SVE BULLETIN. QVM Bulletin: Q-123R3 Date: 18 August, 2010 Aftermarket Plasma Cutting/ Welding Operations on F Trucks

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Carmel Welch
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Q-3R3 SVE BULLETIN SPECIAL VEHICLE ENGINEERING BODY BUILDERS ADVISORY SERVICE E-Mail via website: wwwfleetfordcom/truckbbas (click "Contact Us") Toll-free: (877) 840-4338 QVM Bulletin: Q-3R3 Date: 8

the frame or body of F50-550 units, disconnect the battery, PCM, BCM, ABS, instrument cluster, GPM, NOx Module, SCR and TCM Disconnecting a battery cable is not enough to prevent damage to these

1 Q-3R3 SVE BULLETIN SPECIAL VEHICLE ENGINEERING BODY BUILDERS ADVISORY SERVICE via website: wwwfleetfordcom/truckbbas (click "Contact Us") Toll-free: (877) QVM Bulletin: Q-3R3 Date: 8 August, 00 Aftermarket Plasma Cutting/ Welding Operations on F Trucks Models Affected: All F trucks; Model Year 0 and later Warranty Statement: Before electric welding or plasma cutting the frame or body of F units, disconnect the battery, PCM, BCM, ABS, instrument cluster, GPM, NOx Module, SCR and TCM Disconnecting a battery cable is not enough to prevent damage to these components Damage seen in newly-constructed trucks has been traced back to welding Electronic module damage due to this customer or vehicle modifier action is not covered in vehicle warranty Recommendations: Perform the following operations prior to any plasma cutting/welding operations on new vehicles Following completion of the plasma cutting/electric welding operations, reconnect all disconnected units in reverse order ) Turn the ignition switch to the OFF position and remove the key from the ignition switch ) Disconnect all battery cables from all batteries (Refer to Attachment I and II) 3) Disconnect all three connectors from the Powertrain Control Module (PCM) (For diesel engines refer to Attachment III, steps -4; for gas engines refer to Attachment IV, steps -) 4) Disconnect all seven connectors from the Body Control Module (BCM) (Refer to Attachment V, steps -3 and attachment VI) 5) Disconnect the Antilock Brake System (ABS) Module (Refer to Attachment VII, step 3) 6) Disconnect the fuel tank connector or connectors (dual tanks) from the fuel sender on the fuel tank 7) Disconnect Instrument Cluster (IC) connectors (Refer to Attachment VIII, steps - 7) 8) Disconnect all three Glow Plug Module (GPM) connectors (Refer to Attachment IX) 9) Disconnect the two NOx sensor/module connectors (Refer to Attachment X steps -) 0) Disconnect the 6-way electrical connector on the Secondary Catalyst Reduction (SCR) module (Refer to Attachment XI and XII) ) Disconnect the Transfer Case Control Module (TCCM) module connector (Refer to Attachment XIII) ) Disconnect the Transmission Control Module (TCM) connector (Refer to steps and of Attachment XIV) 3) Disconnect grounds G35, G36 and G40 (protects fuel pump driver module and fuel pump; see Attachment XV) 4) Disconnect ground G0 (protects the Steering Column Control Module (SCCM); see Attachment XV) Originator: BBAS Page of 0 Date Issued: 8/8/0 Q-3R3doc

2 5) Disconnect ground G400 (protects the Reductant Heater and sensor; see Attachment XV) Trucks intended to function as mobile arc welding platforms will need to be designed to eliminate any electrical interaction between the truck's electrical system and any conductive surface that comes in direct contact to the item to be welded Electrical isolation of the welding surface can be achieved by use of highly resistive barriers (ie Teflon, etc) The barrier must include any fasteners that connect a conductive surface to the truck If you have any questions, please contact the Ford Truck Body Builders Advisory Service as shown in the header of this bulletin Attachment I Battery, Mounting and Cables GENERAL PROCEDURES Battery Disconnect WARNING: Batteries contain sulfuric acid and produce explosive gases Work in a well-ventilated area Do not allow the battery to come in contact with flames, sparks or burning substances Avoid contact with skin, eyes or clothing Shield eyes when working near the battery to protect against possible splashing of acid solution In case of acid contact with skin or eyes, flush immediately with water for a minimum of 5 minutes, then get prompt medical attention If acid is swallowed, call a physician immediately Failure to follow these instructions may result in serious personal injury WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM) Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches Refer to the Description and Operation portion of Section 50-0B for location of the RCM and impact sensor(s) To deplete the backup power supply energy, disconnect the battery ground cable and wait at least minute Be sure to disconnect auxiliary batteries and power supplies (if equipped) Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment WARNING: Always lift a plastic-cased battery with a battery carrier or with hands on opposite corners Excessive pressure on the battery end walls may cause acid to flow through the vent caps, resulting in personal injury and/or damage to the vehicle or battery When the battery is disconnected and connected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven to relearn its strategy When the battery is disconnected and connected, the illumination display needs to be calibrated After the battery is connected, rotate the dimmer switch from the lowest dim position to the full bright, dome ON position When disconnecting the battery ground cable to interrupt power to the vehicle electrical system, disconnect the battery ground cable only It is not necessary to disconnect the positive battery cable Disconnect the negative battery cable To connect, tighten to 7 Nm (6 lb-in) Disconnect the positive battery cable To connect, tighten to 7 Nm (6 lb-in) Originator: BBAS Page of 0 Date Issued: 8/8/0 Q-3R3doc

3 Attachment II Battery, Mounting and Cables GENERAL PROCEDURES Battery Disconnect Dual WARNING: Batteries contain sulfuric acid and produce explosive gases Work in a well-ventilated area Do not allow the battery to come in contact with flames, sparks or burning substances Avoid contact with skin, eyes or clothing Shield eyes when working near the battery to protect against possible splashing of acid solution In case of acid contact with skin or eyes, flush immediately with water for a minimum of 5 minutes, then get prompt medical attention If acid is swallowed, call a physician immediately Failure to follow these instructions may result in serious personal injury WARNING: Always deplete the backup power supply before repairing or installing any new front or side air bag supplemental restraint system (SRS) component and before servicing, removing, installing, adjusting or striking components near the front or side impact sensors or the restraints control module (RCM) Nearby components include doors, instrument panel, console, door latches, strikers, seats and hood latches Refer to the Description and Operation portion of Section 50-0B for location of the RCM and impact sensor(s) To deplete the backup power supply energy, disconnect the battery ground cable and wait at least minute Be sure to disconnect auxiliary batteries and power supplies (if equipped) Failure to follow these instructions may result in serious personal injury or death in the event of an accidental deployment WARNING: Always lift a plastic-cased battery with a battery carrier or with hands on opposite corners Excessive pressure on the battery end walls may cause acid to flow through the vent caps, resulting in personal injury and/or damage to the vehicle or battery When the battery is disconnected and connected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy The vehicle may need to be driven to relearn its strategy When disconnecting the battery ground cable to interrupt power to the vehicle electrical system, disconnect the battery ground cable only It is not necessary to disconnect the positive battery cable Disconnect the auxiliary negative battery cable (LH side of the engine compartment) To connect, tighten to 7 Nm (6 lb-in) Disconnect the negative battery cable (RH side of the engine compartment) To connect, tighten to 7 Nm (6 lb-in) 3 Disconnect the positive battery cable (RH side of the engine compartment) To connect, tighten to 7 Nm (6 lb-in) 4 Disconnect the auxiliary positive battery cable (LH side of the engine compartment) To connect, tighten to 7 Nm (6 lb-in) 5 To connect, reverse the disconnect procedure Originator: BBAS Page 3 of 0 Date Issued: 8/8/0 Q-3R3doc

4 Attachment III 303-4B- Electronic Engine Controls Diesel Engine 303-4B- Powertrain Control Module (PCM) Removal Item Part Number Description W PCM nuts ( required) 4A06 PCM bracket 3 4E407 Wiring harness retainer (part of B637) 4 4A464 PCM electrical connector (part of 4406) 5 4A464 PCM electrical connector (part of B637) 6 4A464 PCM electrical connector (part of A58) 7 A650 PCM NOTICE: Make sure the ignition switch is in the OFF position prior to working on the electronic engine controls or the vehicle may be damaged Turn the ignition switch to the OFF position Retrieve the module configuration Carry out the module configuration retrieval steps of the Programmable Module Installation (PMI) procedure For additional information, refer to Section Detach the wiring harness retainer 4 Disconnect the PCM electrical connectors 5 Remove the nuts and the PCM bracket Remove the PCM Installation All vehicles Position the PCM and bracket Install the nuts and tighten to 7 Nm (6 lb-in) Connect the PCM electrical connectors Originator: BBAS Page 4 of 0 Date Issued: 8/8/0 Q-3R3doc

5 Attachment IV 303-4A- Electronic Engine Controls Gasoline Engines 303-4A- Powertrain Control Module (PCM) Special Tool(s) Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool Item Part Number Description W PCM wiring harness support bracket nut ( required) 4A06 PCM wiring harness support bracket 3 Wiring harness retainer (part of C508) 4 PCM electrical connector (part of 555) 5 PCM electrical connector (part of C508) 6 PCM electrical connector (part of A58) 7 A650 PCM Removal and Installation Refer to the Powertrain Control/Emissions Diagnosis (PC/ED) manual for correct Vehicle Communication Module (VCM) hook-up procedure 3 If servicing the PCM, connect the scan tool to the vehicle Allow the scan tool to identify the vehicle and obtain configuration data All programmable module information will automatically be retrieved by the VCM Disconnect the 3 PCM electrical connectors Remove the nuts and position the PCM wiring harness support bracket aside To install, tighten to 7 Nm (6 lb-in) Originator: BBAS Page 5 of 0 Date Issued: 8/8/0 Q-3R3doc

6 Attachment V Multifunction Electronic Modules Body Control Module (BCM) Removal Item Part Number Description Body Control Module (BCM) electrical connectors ( required) (part of4a005) BCM electrical connectors (3 required) (part of A58) 3 BCM electrical connectors ( required) (part of 440) 4 BCM bolts ( required) BCM NOTICE: Electronic modules are sensitive to static electrical charges If exposed to these charges, damage may result Prior to the replacement of the Body Control Module (BCM), it is necessary to upload the module configuration information to the appropriate scan tool This information must be downloaded into the new BCM after installation For additional information, refer to Section 48-0 In the event that As-Built data entry is required (BCM will not communicate), all Integrated Keyhead Transmitters (IKTs) devices must be programmed A minimum of devices are necessary to complete the configuration and turn off the flashing interior lights This step is necessary only if the BCM is being replaced If installing a new BCM, all vehicle keys are erased during the parameter reset procedure Verify at least of the vehicle keys are available prior to carrying out this procedure 3 Upload the module configuration information from the BCM For additional information, refer to Section 48-0 Remove the passenger cowl side trim panel For additional information, refer to Section The upper A58 harness BCM (B+) connector may be more easily removed after the BCM bolts are removed and the BCM can be positioned lower and away from the body in order for the connector release tangs to be accessed and pressed Disconnect the 7 BCM electrical connectors Originator: BBAS Page 6 of 0 Date Issued: 8/8/0 Q-3R3doc

7 Attachment VI Interior Trim and Ornamentation Cowl Side Trim Panel Left side shown, right side similar Regular Cab and Crew Cab NOTICE: To avoid damage to the scuff plate trim panel, remove any retaining clips from the body and attach to the scuff plate trim panel before installing Remove the door opening scuff plate trim panel SuperCab NOTICE: To avoid damage to the scuff plate trim panel, remove any retaining clips from the body and attach to the scuff plate trim panel before installing Lift upward and partially remove the front of the door opening scuff plate trim panel All vehicles If equipped, remove the pushpin retainer Remove the cowl side trim panel To install, reverse the removal procedure Originator: BBAS Page 7 of 0 Date Issued: 8/8/0 Q-3R3doc

8 Attachment VII Vehicle Dynamic Systems Anti-Lock Brake System (ABS) Module Special Tool(s) Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool Item Part Number Description ABS module screw (part of C9) (4 required) C9 ABS module 3 Removal and Installation ABS module electrical connector (part of 4405) This step is only necessary 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 Remove the cooling system degas bottle For additional information, refer to Section A or Section B Refer to exploded view(s) and any Warnings, Notices, Notes, Materials, Specifications, and Special Tools Items in the exploded views may not be listed in order of removal Originator: BBAS Page 8 of 0 Date Issued: 8/8/0 Q-3R3doc

9 Attachment VIII Instrumentation, Message Center, and Warning Chimes Instrument Panel Cluster (IPC) Removal Item Part Number Description Lower instrument panel steering column cover 044F46 Upper instrument panel center finish panel screw cover 3 047A8 Upper instrument panel center finish panel screw cover 4 W70768 Upper instrument panel center finish panel screw ( required) Upper instrument panel center finish panel 6 W70768 Instrument Panel Cluster (IPC) finish panel screws (4 required) IPC finish panel 8 W70768 IPC screws ( required) IPC If installing a new IPC, upload the IPC configuration information to the scan tool For additional information, refer to Section 48-0 Remove the upper instrument panel center finish panel For additional information, refer to Section 50- If equipped with an automatic transmission, apply the parking brake and place the selector level in one of the low ranges Lower the steering wheel tilt adjustment to the lowest position Pull the lower instrument panel steering column cover out to release the retaining clips and remove the cover Remove the 4 screws and the IPC finish panel If equipped, disconnect the electrical connectors Remove the screws and the IPC Disconnect the electrical connectors Installation Position the IPC in the instrument panel, connect the electrical connector and install the screws If equipped, connect the electrical connectors, position the IPC finish panel and install the 4 screws Originator: BBAS Page 9 of 0 Date Issued: 8/8/0 Q-3R3doc

10 Attachment IX C- Glow Plug System 67L Diesel C- Glow Plug Module Exploded View Item Part Number Description 4A464 Glow plug module electrical connector (part of A58) (3 required) W Glow plug module bolt (3 required) 3 B533 Glow plug module Removal and Installation Disconnect the battery ground cable For additional information, refer to Section 44-0 Remove the RH fender splash shield For additional information, refer to Section 50-0 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 Originator: BBAS Page 0 of 0 Date Issued: 8/8/0 Q-3R3doc

11 Attachment X 303-4B- Electronic Engine Controls Diesel Engine 303-4B- Nitrogen Oxides (NOx) Sensor Module Removal Item Part Number Description Nitrogen Oxides (NOx) sensor electrical connector (part of 5J99) 4A464 Nitrogen Oxides (NOx) sensor module electrical connector 3 W5004 NOx sensor module bolt ( required) 4 5K0 NOx sensor module NOTICE: Do not use silicone based sprays or lubricants on any components installed onto or around the diesel exhaust system or intake air distribution and filtering system Silicone reacts with the Nitrogen Oxides (NOx) sensor and may cause permanent damage to the NOx sensor NOTICE: Make sure the ignition switch is in the OFF position prior to working on the electronic engine controls or the vehicle may be damaged Turn the ignition switch to the OFF position Originator: BBAS Page of 0 Date Issued: 8/8/0 Q-3R3doc

12 303-4B-3 Electronic Engine Controls Diesel Engine 303-4B-3 (Continued) Any melting of plastic connectors indicates overheating of the Diesel Particulate Filter (DPF) Address any DPF concerns before installing a new sensor Disconnect the Nitrogen Oxides (NOx) sensor electrical connector and the Nitrogen Oxides (NOx) sensor module electrical connector 3 Remove the bolts and the NOx sensor module Installation Install the Nitrogen Oxides (NOx) sensor module and the bolts Tighten to 5 Nm (8 lb-ft) Do not apply any type of electrical grease or lubricants to the electrical connectors Connect the Nitrogen Oxides (NOx) sensor electrical connector and the Nitrogen Oxides (NOx) sensor module electrical connector Originator: BBAS Page of 0 Date Issued: 8/8/0 Q-3R3doc

13 Attachment XI SCR Electrical Connector Originator: BBAS Page 3 of 0 Date Issued: 8/8/0 Q-3R3doc

14 Attachment XII SCR Electrical Connector Originator: BBAS Page 4 of 0 Date Issued: 8/8/0 Q-3R3doc

15 Attachment XIII A- Four Wheel Drive (4WD) Systems A- Transfer Case Control Module (TCCM) Item Part Number Description W Transfer Case Control Module (TCCM) nuts ( required) 7E453 TCCM Removal and Installation 3 Disconnect the battery ground cable For additional information, refer to Section 44-0 Disconnect the connectors from the Transfer Case Control Module (TCCM) Remove nuts and the TCCM To install, tighten to 4 Nm (35 lb-in) 4 To install, reverse the removal procedure Originator: BBAS Page 5 of 0 Date Issued: 8/8/0 Q-3R3doc

16 Attachment XIV 307-0B- Automatic Transaxle/Transmission TorqShift B- REMOVAL AND Special Tool(s) Transmission Control Module (TCM) Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool Removal Item Part Number Description 55 Transmission Control TCM electrical connector W50 TCM 3 B565 TC The Transmission Control Module (TCM) is located on the left frame rail under the cab With the vehicle in NEUTRAL, position it on a hoist For additional information, refer to Section 00-0 Originator: BBAS Page 6 of 0 Date Issued: 8/8/0 Q-3R3doc

307-0B-3 Automatic Transaxle/Transmission TorqShift 6 307-0B-3 REMOVAL AND INSTALLATION (Continued) NOTICE: Keep the Transmission Control Module (TCM) electrical connector straight disconnecting it

17 307-0B-3 Automatic Transaxle/Transmission TorqShift B-3 REMOVAL AND INSTALLATION (Continued) NOTICE: Keep the Transmission Control Module (TCM) electrical connector straight disconnecting it or damage the the connector terminals can occur Slide the lock tab out to unlock the Transmission Control Module (TCM) electrical connector and disconnect the TCM electrical connector 3 Remove and discard the nuts and remove the TCM Installation Position the TCM in place and install new nuts Tighten to 9 Nm (68 lb-in) NOTICE: Keep the Transmission Control Module (TCM) electrical connector straight connecting it or damage the the connector terminals can occur Connect the TCM electrical connector and slide the lock tab in to lock the connector Originator: BBAS Page 7 of 0 Date Issued: 8/8/0 Q-3R3doc

18 Attachment XV Originator: BBAS Page 8 of 0 Date Issued: 8/8/0 Q-3R3doc

19 Originator: BBAS Page 9 of 0 Date Issued: 8/8/0 Q-3R3doc

20 Originator: BBAS Page 0 of 0 Date Issued: 8/8/0 Q-3R3doc

MY F150 CrewCab 1. Tools Required 10X. Page 1 of 15 DL3J-19A014-AA Copyright Ford 2013 FoMoCo

MY F150 CrewCab 1. Tools Required 10X. Page 1 of 15 DL3J-19A014-AA Copyright Ford 2013 FoMoCo 2013-2014MY F150 CrewCab 1 Tools Required A B C D E F G 4X H I J K 3X L 3X 2X 10X 2X Page 1 of 15 DL3J-19A014-AA Copyright Ford 2013 FoMoCo 2013-2014MY F150 CrewCab 2 Vehicles with selector lever in floor