tool(s)
Oil Suction Gun
303-D104 (D94T-9000-A)
Material
Item Specification
Motorcraft® MERCON® LV MERCON® LV
Automatic Transmission Fluid
(Canada)
Motorcraft® Transfer Case Fluid ESP-M2C166-
XL-12 H
Thread Sealant with PTFE WSK-M2G350-
TA-24 A2

1 7A110 Drain plug
2 7A110 Fill plug
02 .
2. Remove the drain plug and drain the fluid.
3. Clean the drain plug and the drain plug area. Apply thread sealant to the drain plug threads and
install the drain plug.
4. NOTE: Prior to removal, clean the area around the fill plug.
Remove the fill plug.
5. NOTICE: In the Electronic Shift-On-The-Fly (ESOF) transfer case use Motorcraft® Transfer
Case Fluid and in the 2-speed torque-on-demand transfer case use Motorcraft® MERCON® LV
Automatic Transmission Fluid. Incorrect fluid fill will result in transfer case failure.
Using the Oil Suction Gun, fill the transfer case with the recommended fluid, to specification.
z Transfer case capacity is 1.4L (2.9 pt).
z The fluid must be 10 mm (0.393 in) below the fill plug hole.
6. Apply thread sealant to the fill plug threads and install the fill plug.

Transfer Case Rear Output Shaft Seal
Special Tool(s)
Installer, Input Shaft Oil Seal
308-249 (T96T-7127-A)

1 4602 Driveshaft
2 7B215 Rear output shaft seal
3 7A195 Transfer case
Removal
02 .
2. Remove the rear driveshaft. For additional information, refer to Section 205-01 .
3. Using a suitable seal puller, remove the rear output shaft seal.
Installation
1. Using the Input Shaft Oil Seal Installer, install the rear output shaft seal.
2. Install the rear driveshaft. For additional information, refer to Section 205-01 .

Transfer Case
Material
Item Specification
Thread Sealant with PTFE WSK-M2G350-A2
TA-24
Transfer Case — Left Side

1 637077 Transmission support crossmember bolt (4 required)
2 W707959-S Heat shield bolt (2 required)
3 9740124 Transmission support crossmember
4 N621945-S Transmission mount nut (2 required)
5 7E063 Skid plate
6 W503932-S Skid plate-to-frame bolt (4 required)
Transfer Case — Right Side

1 7A443 Transfer case-to-transmission bolt (9 required)
3 7D494 Vent tube
4 W713728-S Transmission mount bolt (4 required)
5 6D091 Transmission mount
6 W709341-S Exhaust support bracket bolt
7 14489 Shift motor electrical connector — ESOF
2. If equipped, remove the 4 skid plate bolts and remove the skid plate.
3. Drain the fluid if the transfer case is to be disassembled.

z Apply thread sealant to the drain plug threads and install the drain plug when finished draining.
Tighten to 15 Nm (133 lb-in).
5. Remove the rear driveshaft. Refer to Section 205-01 .
6. Disconnect the shift motor electrical connector and detach the 2 harness retainer clips from the
transfer case.
7. Disconnect the vent hose from the transfer case.
8. Remove the RH exhaust heat shield bolt from the transmission support crossmember.
9. Remove the LH exhaust heat shield bolt from the transmission support crossmember.
10. Support the front of the transmission.
11. Remove and discard the 4 transmission support crossmember nuts and bolts.
12. Remove the 2 transmission mount nuts and the transmission support crossmember.
13. Remove the bolt from the LH exhaust support bracket.
14. Remove the 4 transmission mount bolts and the transmission mount.
15. Using a transmission jack, position it to the transfer case. Secure the transfer case to the jack with a
safety strap.
16. Remove and discard the 9 transfer case-to-transmission bolts.
17. Separate the transfer case from the transmission and move the transfer case rearward 25.4 mm (1
in). Move the transfer case rearward off the output shaft and lower it from the vehicle.

Transfer Case
Transfer Case — Left Side

1 637077 Transmission support crossmember bolt (4 required)
2 W707959-S Heat shield bolt (2 required)
3 9740124 Transmission support crossmember
4 N621945-S Transmission mount nut (2 required)

5 7E063 Skid plate
6 W503932-S Skid plate bolt (4 required)
Transfer Case — Right Side

1 7A443 Transfer case-to-transmission bolt (9 required)
3 7D494 Vent tube
4 W713728-S Transmission mount bolt (4 required)

5 6D091 Transmission mount
6 W709341-S Exhaust support bracket bolt
7 14489 Shift motor electrical connector
1. Position the transfer case to the transmission and onto the output shaft. With the transfer case 25.4
mm (1 in) from the transmission, push the transfer case to the transmission.
2. NOTE: Do not reuse the old transfer case-to-transmission bolts.
Install 9 new transfer case-to-transmission bolts.

z Tighten the bolts evenly in a cross pattern to 17 Nm (150 lb-in).
3. Install the transmission mount and the 4 transmission mount bolts.

4. Install the LH exhaust support bracket and bolt.

5. Position the transmission support crossmember and the 2 transmission mount nuts.
z Do not tighten at this time.
6. Install the 4 new transmission support crossmember bolts and nuts, then tighten the transmission
support crossmember and transmission mount nuts.
1. Install the transmission support crossmember bolts.
Remove the transmission jack from under the transmission pan rail.
2. Install the transmission support crossmember nuts and tighten to 90 Nm (66 lb-ft).
3. Tighten the transmission mount nuts to 103 Nm (76 lb-ft).
7. Install the LH exhaust heat shield bolt to the transmission support crossmember.
8. Install the RH exhaust heat shield bolt to the transmission support crossmember.
9. Connect the vent hose to the transfer case.
10. Connect the shift motor electrical connector and attach the 2 harness retainer clips to the transfer
case.
11. NOTE: Align the index marks made during removal.
Install the rear driveshaft. Refer to Section 205-01 .
12. NOTE: Align the index marks made during removal.
Install the front driveshaft. Refer to Section 205-01 .
13. Fill the transfer case. Refer to Transfer Case Draining and Filling .
14. If equipped, position the skid plate and install the 4 skid plate bolts.

Transfer Case — 2-Speed Torque-On-Demand
Special Tool(s)
Handle
205-D055 (D81L-4000-A) or
equivalent

307-003 (T57L-500-B)
Installer, Front Axle Oil Seal

205-350 (T95T-3010-A)
Installer, Input Shaft Bearing

308-085 (T83T-7025-C)

308-186 (T90T-7127-B)

308-249 (T96T-7127-A)
Installer, Mainshaft Bearing

308-060 (T77J-7025-K)
Installer, Output Shaft Front

Bearing
308-410

303-367 (T90P-6510-AH)

308-047 (T77F-1102-A)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
XT-10-QLVC
TA-29
2-Speed Transfer Case — Rear Half

1 7917 Snap ring
2 7N063 Spacer
3 7D221 Caged thrust bearing

4 7G362 Hub and coil housing
5 7A534 Ball (3 required)
6 7R428 Cam
7 7D126 Wave spring
8 7917 Snap ring
9 7C108 Clutch assembly
10 7177 Drive sprocket
11 7D221 Caged thrust bearing
12 7C341 Thrust washer (2 required)
13 7A149 Oil pump assembly
14 7H298 Hose clamp
15 4090 Oil pump pickup hose
16 7A098 Oil pickup and filter
17 7G361 Transfer case field coil
18 7025 Rear output shaft support bearing
19 7025 Front output shaft rear bearing
20 7005 Case
21 — Output shaft bushing (part of 7005)
22 7A443 Transfer case bolts (20 required)
23 7A010 Fill plug
24 7045 Coil nut (3 required)
25 N800670-S Shift motor bolt (3 required)
26 7A443C Shift motor bracket bolt
28 7H298 Inner connector retainer
29 7B215 Shift motor seal
30 7B368 Washer (3 required)
31 7H150 Armature
2-Speed Transfer Case — Front Half

31 7A153 Ring gear
32 7064 Snap ring
33 7A398 Front planet carrier

34 7D221 Front planet needle bearing
35 7D164 Reduction hub
36 7061 Output shaft
37 7389 Shift fork
38 7C430 Shift fork pad (2 required)
39 7240 Shift fork shaft
40 7F063 Shift cam assembly
41 7A029 Drive chain
42 7177 Driven sprocket
43 7917 Snap ring
44 7025 Front output shaft support bearing
45 7E290 Magnet
46 7005 Case
47 7B362 Dowel
48 7025 Front input shaft support bearing
49 7B215 Front output shaft oil seal
50 7061 Front output shaft
51 7034 Vent tube
52 7B215 Front input shaft seal
53 7N063 Driven sprocket spacer
Disassembly
1. NOTICE: Seal all openings before cleaning the transfer case exterior. This will prevent entry of
dirt and water, which may cause damage to internal components.
Clean the transfer case exterior with solvent and dry with compressed air.
2. Using the Transmission Holding Fixture, secure the transfer case to a work bench. Rotate the transfer
case so that the output shaft is pointing upward.
3. Remove and discard the rear output shaft seal.
4. Remove the coil wire pin from the electrical connector.

z Remove the wire connector inner retainer.
z Press the release tab and remove the coil wire pin (tan wire).
5. Loosen the 2 transfer case shift motor bracket nuts and remove the bracket bolt.
6. Remove the 3 transfer case shift motor bolts and transfer case shift motor.
7. Remove the 3 coil nuts and washers.
8. NOTE: It is normal to find metal shavings after removing the self-tapping transfer case bolts.
Remove the 20 transfer case cover bolts.
9. Using the pry bosses, separate the transfer case halves.
10. Using the Bearing Cup Remover and the Slide Hammer, remove the rear output shaft support
bearing.
z Inspect the bearing for wear or damage. Install a new bearing as necessary.
11. Using the Bearing Cup Remover and the Slide Hammer, remove the front output shaft rear bearing.

z Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
13. Remove the caged thrust bearing assembly.

14. Remove the cam/coil housing.
15. Remove the steel balls and the cam.
16. Remove the wave spring.
17. Remove and discard the snap ring.
18. NOTICE: When removing the clutch pack assembly, do not separate the clutch pack assembly.
Keep tension on the clutch pack during removal. Set the clutch pack assembly on the bench in
the same position as located in the transfer case. The thrust washer in the lower clutch pack
uses tabs to hold it in place. If the thrust washer is not in place, a transfer case clearance
problem will occur.
NOTICE: If the clutch pack is disassembled, a new clutch pack must be installed and the
armature transferred. Failure to install a new clutch pack can result in component failure.
Remove the clutch pack assembly with the armature.
19. Remove the drive chain and the sprockets as an assembly.

z Inspect the drive chain for wear or damage. Inspect the sprockets for broken or cracked teeth.
Install new components as necessary.
20. Remove the thrust bearing assembly.

1. Remove the thrust washer.
The upper thrust washer may be attached to the sprocket.
2. Remove the thrust bearing.
3. Remove the thrust washer.
z Inspect the washers and bearing for wear or damage. Install new components as necessary.
21. Remove and clean the oil pan magnet.
22. Remove the output shaft sprocket.
23. Remove the oil pump assembly.
24. Remove the output shaft.
25. Remove the reduction shift fork, the reduction hub and the shift cam as an assembly.
z Separate and inspect the reduction hub and the reduction shift fork for wear or damage. Do not
disassemble the shift cam assembly.
26. Remove the shift fork shaft.
27. Remove the front planet.

z Remove the front planet needle bearing, if necessary.
28. Remove the ring gear.

Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
29. Remove the driven sprocket spacer.
30. NOTE: Do not let the front output shaft fall when removing the snap ring.
Remove the snap ring and the front output shaft.

z Inspect the snap ring for wear or damage. Install a new snap ring as necessary.
31. NOTICE: Carefully remove the seal, do not damage the seal bore.
Remove and discard the front output shaft oil seal.
32. NOTICE: Carefully remove the seal, do not damage the seal bore.
Remove and discard the front input shaft seal.
33. Remove the front planet support bearing.
34. Remove the front output shaft support bearing.

35. Remove and discard the shift shaft seal.
Assembly
1. Lubricate all internal components with the recommended transfer case lubricant during reassembly.
2. Clean the mating surfaces of the cases.
3. Using a press and the Output Shaft Front Bearing Installer with the Handle, install the front planet
support bearing.
4. Using a press and the Front Axle Oil Seal Installer with the Handle, install the front output shaft
support bearing.
5. Using the Input Shaft Oil Seal Installer, install a new front output shaft seal.
6. Using the Valve Stem Oil Seal Installer, install a new shift shaft seal.
7. Install the case to the Transmission Holding Fixture. Secure the case and the Transmission Holding
Fixture to the work bench.
8. Using Input Shaft Oil Seal Installer, install a new front input shaft seal.
9. Install the ring gear.

1. Position the ring gear in the case.
10. Install the front output shaft and the snap ring.
11. Install the driven sprocket spacer.
12. NOTICE: If removed, using a press and the Input Shaft Bearing Installer, install the needle
bearing into the front planet. Be careful not to damage the bearing cage.
Install the front planet.
13. Install the shift fork shaft.
14. Assemble the reduction hub and the reduction shift fork. Install the reduction shift fork, the reduction
hub and the shift cam as an assembly.
15. Install the output shaft.
16. NOTE: Make sure the oil pump finger is in the slot in the case.
Install the oil pump assembly.
17. Install the oil pan magnet into the slot in the case.
18. Install the 3-piece thrust bearing assembly.

1. Install the thrust washer.
2. Install the thrust bearing.
3. Install the thrust washer.
19. Install the drive chain and the sprockets as an assembly.
20. NOTICE: When installing the clutch assembly, do not separate the clutch pack assembly. The
thrust washer in the lower clutch pack uses tabs to hold it in place. If the thrust washer is not
in place, a transfer case clearance problem will occur.
NOTICE: If the clutch pack is disassembled, a new clutch pack must be installed and the
armature transferred. Failure to install a new clutch pack can result in component failure.
Install the clutch pack assembly with the armature.
21. Install a new snap ring.
22. Install the wave spring.
23. Install the cam and the steel balls.
24. Install the cam/coil housing.
25. Install the thrust bearing assembly.
27. Using a press and the Mainshaft Bearing Installer, install the rear output shaft support bearing.
28. Using a press and the Mainshaft Bearing Installer, install the front output shaft rear bearing.
29. NOTE: Only apply enough silicone sealant to seal the transfer case halves together.
Apply a bead of silicone sealant to the transfer case mating surface, then position the 2 transfer case
halves together. Tighten the 20 transfer case bolts evenly in a star pattern.
z Position the coil studs through the case holes, making sure the shift cam shaft is aligned with
its case bore and the lockup shift fork spring is in position.
30. Install the 3 coil washers and nuts.

NOTICE: When installing the shift motor, tighten the bracket nuts last. Failure to follow the steps in
the correct order may result in damage to the component.

35. Secure the transfer case shift motor bracket nuts.
36. NOTE: After the wire is inserted into the connector, gently pull the wire back to verify the pin is locked
inside the connector.
37. Secure the transfer case to a transmission jack and remove the transfer case from the Transmission
Holding Fixture.

Transfer Case — Electronic Shift
Special Tool(s)
Handle
205-153 (T80T-4000-W)

307-003 (T57L-500-B)
Installer, Bearing Cup

308-017 (T73T-4222-B)
Installer, Input Shaft Bearing

308-085 (T83T-7025-C)

308-186 (T90T-7127-B)

308-249 (T96T-7127-A)
Installer, Mainshaft Bearing

308-060 (T77J-7025-K)

308-047 (T77F-1102-A)
Remover, Stator Bearing

307-318 (T94P-77001-KH)
Slide Hammer
100-001 (T50T-100-A)
Material
Item Specification
TA-29
Transfer Case Exploded View — Electronic Shift

1 7D164 Lockup hub
2 7D126 Spring
3 7106 Lockup collar

4 7177 Drive sprocket
5 7Z112 Thrust washer
6 7A149 Oil pump assembly
7 7061 Output shaft
8 7100 Reduction hub
9 — Hose clamp
10 9324 Hose
11 7A098 Lube pickup and filter
12 7D221 Thrust bearing
13 7120 Needle bearing
14 7A398 Front planet carrier
15 7064 Snap ring
16 7A153 Ring gear
17 7025 Bearing
18 7005 Case
19 7B215 Input flange seal
20 7034 Vent tube
21 7061 Front output shaft
22 7B215 Front output shaft seal
23 — Dowel (part of 7005)
24 7E290 Magnet
25 7025 Bearing
26 7917 Snap ring
27 7177 Driven sprocket
28 7A029 Drive chain assembly
29 7N063 Driven sprocket spacer

30 7F135 Spring
31 7C430 Shift fork pads
32 7H150 Armature
33 7289 Reduction shift fork assembly
34 7917 Snap ring
35 7G362 Hub and coil housing
36 7917 Snap ring
37 7289 Lockup fork
38 7G361 Transfer case field coil
39 7025 Bearing
40 7005 Case
41 7A443 Bolt
42 N62048C-S2 Nut
44 7A010 Case plug
45 — Bushing (part of 7005)
46 — Sealing ring (part of 7005)
47 7B215 Rear output shaft seal
48 7F293 Shipping plug
49 N800670-S Bolt
50 — Wire connector spacer (part of 7G360)
51 7A443 Bolt
52 — Bar code label (part of 7005)
53 7A010 Case plug
54 7025 Bearing
55 7219 Lockup fork spring
56 7240 Shift rail
57 7F063 Shift cam assembly
58 7B368 Coil nut washer
Disassembly
NOTE: Discard all seals after removing them.
1. Clean the transfer case with solvent and dry with compressed air.
2. Using the Transmission Holding Fixture, secure the transfer case to the bench.
3. Remove the rear output shaft seal.
4. Remove the inner connector retainer. Press the release tab and remove the coil wire from the electric
shift motor electrical connector.
5. Remove the 3 transfer case shift motor bolts, bracket bolt and loosen the 2 bracket nuts.
6. NOTE: The transfer case bolts are self tapping, and it is normal to find metal shavings while removing
the cover.
Remove the 20 transfer case bolts.
7. Using the pry bosses, separate the transfer case covers.
8. Remove the 3 transfer case field coil nuts, washers and transfer case field coil.
9. Using the Bearing Cup Remover with the Slide Hammer, remove the rear output shaft bearing.
10. Using the Bearing Cup Remover with the Slide Hammer, remove the front output shaft bearing.
11. Remove the shift collar hub snap ring.
12. Remove the coil housing.
13. Remove the shift fork.

1. Remove the lockup hub.
2. Remove the shift fork and spring.
14. NOTE: Remove the lockup hub assembly as a single unit. If disassembly is required, proceed with
the following.
Disassemble the lockup hub assembly.

1. Remove the lockup hub snap ring.
2. Separate the lockup collar.
3. Separate the 2 lockup springs.
4. Separate the lockup hub.
5. Remove the armature.
15. NOTE: Remove the drive chain and sprockets as an assembly.
Remove the drive chain, sprockets and the thrust washer.
16. Remove the magnet from its slot in the case.
17. NOTE: The pump assembly is not repairable.
Remove the oil pump and the output shaft as an assembly. Remove the oil pump from the output
shaft.
18. Remove the shift rail.
19. Remove the shift fork and the reduction hub.

1. Remove the shift fork.
2. Remove the reduction hub.
20. NOTE: The electric shift cam is serviced as an assembly. Do not disassemble the shift cam
assembly.
Remove the electric shift cam assembly.
21. Remove the front planet carrier.
22. Remove and discard the front input shaft seal.
23. Remove the thrust bearing.

z Remove the needle bearing, if necessary.

1. Remove the ring gear snap ring.
25. Using the Stator Bearing Remover with the Slide Hammer, remove the front planet carrier bearing.
26. Remove the driven sprocket spacer.
27. NOTICE: Do not let the front output shaft fall while removing the snap ring or damage to the
component may occur.
Remove the front output shaft.

1. Remove the front output shaft snap ring.
2. Remove the front output shaft.
28. Using the Stator Bearing Remover with the Slide Hammer, remove the front output shaft bearing.
29. Using the Bearing Cup Remover with the Slide Hammer, remove the front output shaft seal.
Assembly
1. Using a press and the Bearing Cup Installer with the Handle, install the front output shaft bearing.
2. Using the Input Shaft Oil Seal Installer, install the front output shaft seal.
3. Install the front output shaft.

1. Position the front output shaft.
2. Install the front output shaft snap ring.
4. Install the driven sprocket spacer.
5. Install the front planet carrier bearing.
6. Using the Input Shaft Oil Seal Installer, install the front input seal.
7. Position the ring gear in the case. Install the ring gear snap ring.
8. If removed, using a press and the Input Shaft Bearing Installer, install the needle bearing into the front
planet carrier.
9. Install the front planet carrier and the thrust bearing.
10. Install the electric shift cam assembly.
11. Install the shift fork and the reduction hub.
12. Install the shift rail.
13. Install the oil pump, output shaft and the thrust washer.
14. Install the magnet into its slot in the case.
15. Install the drive chain and the sprockets as an assembly.
16. Install the lockup hub assembly. If the lockup hub assembly was disassembled, carry out the
following steps.
1. Position the lockup collar.
2. Install the lockup collar springs.
3. Install the lockup hub.

4. Install the armature.
5. Install the lockup hub snap ring.
17. Install the lockup hub and the shift fork and spring.
18. Install the coil housing.
20. Using the Mainshaft Bearing Installer, install the rear output shaft bearing.
21. Using the Mainshaft Bearing Installer, install the front output shaft bearing.
22. Install the transfer case field coil, washers and the 3 nuts.
23. NOTE: Only apply enough silicone sealant to seal the transfer case halves together.
Apply a small bead of silicone sealant to the mating surface of the case and cover.
24. Position the 2 transfer case halves and tighten the 20 bolts in the sequence shown.
NOTICE: The following steps need to be performed in the correct order when installing the transfer
case shift motor. Failure to follow the steps in the correct order may result in damage to the
component.

29. Secure the 2 transfer case shift motor bracket nuts.

30. NOTE: After the coil wire is inserted into the connector, gently pull the wire back to verify the pin is
locked inside the connector.
31. Remove the transfer case from the Transmission Holding Fixture.
SECTION 309-00: Exhaust System 2014 F-150 Workshop Manual

lb- lb-
Exhaust intermediate pipe-to-muffler and tail pipe assembly Torca® clamp 47 35 —
Exhaust tip assembly Torca® clamp 47 35 —
Exhaust Y-pipe dual catalytic converter-to-exhaust intermediate pipe bolts a — — —
Exhaust Y-pipe dual catalytic converter-to-exhaust manifold or turbocharger nuts a — — —
Front muffler isolator and bracket assembly bolts 30 22 —
LH isolator cap bolt 55 41 —
Muffler inlet pipe bracket support isolator bolts (3.5L Gasoline Turbocharged Direct 30 22 —
Injection (GTDI) vehicles only)
Rear tailpipe hanger isolator bolts 30 22 —
Rear muffler isolator and bracket assembly bolt 30 22 —
RH catalytic converter-to-LH catalytic converter Torca® clamp 55 41 —
Transfer case skid plate bolts 24 18 —
Transmission crossmember bolts and nuts 90 18 —
Transmission insulator and retainer/exhaust bracket assembly bolts (Four-Wheel Drive 90 66 —
(4WD) vehicles only)
Transmission insulator and retainer/exhaust bracket assembly bolts 90 66 —
Transmission insulator and retainer/exhaust support bracket assembly nuts 103 76 —
Worm gear clamp 7 — 62

Exhaust System
NOTICE: When repairing exhaust system or removing exhaust components, disconnect all Heated
Oxygen Sensor (HO2S) and all Catalyst Monitor Sensor (CMS) at the wiring connectors to prevent
damage to the HO2S and CMS wiring harnesses. Refer to Section 303-14 for location of the HO2S
and CMS .
NOTICE: Oil or grease-based lubricants on the isolators may cause the exhaust hanger isolator to
separate from the exhaust hanger bracket during vehicle operation.
NOTE: Exhaust fasteners are of a torque-prevailing design. Use only new fasteners with the same part
number as the original. Torque values must be used as specified during reassembly to make sure of correct
retention of exhaust components.
The exhaust system:
z has an exhaust Y-pipe dual catalytic converter that is a 2-piece assembly. The RH and LH converters
can be serviced separately as needed.
z has 2 upstream Heated Oxygen Sensor (HO2S) mounted before the catalytic converters.
z has 2 Catalyst Monitor Sensor (CMS) mounted on catalytic converters.
z has an intermediate pipe.
z has muffler brackets with isolators at the front and rear of the muffler, bolted to the body.
z production muffler and tail pipe assembly is a one-piece design.

Exhaust System
1. Verify the concern by running the engine (with the vehicle on the ground) or road testing the vehicle
to duplicate the condition.
2. Visually inspect the components of the exhaust system and related controls that may affect exhaust
gas quality or loss of power.

Mechanical
z Exhaust pipe pinched or crushed
z Damaged muffler and tail pipe assembly
z Broken or damaged exhaust hanger brackets
z Damaged catalytic converter
z Cracked exhaust manifold
z Loose or damaged heat shields
4. Verify that the exhaust system is installed correctly, with Torca® clamps correctly located and
tightened to specification.
5. If the fault is not visually evident, determine the symptom. GO to Symptom Chart - Exhaust System or
GO to Symptom Chart - NVH .
Symptom Chart — Exhaust System
Symptom Chart — Exhaust System

z Vehicle has low z Exhaust pipe z INSPECT the exhaust components
or no power — pinched or crushed for damage. REPAIR or INSTALL
vehicle z Damaged catalytic new components as necessary.
performance converter TEST the system for normal
complaint z Loose obstruction in operation. If the concern is still
exhaust present, REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual for restricted
exhaust.
z Restricted exhaust z CHECK drain holes for foreign
(possible frozen material. PARK the vehicle inside

condensate in to thaw. TEST vehicle for normal
muffler) operation. If concern is still
present, REFER to the Powertrain
Control/Emissions Diagnosis
(PC/ED) manual.
z Burning smell — z Foreign material z INSPECT the exhaust system for
usually occurs caught in exhaust foreign material or missing heat
at idle with system shields. REPAIR or INSTALL new
possible traces z Missing heat shields components as necessary. TEST
of smoke z Fluid leak on the system for normal operation
exhaust after the repair.
z Odor — z Catalytic converter z At times, a slight sulfur smell is
described as a normal for catalytic converters. The
sulfur or rotten cause is the sulfur content in the
egg smell gasoline being used. ADVISE
customer, no repair required.
z Rich fuel conditions z REFER to the Powertrain
z Misfire conditions Control/Emissions Diagnosis
z Excessive sulfur (PC/ED) manual.
content in fuel
z Visible rust on z Catalytic z Surface rust is a characteristic of
surface of converter/exhaust materials used on exhaust
exhaust pipes system systems. Exposure to heat or road
salt may result in surface rust.
INSPECT for perforations. If there
are no perforations, condition is
normal.
z Rattle, squeaks z Loose or damaged z INSPECT the exhaust system for
or buzz-type heat shield loose or missing heat shields or
noise — from the foreign material trapped between
bottom of vehicle the heat shields and the exhaust
system components. If any heat
shields are loose, INSTALL worm
gear clamp 7L5Z-5A231-AA and
tighten to 7 Nm (62 lb-in). If the
heat shields are missing, INSTALL
new heat shields or exhaust
system components as necessary.
If a rattle, noise or buzz condition
persists, INSTALL a new heat
shield or component as necessary.

operation after the repair.
z Loose or damaged z CHECK that the exhaust isolators
exhaust isolators are correctly installed. INSPECT
the exhaust isolators for wear or
damage. INSTALL new isolators
as necessary. TEST the system for
normal operation after the repair.
z Damaged exhaust z INSPECT the exhaust system
isolator hanger components for damage or broken
bracket hangers. INSTALL new
CHECK for loose or damaged
exhaust hanger brackets or
fasteners. TIGHTEN bolts to
specification or INSTALL new
components as necessary. TEST
the system for normal operation
after the repair.
z Catalytic converter z MOVE the exhaust system to
z Muffler simulate the bouncing action of the
vehicle, checking for exhaust-to-
body contact while moving the
exhaust system. Using a rubber
mallet, lightly TAP on the exhaust
components one at a time to
duplicate the noise concern.
DETERMINE if there are any loose
or broken baffles or element.
after the repair.
z Exhaust grounded z INSPECT for signs of exhaust
to chassis components-to-body contact. If
necessary, CARRY OUT the
Exhaust System Alignment in this
section.
z Drone or clunk z Loose or damaged z INSPECT exhaust isolators for
type noise — exhaust isolators wear or damage. INSTALL new
from bottom of isolators as necessary. TEST the
vehicle system for normal operation after
the repair.
z Exhaust grounded z INSPECT for signs of exhaust
to chassis components-to-body contact. If
necessary, CARRY OUT the
section.
z Whistles, boom, z Exhaust system z INSPECT the entire exhaust
hum or ticking- leak system for leaks. CHECK for
type noise — punctures, loose or damaged
noise tends to Torca® clamps/fasteners, sensors
change as or broken welds. EXAMINE the
engine warms. chassis for grayish-white or black
Noises are often exhaust soot, which would indicate
accompanied by exhaust leakage at that point. To

exhaust fumes magnify a small leak, have an
assistant hold a shop towel over
the tail pipe outlet, while listening
for a leak. REPAIR or INSTALL
z Catalytic converter z MOVE the exhaust system to
z Muffler simulate the bouncing action of the
vehicle, checking for exhaust-to-
body contact while moving the
exhaust system. Using a rubber
mallet, lightly TAP on the exhaust
after the repair.
z Exhaust muffler z NOTE: Check with vehicle on the
drain hole enlarged ground, not on a hoist.
due to corrosion
CONFIRM drain holes are the
noise source. INSTALL new
after the repair.
z Thermal expansion z This is a normal condition.
of exhaust versus
heat shields
z Hissing or z Exhaust system. z MOVE the exhaust system to
rushing noise — Exhaust flow simulate the bouncing action of the
high frequency through pipes vehicle, checking for exhaust-to-
sound. Vehicle body contact while moving the
performance is exhaust system. Using a rubber
unaffected mallet, lightly TAP on the exhaust
CHECK for missing or leaking
Torca® clamps or couplings.
after the repair.
z Pinging noise — z Catalytic z Cool down pinging is the exhaust
occurs when converter/exhaust system expanding and contracting
exhaust system system during heating and cooling. This is
is hot, engine z Thermal expansion a normal condition.
turned off of exhaust system
z Vibration — z Loose or damaged z INSPECT the exhaust isolators for
occurs at idle exhaust isolators wear or damage. INSTALL new
and at low isolators as necessary. TEST the

speeds. Also system for normal operation after
accompanied by the repair.
clunk or buzz
type noise
z Loose or damaged z INSPECT the exhaust isolator
exhaust isolator hanger brackets for wear or
hanger brackets damage. INSTALL or REPAIR as
necessary. TEST the system for
z Damper missing or z INSPECT for missing or damaged
damaged, if damper. INSTALL new
equipped components as necessary. TEST
after the repair.
z Exhaust system z CARRY OUT the Exhaust System
grounded to Alignment in this section.
chassis
z Engine drumming z Damaged or z INSPECT the exhaust system for
noise — normally misaligned exhaust loose or damaged fasteners,
accompanied by system Torca® clamps, couplings or
vibration isolators. CARRY OUT the
z Sputter type z Damaged or worn z INSPECT the exhaust system for
noise — noise exhaust system leaks or damage. REPAIR as
worse when cold, necessary. TEST the system for
lessens or normal operation after the repair.
disappears when
the vehicle is at
operating
temperature
z Thumping noise z Misaligned exhaust z CHECK the exhaust system-to-
— from the system chassis clearance. CHECK the
bottom of the exhaust system isolators for
vehicle, worse at damage. REPAIR as necessary.
acceleration TEST the system for normal
z Engine vibration z Strain on exhaust z CARRY OUT the Exhaust System
— is felt with system isolators Alignment in this section. REPAIR
increases and as necessary. TEST the system for
decreases in normal operation after the repair.
engine rpm
z Drumming noise z Exhaust system z GO to Pinpoint Test A .
— occurs inside vibration excites the
the vehicle body resonances
during idle or inducing interior
high idle, hot or noise
cold. Very low-
frequency
drumming is very
rpm dependent
Pinpoint Test
Pinpoint Test A: Drumming Noise

z Exhaust system
PINPOINT TEST A: DRUMMING NOISE

A1 CHECK THE EXHAUST SYSTEM
z Increase the engine rpm until the noise is the loudest. REFER to Exhaust System Alignment
Note the engine rpm. in this section. TEST the system for
z Ignition OFF. normal operation.
z Add approximately 9 kg (20 lb) of weight to the exhaust
system. First place the weight at the tail pipe and test, No
then at the front pipe. CONDUCT a diagnosis on other
z Start the engine. suspect systems. REFER to Section
z Increase the engine rpm and listen for the drumming 100-04 .
noise. Note the engine rpm if the noise occurs.
z Ignition OFF.
z Determine the amount of vibration that occurs with the
drumming noise.
z Is the noise/vibration reduced or eliminated, or
does the noise/vibration occur at a different rpm?

Exhaust System Alignment
02 .
2. If equipped, release the 4 fasteners and remove the splash shield.
3. Loosen all exhaust system component fasteners adjoining the exhaust system.
4. Loosen the 2 front muffler isolator and bracket assembly bolts.
5. Loosen the LH isolator cap bolt.
6. Make sure the button on the exhaust intermediate pipe is fully inserted into the L-notch on the muffler
and tail pipe assembly inlet pipe.

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2014 F-150 Workshop Manual Page 1 sur 10

SECTION 100-01: Identification Codes 2014 F-150 Workshop Manual

Vehicle Identification Number (VIN)

Vehicle Identification Number (VIN) Tag Locator

World Manufacturer Identifier (WMI)

z 1FT - Ford Motor Company, USA, truck (completed vehicle)

Brake Type and Gross Vehicle Weight Rating (GVWR)

Line and Body Type

z X1R - Ford F-150, 4WD , SuperCab, styleside, SVT

The ninth VIN position is a government-assigned, computer-generated check digit.

The tenth VIN position is the model year code.

The eleventh VIN position is the assembly plant code.

z F - Dearborn (Dearborn, Michigan, USA)

Vehicle Certification (VC) Codes

Vehicle Certification (VC) Label Locator

5 Interior trim code

Primary Exterior Color Codes

Exterior Accent Color Codes

z 163 - 4,140 mm (163 in)

Interior Trim Type

Interior Trim Color

Tape and paint stripe codes do not apply.

The following lists the available axle ratios:

z 15 - 3.15 non-limited slip

z Front spring base part number - 5310

Powertrain Calibration Information

Revision Level (not printed on label)

z 01-04 - Preliminary levels

SECTION 100-02: Jacking and Lifting 2014 F-150 Workshop Manual

Jacking and Lifting

Jacking Points — Front

Jacking Points — Rear

The rear jacking points are located on the rear axle.

Frame Lifting Points

Noise, Vibration and Harshness (NVH)

A pronounced series of rapidly repeating rattling or clicking sounds.

A short-duration, high-pitched noise associated with a slipping drive belt.

A repetitious, low-pitched sound. A loud chuckle is usually described as a knock.

A sharp, brief, non-resonant sound, similar to actuating a ball point pen.

Cycles Per Second

Cycles per second. Same as hertz (Hz).

A mid-frequency sound, related to squeak. Sound varies with temperature conditions.

A unit of measurement, referring to sound pressure level, abbreviated dB.

A low-frequency, steady sound, like a freezer compressor. Also described as a moan.

The rate at which a cycle occurs within a given time.

Steady, high-frequency noise. Vacuum leak sound.

A heavy, loud, repetitious sound, like a knock on the door.

A constant, low-frequency tone. Also described as a hum.

A short-duration, high-frequency sound, which has a slight echo.

A slow, pulsing movement.

A random and momentary or short-duration noise.

Intermittent sound of varying frequency, sounds similar to shuffling through leaves.

A high-pitched transient sound, similar to rubbing fingers against a clean window.

A long-duration, high-pitched noise.

A dull beat caused by 2 items striking together.

A rhythmic tap, similar to a clock noise.

A noise or vibration that is momentary, a short duration.

A constant, high-pitched noise. Also described as a screech.

Noise, Vibration and Harshness (NVH)

Mastertech® Series MTS 4000

Squeak and Rattle Repair Kit

Ultrasonic Leak Detector

The shortest route to an accurate diagnosis results from:

Frequencies should be read in the "average" mode.