ISSUE: The generator belt may roll off of the pulley due to generator mounting bracket failure and/or misalignment.

Transcription

1 96-1, Publication Date: JANUARY 2, 1996 MEDIUM/HEAVY TRUCK: L SERIES ISSUE: The generator belt may roll off of the pulley due to generator mounting bracket failure and/or misalignment. ACTION: Replace the generator mounting bracket with a new generator mounting bracket which is cast. This should reduce the possibility of a flexing failure and/or misalignment. The new generator mounting bracket is included with the Generator Mounting Bracket Kit (F2HZ-8620-AA). Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the negative battery cables from the batteries. 2. Remove the generator, mounting brackets and fasteners. Refer to the appropriate L-Series Service Manual, Section 14-02C. Retain the generator and parts numbered 1 through 3 and 5 through 8 in Figure 1 for reuse. Discard all remaining parts.

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3 Figure 1 - Article For vehicles, the water filter mounting bracket must be removed and modified using a band saw, or equivalent, as shown in Figure 3 to gain clearance for the new generator bracket. For fleets or dealers not equipped with a band saw, a smaller water filter bracket is available from Detroit Diesel Corporation. This bracket ( ) may be obtained locally.

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5 Figure 3 - Article Reinstall the new or modified water filter bracket and torque the M10 bolts to N-m (43-54 lb-ft). Install the water filter assembly to the bracket and torque the M8 bolts to N-m (22-28 lb-ft). Install the three (3) M10 bolts (Item 3 in Figure 1) in the original locations in the gear housing and torque to N-m (43-54 lb-ft). 5. Install the new generator bracket using two (2) 3/8"-16x6 Grade 8 bolts, four (4) 3/8"x0.75x0.10 Grade 8 flatwashers (44877-S2 or equivalent) and two (2) 3/8"-16 Grade 8 torque prevailing nuts (34987-S2 or equivalent) as shown in Figure 2. The new bracket's upper mounting hole should be in the same location as Item 4 in Figure 1. Torque the 3/8" nuts to 57 N-m (42 lb-ft). 6. Install the adapter block and jam nuts removed earlier on the new adjusting link. Leave the nuts loose at this time. Install the adjusting link on the gear cover by removing the existing gear cover bolt. Install the spacer ( S2), adjusting link, and a 10mmx1.5x110 washer (N S2) with a M10x1.5x110 P.C bolt (N S100) as shown in Figure 2. Do not torque at this time.

6 Figure 2 - Article Install the generator on the mounting bracket and to the adapter block using the bolts and washers removed earlier. Install a new 1/2"-13 Grade 8 torque prevailing nut (34989-S2) on the generator mounting bolt. Do not torque at this time. 8. Install the new belt kit onto the accessory drive pulley. Adjust the generator to obtain Newtons of force ( Lbf) on the belts. 9. Torque the M10 adjusting link-to-gear case bolts to N-m (43-54 lb-ft). Torque the 1/2" adjusting block-to-generator bolt to N-m ( lb-ft). Torque the 1/2" locknut which mounts the generator to N-m ( lb-ft). 10. Reconnect the negative battery cables. Start the engine and run for 10 minutes. Stop the engine and recheck belt tension. Tension should be Newtons of force (90-95 Lbf). Readjust as

7 necessary. The following parts are contained in the Generator Mounting Bracket Kit (F2HZ-8620-AA): One (1) Belt Adjusting Link One (1) Generator Mounting Bracket Two (2) 3/8"-16x6 Grade 8 Bolts Four (4) 3/8"x0.75x0.10 Grade 8 Flatwashers Two (2) 3/8"-16 Grade 8 Torque Prevailing Nuts One (1) Spacer One (1) 10mmx1.5x110 Washer One (1) M10x1.5x110 P.C Bolt One (1) 1/2"-13 Grade 8 Torque Prevailing Nut One (1) 1/2"x57.5 Belt Kit (consists of two (2) belts) OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES:

8 96-2, Publication Date: JANUARY 15, 1996 MEDIUM/HEAVY TRUCK: L SERIES ISSUE: The generator drive belts may roll off of the drive pulley or wear excessively due to generator misalignment with the fan pulley. ACTION: Replace the generator support bracket with a revised generator support bracket which has the mounting hole positions adjusted to properly locate the generator. This should reduce the possibility of misalignment between the generator and fan pulley. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the negative battery cables from the batteries. 2. Remove the generator drive belts. Refer to the appropriate L-Series Service Manual, Section 03C Inspect the belt system to verify there are no loose or damaged components which could affect belt alignment. 4. Inspect the generator to make sure it spins freely and the pulley runs true without wobble. Repair as necessary any concerns found in Steps 3 and 4. If no other concerns were found, proceed to Step Remove the generator following the Service Procedure listed in Section 14-02C of the appropriate L-Series Service Manual. 6. Remove the two (2) bolts and washers that attach the generator pivot bracket to the mounting bracket. Refer to Figure 1. Retain both the bolts and pivot bracket.

9 Figure 1 - Article

10 7. Remove the four (4) bolts and washers that attach the existing mounting bracket to the engine and remove the mounting bracket. Retain the bolts and washers and discard the mounting bracket. 8. Install the new generator mounting bracket (F6HZ-10A313-HA) onto the engine using the same four (4) bolts and washers that were removed in the previous Step. Torque these bolts to N-m (31-42 lb-ft). 9. Install the pivot bracket and the two (2) bolts and washers that were retained in Step 5. Torque these bolts to N-m (31-42 lb-ft). 10. Install the generator as outlined in Section 14-02C of the appropriate L-Series Service Manual. 11. Install the drive belts and adjust the tension as outlined in Section 03C-05 of the appropriate L-Series Service Manual. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES:

11 96-2, Publication Date: JANUARY 15, 1996 MEDIUM/HEAVY TRUCK: L-8000, LN-8000 This TSB is being republished in its entirety to include the latest level parts. ISSUE: Some vehicles may have a driveshaft imbalance when operated at high road speeds. This imbalance can result in a crack in the torque converter housing of the transmission and/or driveshaft twisting. The transmission can then fail due to fluid loss from the crack, and/or the driveshaft bending/breaking. The driveshaft imbalance occurs when transmission torquing forces bend the shaft when in overdrive. ACTION: The driveshaft bending can be corrected by replacing the existing driveshaft with a shorter shaft. This requires the addition of a coupling shaft (with center bearing) and supporting components. Refer to the following procedure for service details. NOTE: THE VIBRATION CAUSED BY THE DRIVESHAFT IMBALANCE MAY NOT BE NOTICED BY THE DRIVER. SERVICE PROCEDURE Verify that the concern vehicle is equipped with an MD-Series electronic automatic transmission and has a one-piece Spicer 1710 Series driveline over 1575mm (62") in length (as measured between the transmission yoke and axle yoke). 1. Remove the driveshaft (refer to Section in the appropriate Service Manual) and rework it by shortening the tube length by 685.8mm (27"). 2. Three (3) different driveshafts were in production depending on the rear axle. Refer to Chart #1 for the current and reworked tube lengths. 3. Obtain a coupling shaft (E7HZ-4817-CSA, Spicer ) and two (2) axle wedges with 3 degree angle (F5HZ-4357-AA). 4. Remove the existing 2 degree axle wedges from the top of the rear spring seats. 5. Install the 3 degree wedges (F5HZ-4357-AA), ensuring the thick end of each wedge is to the rear of the vehicle. a. Use new U-bolts and new torque prevailing nuts (refer to Figure 2 for proper U-bolt usage). b. Torque U-bolts N-m ( lb-ft).

12 6. Drill a hole for 1/2" bolt in the frame web mm (83.54") behind the front axle centerline and 112.3mm (4.42") below the inside of the top frame flange. 7. Drill a second hole for a 5/8" bolt in the same area mm (85.38") behind the front axle centerline and 130.0mm (5.12") below the inside of the top frame flange. 8. Drill similar holes in the opposite frame rail. 9. Install angle brackets (D4HZ-4K007-A and D4HZ-4K007-B) using one (1) 1/2" bolt (1 nut and 2 flatwashers) and one (1) 5/8" bolt (1 nut and 2 flatwashers) to attach each bracket to one (1) frame rail (refer to Figure 1). Figure 1 - Article a. Torque 1/2" nuts N-m ( lb-ft).

13 b. Torque 5/8" nuts N-m ( lb-ft). 10. Install the "X" crossmember (DOHZ-4808-A) across the tops of the angle brackets using 1/2"-13x1.50 bolts. Install nuts and flatwashers (Figure 1). Torque 1/2" nuts N-m ( lb-ft). 11. Install bracket (F3HZ-4691-A) below the "X" crossmember (DOHZ-4808-A) using four (4) of the 3/8"-16x1.50 bolts and nuts with eight (8) flatwashers. Torque 3/8" nuts N-m (31-42 lb-ft). 12. Install the lower bearing support plate (F3HZ-4831-E). Align the edges of the plate with the upper bracket, keeping the edges aligned. Slide the lower support plate up until the holes match between the lower plate and holes numbered "2" of the upper bracket (F3HZ-4691-A). 13. Offset the lower support plate (F3HZ-4831-E) directly to the right by 22.4mm (0.88") so that the holes now align with the holes numbered "3" on the upper support bracket (F3HZ-4691-A). 14. Use the remaining 3/8" fasteners to attach the support plate (F3HZ-4831-E) to the upper support bracket (F3HZ-4691-A). Refer to Figure 1. Maintain a 22.4mm (0.88") offset to the right. Torque 3/8" nuts from N-m (31-42 lb-ft). 15. Attach the coupling shaft assembly (E7HZ-4817-CSA) to the transmission output yoke using the straps and bolts removed earlier. Torque nuts N-m ( lb-ft). 16. Attach the coupling shaft assembly (E7HZ-4817-CSA) to the lower support plate (F3HZ-4831-E) using two (2) 1/2"-13x1.25 bolts, nuts and four (4) flatwashers. Torque 1/2" nuts N-m ( lb-ft). 17. Reinstall the driveshaft by connecting one (1) end to the rear of the coupling shaft and the other end to the axle input yoke. 18. The U-joint straps and bolts may be reused at the rear axle, but two (2) new straps (E7HZ-4A254-B) and four (4) new bolts (F1HZ-4N272-B) must be used when connecting the driveshafts. Torque all U-joint bolts N-m ( lb-ft).

14 Figure 2 - Article Drive the vehicle a short distance. Retorque the axle U-bolts from N-m ( lb-ft). NOTE: THE REAR AXLE U-BOLTS SHOULD ALSO BE RETORQUED AT 1600 KM (1,000 MILES) AFTER THIS MODIFICATION. THEN, FOLLOW THE MAINTENANCE SCHEDULE FOR PROPER INTERVALS.

15 OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES: ,

16 96-3, Publication Date: JANUARY 29, 1996 MEDIUM/HEAVY TRUCK: CARGO SERIES, F & B SERIES, L SERIES ISSUE: An engine miss may occur on one or two cylinders when the engine is warm and operating between 800 and 1100 rpms. This may be caused by the fuel lift pump creating high pressure fuel pulsations that may affect the operation of the fuel injection pump. ACTION: Replace the steel fuel supply line between the fuel filter and the fuel injection pump with a combination steel and rubber line. The rubber line portion will act as a damper that reduces the effect of the high pressure pulsations. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Loosen one (1) of the banjo screws from the existing steel fuel supply line that is routed from the fuel filter to the fuel injection pump. A small amount of diesel fuel may leak from the line, therefore, an appropriate container should be used to contain the fuel. 2. Once the fuel has been drained from the line, remove the banjo screws and steel fuel supply line from the engine. Retain the banjo screws for installation of the new line. a. The FD1460 uses a P-clip to support the steel fuel supply line. This will need to be unbolted before the line can be removed. Retain the P-clip and bolt for reinstallation on the new line. 3. Refer to Figure 1 for the following Step. Install the new steel portion of the fuel supply line onto the fuel injection pump using new banjo seals and the original banjo screw. Secure the line finger tight to the injection pump.

17 Figure 1 - Article a. Refer to Figures 1 through 4 for the following Step. For the FD1460 only, install the previously removed P-clip onto the steel portion of the new fuel supply line. Insert the bolt through the P-clip, install it into the intake manifold and tighten to 24 N-m (18 lb-ft).

18 Figure 2 - Article

19 Figure 3 - Article

20 Figure 4 - Article Slide the rubber line onto the steel line. Install one (1) hose clamp onto the rubber line so that it is positioned behind the flare in the steel line. Do not tighten the hose clamp at this time. a. For the FD1460, position the rubber line onto the steel line so that it contacts the P-clip that was installed in the previous Step. b. For the FD1460 only, slide the P-clip that came with the kit onto the rubber portion of the line so that the eye is facing downward and the tab is horizontal (Figure 3). 5. Loosely install the banjo connector on the filter head using two (2) new banjo seals and the previously removed banjo screw. 6. Position a hose clamp over the rubber hose, then install the hose onto the filter head banjo connector. The rubber hose may need to be adjusted to properly fit onto both the steel line and banjo connector. a. For the FD1460 only, position the P-clip on the rubber hose so that it aligns with the most rearward capscrew on the intake manifold. Remove this capscrew, install the P-clip onto the capscrew and reinstall the capscrew. Torque the capscrew to 24 N-m (18 lb-ft) (Figures 3 and 4). NOTE: WHEN THE INSTALLATION IS COMPLETE, THE FD1460 WILL HAVE TWO (2) P-CLIPS TO SUPPORT THE NEW COMBINATION LINE. ONE WILL BE ON THE STEEL PORTION AT THE #4 BOLT HOLE POSITION AND THE OTHER WILL BE SUPPORTING THE RUBBER PORTION AT THE #1 BOLT HOLE (FIGURE 4). THE FD1060 USES A SHORT COMBINATION LINE, THEREFORE, SUPPORTING CLIPS ARE NOT REQUIRED. 7. Properly position both hose clamps so that they will seal the hose to the steel line and hose to banjo connector connection. Torque the clamps to 5 N-m (44 lb-in). 8. Check the rubber portion to verify it is positioned and routed properly and will not chafe on any of the engine components. 9. Bleed the air from the fuel system by following the service procedure listed in the appropriate Powertrain/Drivetrain Service Manual, Sections 03A and 04A. 10. Start the engine and inspect the new fuel supply line for leaks. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE

21 DEALER CODING OASIS CODES: ,

22 96-4, Publication Date: FEBRUARY 12, 1996 MEDIUM/HEAVY TRUCK: L SERIES ISSUE: The cab rear mounts may crack around the upper bolt hole where it attaches to the cab. This may be due to high loads on the material caused by the clamp force of the attaching bolt. If not repaired, the cracks will lead to separation of that mount. ACTION: Install a revised cab mount with a larger washer to further distribute the bolt force and reduce the potential for cracks. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Properly support the rear of the cab so that the new rear cab mounts may be installed. 2. Remove the cab-to-mount bolt, washers and nut (Items 2, 3 and 4 in Figure 1) from each mount. Retain the bolts and discard the nuts and washers.

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24 Figure 1 - Article Remove the four (4) bolts, washers and nuts that secure each cab mount to the crossmember (Items 5, 6 and 7 in Figure 1). Retain the bolts and washers; discard the nuts. 4. Remove the old cab mount from the crossmember (Item 1 in Figure 1) and discard. 5. Install the new cab mounts onto the crossmember (Item 8 in Figure 2).

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26 Figure 2 - Article Loosely install the bolts and washers that were previously retained in Step 2 and eight (8) 3/8"-16 hex torque prevailing nuts (34987-S2 or equivalent) into the new cab mount and crossmember. 7. Using the new washers ( S2) (Item 9 in Figure 2) and new 1/2"-13 hex torque prevailing Grade 8 nuts, loosely secure the cab-to-mount bolts as shown in Figure 2. The new cab mount requires only two (2) washers to be used instead of the four (4) previously used. 8. Torque the cab-to-mount bolts to N-m ( lb-ft) and the cab mount-to-crossmember bolts to N-m (31-42 lb-ft). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES: , , ,

27 96-4, Publication Date: FEBRUARY 12, 1996 MEDIUM/HEAVY TRUCK: L SERIES ISSUE: The MD-3000 transmission module may see a false anti-lock brake signal if Circuits #4 (W-Bk) and #5 (R-Bk) on the -7C078- wiring harness are inadvertently connected. These wires are from the same wiring harness and if the vehicle was equipped with anti-lock brakes, they would be connected to another wiring harness. If the vehicle is not equipped with anti-lock brakes, the connectors should be left unplugged. ACTION: If a reduced power concern is noted on the subject vehicles and the vehicle is not equipped with anti-lock brakes, visually inspect the -7C078- wiring harness to see if Circuits #4 (W-Bk) and #5 (R-Bk) have been inadvertently connected. For the transmission to function properly these two (2) connectors should not be connected together. Refer to Figures 1 through 3.

28 Figure 1 - Article

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30 Figure 2 - Article Figure 3 - Article NOTE: THESE CIRCUITS ARE ONLY USED ON VEHICLES EQUIPPED WITH ANTI-LOCK BRAKES. IF SO EQUIPPED, THESE WIRES WOULD BE CONNECTED TO THE ANTI-LOCK SYSTEM ELECTRICAL HARNESS. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES:

31 96-4, Publication Date: FEBRUARY 12, 1996 MEDIUM/HEAVY TRUCK: L SERIES ISSUE: A noise and/or vibration at the vertical exhaust pipe-to-cab connection area may occur on some vehicles. This may be due to wear out of the rubber insulators that connect the vertical exhaust pipe to the cab. ACTION: Replace the "EPDM" rubber insulators with revised "natural" rubber insulators (D3HZ-5281-A). Refer to the following Service Procedure for details. SERVICE PROCEDURE NOTE: TEN (10) INSULATORS ARE USED ON EACH VEHICLE WITH THE CAB-MOUNTED VERTICAL EXHAUST PIPE. 1. The insulators (Figure 1) can be removed and replaced with the revised insulators as necessary. Refer to the appropriate year L-Series Powertrain/Drivetrain Service Manual, Section 09-00, for general information regarding exhaust system service. 2. After the revised insulators (D3HZ-5281-A) have been installed, install the shoulder bolts and washers. Torque the bolts to N-m (31-42 lb-ft). Refer to Figure 1.

32 Figure 1 - Article

33 OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES: , ,

34 96-5, Publication Date: FEBRUARY 26, 1996 MEDIUM/HEAVY TRUCK: F SERIES, L SERIES ISSUE: Oil may leak at the road draft tube on some vehicles. This may be caused by the current valve cover not having an internal oil baffle, which allows the oil to flow through the road draft tube. ACTION: Replace the valve cover with a revised design valve cover. The revised valve cover has an internal oil baffle which will reduce the possibility of oil leaking out of the road draft tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Remove the crankcase road draft tube assembly and any other components that may be attached to the valve cover. 2. Remove the six (6) valve cover mounting capscrews and retain for future use. 3. Remove the existing valve cover. 4. Remove the reusable gasket from the existing valve cover. Inspect the gasket. The gasket may be reused if it is not damaged. If required, obtain a new valve cover gasket (F3HZ-6584-B, Cummins # ). 5. Discard the existing valve cover. 6. Install the valve cover gasket into the new valve cover (F3HZ-6582-AA, Cummins # ). 7. Install the valve cover onto the engine. 8. Install the new O-ring seals included with the valve cover onto the six (6) capscrews. 9. Install the capscrews and torque to 24 N-m (18 lb-ft) in sequence starting from the middle and alternating from side-to-side toward the ends of the valve cover. Refer to the following Torque Sequence Chart. Capscrew #1 is the forward-most on the engine and the #6 screw is the rearward-most.

35 10. Assemble the road draft tube which is included with the valve cover as shown in Figure 1. Torque the hose clamps to N-m (30-40 lb-in). Torque the screw to 24 N-m (18 lb-ft). Figure 1 - Article Reattach any components that had to be removed to provide access to the valve cover.

36 12. Start the engine and verify no oil leaks are present. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES: ,

37 96-6, Publication Date: MARCH 11, 1996 MEDIUM/HEAVY TRUCK: L SERIES This TSB is being republished in its entirety to update the Service Procedure. ISSUE: Some vehicles may have a "no crank" condition. This is due to damage to the contacts inside the switch and/or the electrical connection to the ignition switch, caused by high amperage overloading from added vehicle electrical circuits/accessories. ACTION: Install a jumper wiring assembly, which adds a relay, into the ignition switch and a new connector for the ignition switch circuit for increased circuit capacity. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the negative terminal of the battery. 2. Remove screws which retain the left side instrument panel and remove panel. 3. Disconnect the ignition switch, including the Black (57) ground wire from the switch casing. Push connector and wiring below the instrument panel to gain access to connector shell. Refer to Figure 1.

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39 Figure 1 - Article NOTE: VEHICLES USE A YELLOW (21) WIRE, WHILE THE VEHICLES USE A BLACK/YELLOW (37) WIRE IN THE IGNITION SWITCH CONNECTOR AS SHOWN IN FIGURE Using a small screwdriver, depress the terminal locking tabs and remove the Yellow (21) or Black/Yellow (37) and Black/Green (297) wire terminals from the ignition switch connector shell. 5. Cut the wires removed from the connector shell 50.8mm (2") from the end. Also, cut the Black (57) ground wire 127mm (5") from the end. Strip all three (3) wires 8mm (0.3"). Before installing the jumper assembly, secure its relay to the electrical connector with an adjustable strap ( S). Insert the three (3) stripped wires into the corresponding butt splices of the new jumper assembly and crimp (the jumper assembly has the identical color coding of the existing wires). For vehicles, the Yellow (21) wire will be spliced into the Black/Yellow wire. 6. Apply heat to each butt splice until tubing shrinks and adhesive flows from each end of the butt splice. 7. Install the Black/Yellow (37) and Black/Green (297) wires of the jumper assembly into the connector shell using a small pair of needle nose pliers. Make sure they are in their correct locations (Figure 1). 8. Using electrical tape, secure the two (2) adjacent butt splices together from the jumper harness. 9. Reinstall the ignition switch connector to the switch; also, connect the Black (57) ground wire to the switch casing. 10. Install instrument panel. Reconnect the battery(s) negative terminals; torque to 20.3 N-m (15 lb-ft). 11. Secure jumper assembly to the existing wiring or air lines with an adjustable strap ( S). OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING

40 OASIS CODES: ,

41 96-6, Publication Date: MARCH 11, 1996 MEDIUM/HEAVY TRUCK: L SERIES ISSUE: The oil fill pipe assembly may crack at the base and leak engine oil on some vehicles. This may be due to the oil fill pipe length, in combination with engine vibrations, causing stress and eventual cracking at the fill pipe base. ACTION: Replace the oil fill pipe with a revised Oil Fill Pipe Assembly (F5HZ-6763-CA). The oil fill pipe was revised by shortening the pipe 127mm (5") and removing the upper support bracket. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Clean and inspect the oil fill tube assembly for cracks along the tube and at the tube-to-base plate connection point. If a crack is noted, proceed to Step 2. If no cracks are present, the oil leak may be coming from the tube-to-engine gasket (Figure 1) or another point on the engine. Figure 1 - Article

42 2. To gain access to the fill tube, remove the road draft tube P-clip-to-engine attaching bolt. Retain the bolt and then move the draft tube (Figure 1). 3. Remove the fill tube, upper support bracket-to-a/c compressor support bracket, nut and washer and retain (Figure 1). NOTE: REFER TO FIGURE 2 FOR STEPS 4 THROUGH 10.

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44 Figure 2 - Article Remove the oil dipstick support bracket attaching bolt (Item 1). 5. Remove the two (2) fill tube-to-engine attaching bolts and washers (Item 2), and the upper coolant pipe support bracket and retain. Remove and discard the oil fill tube. 6. Clean any gasket residue from the tube engine mounting surface. 7. Using a new gasket (E9HZ-6B888-A) (Item 3), install the revised oil fill pipe (F5HZ-6763-CA) (Item 4), along with the upper coolant pipe support bracket onto the engine using the two (2) attaching bolts and washers (Item 2). Torque the bolts to N-m ( lb-ft). 8. Reinstall the A/C compressor support bracket nut and washer and torque to N-m ( lb-ft). 9. Install the oil dipstick support bracket bolt (Item 1) and torque to N-m ( lb-in). 10. Reposition the road draft tube, then reinstall the P-clip to the engine using the retained bolt. Torque the bolt to N-m (31-41 lb-ft). OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES: ,

45 TSB Article has been superseded by Article

46 96-7, Publication Date: MARCH 25, 1996 MEDIUM/HEAVY TRUCK: L SERIES ISSUE: The back panel of the cab may crack on some vehicles. The cracking occurs at the spot welds on the top LH side of the back panel, on vehicles equipped with air fairings. This may be caused by wind and road loads which stress the back panel-to-inner reinforcement spot welds, causing the back panel to crack. ACTION: Install a Reinforcement Kit (F5HZ-90280K96-CA) to the back panel of the cab. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. If necessary, remove the existing LH upper side fairing attachment brackets and save fasteners for reinstallation. 2. Grind away damaged back panel sheet metal in the crack area. 3. Drill both ends of crack before welding. Wire weld the sheet metal using ER 70S-6 to the inner corner bracket at the crack area. Anneal the weld areas with gas heat. 4. Apply one coat of self-etching primer following manufacturer's label directions. Apply 2.0 mils of primer surfacer. Apply top coat material following manufacturer's label directions. 5. Remove the existing fastener at the end of the upper LH fairing "boomerang" bracket (Figure 1).

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48 Figure 1 - Article Install the reinforcement (Figure 1, Item 1) onto the air fairing, but do not tighten fastener at this time. Position the reinforcement as shown in Figure Place the stud plate (Figure 1, Item 2) on the back panel such that the stud passes through the middle of the slot in the end of the reinforcement brace. 8. Using the pre-drilled holes in the stud plate as a template, scribe the center of each mounting hole into the back panel. 9. Remove the stud plate and reinforcement, punch and drill six (6) scribe holes with a 0.360"/0.355" drill bit. 10. Set six (6) insert nuts (Figure 1, Item 5) into the holes in the back panel. 11. Install the stud plate seal (Figure 1, Item 3) and the stud plate (Figure 1, Item 2) onto the back of the cab using six (6) 1/4"-20x0.86 bolts included in the kit (Figure 1, Item 4). Torque bolts from 8-15 N-m (6-11 lb-ft). 12. Place the reinforcement brace back in the vehicle (Figure 1). Replace the fastener removed off the fairing to secure the reinforcement. Install the 3/8"-16 nut and 1/8" flatwasher (Figure 1, Items 6 and 7) included in the kit to secure the reinforcement to the stud plate. Torque nuts from N-m (25-38 lb-ft).the Reinforcement Kit (F5HZ-90280K96-CA) consists of: One (1) Reinforcement One (1) Stud Plate One (1) Seal - Plate Six (6) 1/4"-20 Hex Flange Bolts Six (6) 1/4"-20 Insert Nuts One (1) 3/8"-16 Hex Flange P/T One (1) 3/8" Flatwasher One (1) Instruction Sheet (I.S. #6862A) OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE

49 DEALER CODING OASIS CODES:

50 96-7, Publication Date: MARCH 25, 1996 MEDIUM/HEAVY TRUCK: L SERIES ISSUE: The engine may stall when the instrument panel-mounted parking brake actuation knob is pulled to set the brakes. This may be caused by a momentary interruption of battery power to the engine Electronic Control Module (ECM), which stalls the engine. ACTION: Relocate the battery power feed wire for the ECM from the engine brake circuit breaker to the engine circuit breaker. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the battery ground cable. 2. On the upper right side of the dash, locate and remove the circuit breaker cover. 3. Locate the Red/Green (69) wire on the #2 circuit breaker. The wire is attached to the circuit breaker panel just below the #2 circuit breaker. The #2 circuit breaker is the second from the left side of the circuit breaker panel and is labeled "ENG.BRK". Remove the wire eyelet retaining nut and remove the Red/Green wire. Reinstall the retaining nut onto the #2 circuit breaker and torque to N-m (13-17 lb-in).

51 Figure 1 - Article

52 4. Locate the #6 circuit breaker. The #6 circuit breaker is the sixth from the left side of the circuit breaker panel and is labeled "ENGINE". Remove the wire eyelet retaining nut for the #6 circuit breaker. Install the Red/Green (69) wire onto the stud and reinstall the retaining nut and torque to N-m (13-17 lb-in). 5. Reconnect the battery ground cable. NOTE: TSB PROVIDES THE SERVICE REPAIR FOR L-SERIES VEHICLES THAT MAY HAVE THIS CONCERN. OTHER APPLICABLE ARTICLES: WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES: , , ,

53 96-7, Publication Date: MARCH 25, 1996 MEDIUM/HEAVY TRUCK: F & B SERIES, L SERIES This TSB is being republished in its entirety to include model years. ISSUE: In December, 1991, the stoplamp diode was revised from a "plug-in" to an integral "in-the-harness" component. Some difficulty may be experienced in locating the stoplamp diode in the subject vehicles. A procedure has been developed for replacing the diode without having to disassemble the harness to find the diode. ACTION: If service is required, use the following procedure to locate and replace the stoplamp diode. DIODE INSTALLATION PROCEDURE - F-SERIES CAB AND COWL 1. Unscrew the fuse block mounts from the truck instrument panel and rotate the fuse block to expose wires on the back of the block. 2. Remove the brake pedal wire harness connector from the stoplamp switch located behind the brake pedal arm. 3. Route the add-on diode jumper covered wire assembly (yellow end) through the instrument panel and above the bellows seal on the brake actuator, Figure 2.

54 Figure 2 - Article Install first connector. a. Attach a blue Scotchlock Connector #560 or equivalent onto the solid red wire behind the fuse block as shown in Figure 2. NOTE: MAKE SURE THE TAB OPENING IS DIRECTED UPWARD TOWARD THE MAIN WIRE ASSEMBLY ( ). b. Insert the blue end of the add-on diode jumper covered wire assembly into the blue Scotchlock Connector #560. c. Using Scotchlock Tool #E-9BM or adjustable pliers, squeeze the metal contact flush in the connector and close the plastic cover over the connector. 5. Install second connector. a. Attach a yellow Scotchlock Connector #562 or equivalent onto the red wire just behind the brake pedal connector as shown in Figure 1, View A.

55 Figure 1 - Article b. Insert the yellow end of the colored wire assembly into the yellow Scotchlock Connector #562. c. Using Scotchlock Tool #E-9BM or adjustable pliers, squeeze the metal contact flush in the connector and close the plastic cover over the connector. 6. Install a wrap of 3/4" (19mm) wide blue colored tape to the wiring assembly on the outside of the wire trunk near the built-in diode to signify that this TSB service was performed. 7. Wrap the Scotchlock connectors with electrical tape to assure the plastic cover remains closed. a. Rotate and reinstall the fuse block on the truck. b. Plug the brake pedal connector onto the brakelamp switch. DIODE INSTALLATION PROCEDURE - L-SERIES CITY DELIVERY 1. Open the fuse panel compartment door to expose the fuse block. 2. Locate the diode assembly (#IN4004 printed on diode) below the relays as shown in Figure 3.

56 Figure 3 - Article Using a wire cutter, cut and remove the plastic tie wrap holding the diode assembly to the harness. 4. Using a new diode assembly (#MR754 printed on diode), identify and match the direction of the old diode installation by comparing arrows marked on the diode coverings. 5. Install the first connector. a. Attach a yellow Scotchlock Connector #562 or equivalent onto the red 12 gauge wire on the double wire end of the old diode assembly. b. Insert the yellow end of the covered wire assembly into the yellow Scotchlock Connector #562. c. Using Scotchlock Tool #E-9BM or adjustable pliers, squeeze the metal contact flush in the connector and close the plastic cover over the connector. 6. Install the second connector. a. Attach a blue Scotchlock Connector #560 or equivalent onto the single red 14 gauge wire. b. Insert the blue wire fully into the blue Scotchlock Connector #560. c. Using Scotchlock Tool #E-9BM or adjustable pliers, squeeze the metal contact flush in the connector and close the plastic cover over the connector. 7. Install a wrap of 3/4" (19mm) wide blue colored tape to the wiring assembly on the outside of the wire trunk near the built-in diode to signify that this TSB service was performed. 8. Wrap the Scotchlock connectors with electrical tape to assure the plastic cover remains closed. Tuck the diode assembly below the relays.

57 DIODE INSTALLATION PROCEDURE - L-SERIES FLEET DELIVERY 1. Unscrew the dash panel to expose the fuse block. 2. Unscrew the fuse block from the instrument panel and tilt the block forward to expose the diode assembly (#IN4004 printed on diode). See Figure 4. Figure 4 - Article Using a wire cutter, cut and remove the plastic tie wrap holding the diode assembly to the harness. 4. Using a new diode assembly (#MR754 printed on diode), identify and match the direction of the old diode installation by comparing arrows marked on the diode coverings. 5. Install the first connector. a. Attach a yellow Scotchlock Connector #562 or equivalent onto the red 12 gauge wire on the double wire end of the new diode assembly. b. Insert the yellow end of the covered wire assembly into the yellow Scotchlock Connector #562. c. Using Scotchlock Tool #E-9BM or adjustable pliers, squeeze the metal contact flush in the connector and close the plastic cover over the connector. 6. Install the second connector. a. Attach a brown Scotchlock Connector #567 or equivalent onto the single red 12 gauge wire. b. Insert the blue wire fully into the brown Scotchlock Connector #567.

58 c. Using Scotchlock Tool #E-9BM or adjustable pliers, squeeze the metal contact flush in the connector and close the plastic cover over the connector. 7. Install a wrap of 3/4" (19mm) wide blue colored tape to the wiring assembly on the outside of the wire trunk near the built-in diode to signify that this TSB service was performed. 8. Wrap the Scotchlock connectors with electrical tape to assure the plastic cover remains closed. Reinstall the fuse block on the instrument panel and screw the dash cover on the dashboard. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES: , ,

59 96-7, Publication Date: MARCH 25, 1996 MEDIUM/HEAVY TRUCK: CARGO SERIES, F SERIES, L SERIES ISSUE: Oil may leak on the side of the FD1460 engine. This may happen because the oil level indicator (dipstick) rises out of its normal retained position approximately 12.7mm (0.5") when the engine is running. Oil can then seep up the tube and be spread on the engine by the cooling fan. ACTION: Install a revised oil level indicator (dipstick) and tube with improved retention due to the expansion plug design, preventing the dipstick from rising out of the tube. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Clean the area around the oil level indicator. 2. Remove the existing oil level indicator and tube assembly and discard. 3. Remove any existing sealant from the hole in the engine block, taking care to avoid contaminating the engine oil. 4. Coat the knurled portion of the Tube Assembly (F6HZ-6B667-CA) with Loctite 262 (E2FZ B), Figure 1.

60 Figure 1 - Article Insert the tube into the block, making sure that the shoulder seats against the engine block machined surface (Figures 1 and 2). The tube must be oriented as shown for the F/L-Series to avoid interference with the power steering pump. CF-Series (Cargo) is tie-strapped as shown in Figure 2.

61 Figure 2 - Article Use the existing clip and secure the tube assembly. 7. Install the new oil level indicator in the tube and tighten the screw to seat the expansion plug. OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE

62 DEALER CODING OASIS CODES:

63 96-8, Publication Date: APRIL 8, 1996 MEDIUM/HEAVY TRUCK: F & B SERIES, L SERIES ISSUE: The brakelamp switch may cause the rear lamps to be constantly illuminated on some vehicles. This may be due to the brakelamp switch plunger deforming, which will keep the internal electrical contacts closed and, in turn, keep the brakelamps illuminated. ACTION: Replace the brakelamp switch with a revised switch. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Disconnect the brakelamp switch from its wiring harness connector. 2. Turn the brakelamp switch counterclockwise (the brakelamp switch housing is threaded) to remove it from the retaining clip and brake pedal assembly (Figure 1, Item 3). Discard the switch. Figure 1 - Article Inspect the retaining clip (Figure 1, Item 1) for damage or wear. If damage or wear is noted, replace

64 the retaining clip with a new clip (C8TZ-13A629-A). Once the old clip is removed, install the new clip and ensure it is fully seated in the brake pedal assembly. If the retaining clip is still serviceable, proceed to Step While pushing the brake pedal down, insert the new brakelamp switch (F6HZ EA) (Figure 1, Item 2) into the spring retaining clip. Push the switch all the way in until the unthreaded portion of the switch is against the retaining clip. 5. Pull the brake pedal all the way up to the upper stop. Inspect the switch plunger. It should be fully depressed by the upper stop. If necessary, the switch position may be adjusted to ensure the plunger is properly actuated. 6. Rotate the brakelamp switch 1/4 turn either way. 7. Install the electrical connector onto the switch. 8. Check to ensure the brakelamps operate properly. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES: , , ,

65 TSB Article has been superseded by Article

66 96-8, Publication Date: APRIL 8, 1996 MEDIUM/HEAVY TRUCK: CARGO SERIES, F & B SERIES, L SERIES ISSUE: The Front End Accessory Drive (FEAD) belt may have high wear or roll off of the drive pulleys on some vehicles. This may be due to the back edge of the plastic FEAD tensioner pulley wearing, causing FEAD belt misalignment and/or FEAD belt roll-off of the drive pulleys. ACTION: Install a revised Pulley Belt Tensioner (F5HZ-6B209-A). The revised tensioner has a steel pulley and will resist wear better than the previous design belt tensioner. Refer to the following Service Procedure for details. SERVICE PROCEDURE 1. Inspect the automatic tensioner plastic pulley for excessive wear (Figure 1). Figure 1 - Article NOTE: THE PLASTIC PULLEY IS DESIGNED WITH A CROWN ACROSS ITS FACE. A PULLEY THAT IS WORN EXTENSIVELY WILL HAVE THE REAR PORTION (THE SIDE CLOSEST TO THE ENGINE)

67 WORN DOWN. NOTE: IF IT IS NECESSARY TO REMOVE THE ACCESSORY DRIVE BELT (SERPENTINE DRIVE BELT) TO INSPECT THE TENSIONER PULLEY, FOLLOW THE PROCEDURE LISTED IN STEP If the tensioner pulley is worn, replace it with the revised pulley tensioner using Steps 2a-2k. a. Rotate the automatic belt tensioner using a 3/8" breaker bar or ratchet in the square of the belt tensioner arm to release the drive belt tension. Refer to Figure 2. Figure 2 - Article b. With the tension released, remove the drive belt from the tensioner pulley. c. Inspect the original drive belt for wear. If it is still serviceable, it may be reused. If wear is noted, replace the belt. Refer to the Parts Block in this article for correct usage. NOTE: THE PARTS CATALOG INCORRECTLY CALLS OUT AN F3HZ-8620-M BELT FOR SOME APPLICATIONS. USE ONLY THE BELTS LISTED IN THIS ARTICLE. NOTE: IF THE DRIVE BELT NEEDS TO BE REPLACED AND THE VEHICLE IS EQUIPPED WITH HYDRAULIC BRAKES, THE HYDRAULIC PUMP DRIVE BELT WILL HAVE TO BE REMOVED BEFORE THE SERPENTINE DRIVE BELT CAN BE REMOVED FROM THE ENGINE. FOR REMOVAL PROCEDURE, REFER TO THE APPROPRIATE MODEL/YEAR POWERTRAIN/DRIVETRAIN SERVICE MANUAL, PAGE 03A d. Remove the drive belt tensioner attaching bolt from the support plate and remove the tensioner. Refer to Figure 2.

68 e. Install the revised tensioner with the steel pulley onto the support bracket using the bolt previously removed. Torque the bolt to 84 N-m (62 lb-ft). f. Install the new belt or make sure the original belt is wrapped properly around the crankshaft, fan, generator and A/C compressor or idler pulleys (Figure 3). The belt must be completely seated in the grooves of each pulley.

69 Figure 3 - Article g. Position the drive belt on the inside of the tensioner pulley.

70 h. With one hand, rotate the tensioner to release drive belt tension, then with the other hand guide the drive belt onto the water pump pulley. Carefully release the tensioner to tighten the drive belt. i. Check again to verify drive belt is properly positioned in all the drive pulley's grooves. NOTE: IF SO EQUIPPED, REINSTALL THE HYDRAULIC PUMP DRIVE BELT BY REFERRING TO THE APPROPRIATE MODEL/YEAR POWERTRAIN/DRIVETRAIN SERVICE MANUAL, PAGE 03A j. Start the engine and check the belt and tensioner for proper operation. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: Eligible Under Basic Warranty Coverage LABOR ALLOWANCE DEALER CODING OASIS CODES: , , ,

71 96-8, Publication Date: APRIL 8, 1996 MEDIUM/HEAVY TRUCK: CARGO SERIES, F & B SERIES, L SERIES ISSUE: An engine air intake heater system retrofit kit is now available from Cummins Engine Company. This cold start aid can be installed on Ford Motor Company vehicles equipped with an FD1060 engine. It is designed to improve the cold start capabilities and quicken engine warm-up. ACTION: Refer to the following Service Procedure for details when installing the Air Intake Heater System Retrofit Kit. SERVICE PROCEDURE WARNING: IF THIS AIR INTAKE HEATER KIT IS INSTALLED ON AN ENGINE, DO NOT USE STARTING FLUIDS (ETHER) WHEN STARTING THE ENGINE. IF THE ENGINE WAS ORIGINALLY EQUIPPED WITH AN OPTIONAL AUTOMATIC ETHER INJECTION SYSTEM, IT MUST BE REMOVED FROM THE ENGINE PRIOR TO THE INSTALLATION OF THIS AIR INTAKE HEATER KIT. THE USE OF STARTING FLUIDS (ETHER) IN AN ENGINE EQUIPPED WITH AN AIR INTAKE HEATER COULD RESULT IN ENGINE DAMAGE AND/OR PERSONAL INJURY. The Cummins Engine Company air intake heater retrofit kit is generic and is designed to be used on all Cummins B-Series, 5.9L engines regardless of the vehicle manufacturer. The instruction sheets included in the kit provide only general installation guidelines and were not exclusively developed for Ford Motor Company. Questions regarding the operation of this air intake heater system, or the retrofit kit, should be directed to a Cummins engine distributor or Cummins Engine Company at It is very important the kit installation instructions and recommendations be followed properly to make sure the air intake heater system will perform correctly and the operation of other engine components is not affected. This system is designed to operate only on 12 volt electrical systems. For this system to function properly it is necessary that the vehicle be properly equipped with the following: A minimum 95-amp generator. (1) For vehicles in areas where the ambient temperature does not generally fall below 0 C (32 F) and the vehicle is equipped with "heavy" accessories (hydraulic pump/pto and/or an automatic transmission), a battery pack with 1000 CCA and Reserve Minutes of 160 is recommended. (2) For vehicles in areas where the ambient temperature does not generally fall below 0 C (32 F) and the vehicle is equipped with "light" accessories (manual transmission), a battery pack with 850 CCA and Reserve Minutes of 160 is recommended.

72 (1) For vehicles in areas where the ambient temperature may fall to -23 C (-10 F) and the vehicle is equipped with "heavy" accessories (hydraulic pump/pto and/or an automatic transmission), a battery pack with 1500 CCA and Reserve Minutes of 320 is recommended. (2) For vehicles in areas where the ambient temperature may fall to -23 C (-10 F) and the vehicle is equipped with "light" accessories (manual transmission), a battery pack with 1250 CCA and Reserve Minutes of 320 is recommended. The installation of this system will require that several new electrical wire harnesses be made locally and that these wires be connected into the existing vehicle electrical system. It is very important that these connections are made properly following the guidelines provided in the Ford Heavy Truck Wiring Interconnect Manual, the Ford Heavy Truck Body Builders Manual and the Ford Service Manuals. During installation of the air intake heater kit, it is very important that all components be installed in a way that prevents damage to the kit or other vehicle components. The controller module must NOT be located in an area of high heat above 88 C (190 F), otherwise damage could result. The contact relay must be oriented upright or on a horizontal plane. The wiring harnesses should be properly supported and clipped to prevent chafe from damage by moving components or heat from the exhaust system. The part number for the Air Intake Heater System Retrofit Kit from Cummins is # To install this kit onto a Ford vehicle equipped with an FD1060 engine (Cummins B-Series, 5.9L engine) the following additional parts are required: OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: , , ,

73 96-9, Publication Date: APRIL 22, 1996 MEDIUM/HEAVY TRUCK: CARGO SERIES, F & B SERIES, L SERIES ISSUE: Kits for repairing wiring harness connectors are now available for service. These kits will save the cost of replacing an entire wiring harness when only the connector needs replacing. ACTION: Refer to Figure 1 to determine which kit is needed for the necessary repair. Follow the Instruction Sheet included with the kit. Each kit will include a connector, spacer, grommet and the required number of pigtails (8" wire crimped to a terminal and butt splice) needed to completely service any one of the components. Figure 1 - Article NOTE:

74 A MASTER KIT HAS BEEN DEVELOPED WHICH CONTAINS TWO (2) OF EACH OF THE KITS TO SERVE AS AN INITIAL STOCKING ORDER. OTHER APPLICABLE ARTICLES: NONE WARRANTY STATUS: INFORMATION ONLY OASIS CODES: ,

75 96-9, Publication Date: APRIL 22, 1996 MEDIUM/HEAVY TRUCK: CARGO SERIES ISSUE: Some vehicles may have a lack of heat, binding of the climate control levers and/or repeat failure of the climate control system actuator cables. This may be caused by the air damper door binding in the heat plenum and/or the actuator cables not being the correct length. ACTION: Modify the blend air door to minimize the potential for binding and, if necessary, replace the actuator cables. This will resolve the binding of the air door and reduce the possibility of repeat repairs. Refer to the following Service Procedure for details. SERVICE PROCEDURE CAB VENTS INSPECTION Visually inspect the two (2) foot level fresh air vents to ensure the doors are closed and sealed. If necessary, close the doors or make the repairs so that the doors are functioning properly. Refer to Figure 1. Figure 1 - Article AIR DAMPER DOOR MODIFICATION 1. Disconnect the battery ground cable. 2. If the vehicle is equipped with air conditioning it will be necessary to remove the A/C components from inside the cab to gain access to the heater plenum.