Servicing - A/t Ford Econoline E350

IDENTIFICATION

Note. Unless otherwise specified, references to Pickup include the F350 Super Duty commercial chassis.

AUTOMATIC TRANSMISSION APPLICATIONS

MANUAL TRANSMISSION APPLICATIONS

TRANSFER CASE APPLICATIONS

Oil Pan Gasket (AOD) ID. Scheme 158

Oil Pan Gasket (A4LD) ID. Scheme 159

Oil Pan Gasket (C-6) ID. Scheme 160

Oil Pan Gasket (E4OD) ID. Scheme 161

Automatic Transmission

Vehicles used in normal service do not require regularly scheduled maintenance. Fluid level should be checked whenever underhood maintenance is performed or if leakage is detected. Adjust clutch bands on A4LD and C-6 when quality of shifts deteriorates or improper band adjustment is indicated.

On vehicles used for fleet service or those operated under severe conditions (such as police, taxi or towing), regular transmission fluid change is required every 30,000 miles or when fluid appears discolored.

Manual Transmission

Under normal driving conditions, replace transmission fluid every 60,000 miles. Perform service every 30,000 miles if vehicle is operated under the following severe driving conditions

1. Heavy loads in hilly terrain
2. In hot weather greater than 90°F (32°C)
3. Maximum loads
4. Operating a transmission mounted PTO unit
5. Towing trailer or carrying a slide-in camper

Transfer Case

Under normal driving conditions, replace transfer case fluid every 60,000 miles. Under heavy 4WD driving conditions, replace fluid more frequently.

CHECKING FLUID LEVEL

Note. Pickup F350 Super Duty commercial chassis have a parking brake assembly mounted on rear of the transmission. Parking brake assembly contains a separate reservoir and fluid level must be checked separately from the transmission. See PARKING BRAKE ASSEMBLY under CHECKING FLUID LEVEL.

1. With vehicle on level surface, start engine and operate it until engine and transmission are at normal operating temperature. Apply parking brake. With engine idling, shift transmission through all gear ranges, ending in Park. On 4WD models, ensure transfer case is in any gear range EXCEPT Neutral before checking transmission fluid level.
2. Check transmission fluid level. Fluid level should be within the crosshatched area on the dipstick. Add fluid through filler tube as needed. DO NOT overfill.

Check lubricant level at filler plug hole on side of transmission. Fluid level should be even with bottom of filler plug hole. Add lubricant as needed.

Parking Brake Assembly (Pickup F350 Super Duty Commercial Chassis)

Check lubricant level at filler plug hole on side of parking brake assembly mounted on rear of transmission. Fluid level should be even with bottom of filler plug hole. Add lubricant as needed.

Remove filler plug. Fluid level should be even with bottom of filler plug hole. Add lubricant as needed.

All automatic transmissions use Motorcraft Mercon ATF (XT-2-QDX).

On Mitsubishi FM146 models, use SAE 80W Gear Lube (D8DZ-19C547-A). On all other models, use Motorcraft Mercon ATF (XT-2-QDX).

Parking Brake Assembly (Pickup F350 Super Duty Commercial Chassis)

Use Motorcraft Mercon ATF (XT-2-QDX).

All transfer cases use Motorcraft Mercon ATF (XT-2-QDX).

FLUID CAPACITIES

Note. Approximate fluid capacities are listed. Determine correct fluid level by mark on dipstick or by gauging fluid level at filler plug hole.

AUTOMATIC TRANSMISSION REFILL CAPACITIES (1) (2)

MANUAL TRANSMISSION REFILL CAPACITIES (1)

TRANSFER CASE REFILL CAPACITIES

1. Raise and support vehicle. Loosen oil pan bolts. Tap oil pan to break gasket seal, allowing fluid to drain. Remove retaining bolts, oil pan and gasket.
2. Remove retaining bolt (if equipped), oil filter/screen and gasket. Install NEW gasket, oil filter/screen and oil pan. Tighten retaining bolt to specification. See TORQUE SPECIFICATIONS table at end of article.
3. On A4LD applications, add 3 quarts (2.8L) of ATF or 5 quarts (4.7L) on all other applications of ATF to transmission. Use Motorcraft Mercon ATF (XT-2-QDX).
4. Check fluid level. See CHECKING FLUID LEVEL under LUBRICATION. When filling transmission, refer to AUTOMATIC TRANSMISSION REFILL CAPACITIES table. Recheck fluid level when transmission is at normal operating temperature. DO NOT overfill.

Raise and support vehicle. Remove drain plug and drain fluid. Install drain plug. Remove filler plug. Refill transmission with proper fluid to bottom of filler plug hole. See RECOMMENDED FLUID under LUBRICATION. When filling transmission, refer to MANUAL TRANSMISSION REFILL CAPACITIES table. Install filler plug.

No servicing information is available from manufacturer.

Raise and support vehicle. Remove drain plug and drain fluid. Install drain plug. Remove filler plug. Refill transfer case with proper fluid to bottom of filler plug hole. See RECOMMENDED FLUID under LUBRICATION. When filling transfer case, refer to TRANSFER CASE REFILL CAPACITIES table. Install filler plug.

AUTOMATIC TRANSMISSION BANDS

Note. The A4LD has an adjustment for intermediate and overdrive bands and the C-6 has only the intermediate band. (Scheme 162)and (Scheme 163).

A4LD & C-6

1. Raise and support vehicle. Ensure area around the band adjusting screw is clean. (Scheme 162)or (Scheme 163). Remove and discard adjusting screw lock nut. Install NEW lock nut and tighten to 120 INCH lbs. (14 N.m).
2. On A4LD models, back off adjusting screw 2 turns. On C-6 models, back off adjusting screw 1 1/2 turns. Hold adjusting screw in position and tighten NEW lock nut to 35-40 ft. lbs. (47-54 N.m).

Scheme 162

Scheme 163

KICKDOWN CONTROL CABLE (A4LD)

Note. Kickdown control cable self-adjusts after installation by depressing accelerator pedal to floor. If kickdown cable is removed, it may need to be reset and then readjusted.

Initial Resetting Procedure & Adjustment

If kickdown cable has been removed it must be reset when installing. From under the hood, depress adjustment D-flat while pulling the cable conduit out from the body. (Scheme 164) Adjust kickdown cable by depressing accelerator pedal to floor.

Note. If transmission kickdown is difficult to achieve at wide open throttle, ensure accelerator pedal travel is not restricted by floor mats.

Scheme 164

THROTTLE VALVE (T.V.) CONTROL CABLE (AOD)

Note. T.V. control cable is locked to proper length during initial assembly. Control cable may require adjustment if throttle body, control cable or transmission is replaced.

Scheme 165

1. Apply parking brake and place transmission in Neutral. DO NOT place transmission in Park. On F150/250 and Bronco models, remove cable linkage protective cover. On all models, ensure throttle lever is resting against idle stop. DO NOT adjust idle stop.
2. Ensure T.V. control cable is properly routed, free of sharp bends and operates freely. Using small screwdriver, pry lock tab outward to release T.V. control cable at throttle body. (Scheme 165)
3. Install a return spring on T.V. control lever at the transmission and hook spring on rear of transmission case. Ensure T.V. control lever is held in idle position (fully rearward toward rear of transmission). NOTE: If necessary, use 2 return springs to retain T.V. control lever in position.
4. With T.V. cable lock tab released and return spring in place, rotate T.V. control lever at transmission approximately 10-30 degrees and return slowly. Push lock tab downward on T.V. control cable at throttle body until lock tab is flush. Remove return spring.

T.V. Pressure Check & Adjustment With Engine On

1. Remove plug and install Pressure Gauge (T86L-70002-A) in T.V. pressure tap on side of transmission case. (Scheme 166) Remove cover from T.V. control cable linkage.
2. Insert tapered end of T.V. Cable Control Pressure Gauge Adjuster (T86L-70332-A) between slug on end of cable and plastic fitting attached to throttle lever. (Scheme 167)
3. Push T.V. cable control pressure gauge adjuster inward as far as possible, forcing slug away from plastic fitting. Start engine and operate until engine and transmission are at normal operating temperature. NOTE: Transmission fluid temperature should be 100-150°F (37-65°C) when checking T.V. pressure. DO NOT perform T.V. pressure check unless transmission fluid temperature is correct.
4. Apply parking brake. Place transmission in Neutral. DO NOT check T.V. control pressure with transmission in Park. With engine idling, note T.V. control pressure is 28-38 psi (1.97-2.67 kg/cm 2 ).
5. If T.V. control pressure is not within specification, T.V. control cable must be adjusted. To adjust T.V. control cable, pry up on T.V. control cable locking tab at throttle body. (Scheme 167)
6. The adjuster preload spring should cause adjusting slider to move away from throttle body, causing T.V. control pressure to increase. Push on adjusting slider from behind throttle body bracket until T.V. control pressure is 33 psi (2.3 kg/cm 2 ). (Scheme 167)
7. While holding slider, push T.V. control cable locking tab downward as far as possible to lock slider into position. Remove T.V. cable control pressure gauge adjuster. Allow engine to return to idle.
8. With engine idling and transmission in Neutral, T.V. control pressure should be less than 5 psi. (.3 kg/cm 2 ), preferably near zero. If T.V. control pressure is not as specified, readjust. Remove pressure gauge. Install and tighten plug to specification. See TORQUE SPECIFICATIONS table at end of article.

Scheme 166

Scheme 167

Bronco, Pickup & Van

1. Apply parking brake. On models with C-6 transmissions, place gearshift in "D" position. On models with AOD or E4OD transmissions, place gearshift in the circle "D" (overdrive) position.
2. On all models, hold gearshift lever against stop by hanging a 3-lb. (1.4 kg) weight on gearshift lever. Loosen shift rod-to-bellcrank assembly retaining nut. (Scheme 168)
3. Move manual lever on transmission to fully rearward position. Move manual lever forward to "D" position on C-6 models or circle "D" (overdrive) position on AOD and E4OD models.
4. With gearshift lever and manual lever on transmission in "D" or circle "D" (overdrive) position, tighten retaining nut to specification. See TORQUE SPECIFICATIONS table at end of article. Remove weight from gearshift lever. Check for normal operation in all selected positions.

Scheme 168

Aerostar, Explorer & Ranger

1. With engine off and parking brake applied, place gearshift in OD position. Hang a 3-lb. (1.4 kg) weight on gearshift lever.
2. Raise and support vehicle. Release lock tab on top of gearshift cable at transmission bracket by pushing the 2 tangs downward. Disconnect gearshift cable from manual lever on transmission.
3. On Aerostar models, move manual lever all the way forward and then rearward 3 detent positions. On Explorer and Ranger models, move manual lever all the way rearward and then forward 3 detent positions.
4. On all models, reconnect gearshift cable at manual lever on transmission. Push lock tab downward. Ensure lock tab fully engages and gearshift cable is locked in place.
5. Ensure gearshift cable is properly secured to floor panels. Lower vehicle. If shift indicator does not align with OD position on instrument panel, rotate thumb screw near shift indicator until properly aligned. Remove weight from gearshift.

Note. If necessary, remove steering column covers to access thumb screw for shift indicator adjustment. Ensure transmission operates in all gear ranges with correct transmission detent position.

1. Apply parking brake. On models with C-6 transmissions, place gearshift in "D" position. On models with AOD or E4OD transmissions, place gearshift in the circle "D" (overdrive) position.
2. On all models, raise and support vehicle. Disconnect gearshift cable from manual lever on transmission. Pull downward on lock tab on gearshift cable at transmission bracket.
3. Move manual lever on transmission to fully forward position. Move manual lever backward 4 detent positions to "D" position on C-6 models or circle "D" (overdrive) position on AOD and E4OD models.
4. Reconnect gearshift cable to manual lever on transmission. Push lock tab upward. Lower vehicle.
5. If shift indicator does not align with "D" position on C-6 models or circle "D" (overdrive) position on AOD and E4OD models, rotate thumb screw near shift indicator until properly aligned. Remove weight from gearshift.

Note. If necessary, remove steering column covers to access thumb screw for shift indicator adjustment. Ensure transmission operates in all gear ranges with correct transmission detent position.

AOD & A4LD

Neutral safety switch is located on side of transmission case and is non-adjustable. Use Socket (T74P-77247-A) when replacing neutral safety switch or neutral safety switch will be damaged.

C-6

1. Ensure gearshift cable or linkage is properly adjusted. See GEARSHIFT CABLE or GEARSHIFT LINKAGE under ADJUSTMENTS. Apply parking brake. Place gearshift in Neutral.
2. Loosen MLPS retaining screws. Install MLPS Aligner (T92P-70010-AH) in 3 slots on switch and actuator plate of MLPS. (Scheme 169) CAUTION: Ensure each leg of MLPS aligner engages with each slot of MLPS.
3. Tighten MLPS retaining screws to specification. See TORQUE SPECIFICATIONS table at end of article. Remove MLPS aligner.
4. Proper adjustment can be confirmed by ensuring etched line in actuator and housing are aligned with gearshift in Neutral. Ensure vehicle starts only in Park and Neutral and back-up lights operate in Reverse.

Scheme 169

E4OD

Remove shift linkage from transmission. Loosen MLPS retaining screws. Using MLPS Aligner (T89T-70010-J), align manual lever position sensor for Neutral gear. (Scheme 170) Tighten retaining bolts to specification. See TORQUE SPECIFICATIONS table at end of article. Install shift linkage.

Scheme 170

FUEL INJECTION PUMP LEVER (FIPL) SENSOR (DIESEL)

Note. Checking and adjusting FIPL requires a STAR Tester (007-00004) and Adapter Cable (007-00010).

Checking FIPL Sensor Operation

1. Perform Key On Engine Off (KOEO) Self-Test. See KOEO SELF-TEST in appropriate G - TEST W/CODES article in the ENGINE PERFORMANCE Section. During KOEO self-test, hold throttle to wide open position until fault codes have been displayed.
2. After last fault code has been displayed, press Overdrive Cancel Switch (OCS) to initiate FIPL sensor adjustment mode. In the adjustment mode, this will allow Star Tester to be used as an audible guide in checking and adjusting FIPL sensor. NOTE: Star tester will remain in adjustment mode for 10 minutes. Steps 3) and 4) must be done within this time frame. If time limit is exceeded, procedure must be repeated starting at step 1).
3. Remove throttle cable from throttle lever on right side of fuel injection pump. Place a.515" (13.08 mm) Gauge Block (T83T-7B200-AH) between gauge boss and maximum throttle travel screw. (Scheme 171) Hold throttle lever open against gauge block.
4. A steady tone from Star Tester indicates proper FIPL sensor adjustment. If FIPL sensor setting is too low, Star tester will emit a slow beeping sound (one beep per second). If FIPL sensor setting is too high, Star tester will emit a fast beeping sound (4 beeps per second). Adjust FIPL sensor if necessary.

Scheme 171

Adjusting FIPL Sensor

1. To adjust FIPL sensor, loosen FIPL sensor retaining screws. (Scheme 171) Rotate FIPL sensor until steady tone is heard from Star tester. A steady tone indicates FIPL sensor is properly adjusted. CAUTION: FIPL sensor bracket is permanently attached to fuel injection pump with tamper-proof screws. DO NOT loosen FIPL sensor bracket screws or move bracket to adjust FIPL sensor.
2. If FIPL sensor cannot be adjusted to obtain a steady tone, replace FIPL sensor and repeat adjustment procedure.
3. Remove gauge block. Open throttle to wide open position 5 times. Reinstall gauge block and recheck FIPL sensor adjustment. Readjust if necessary. Remove gauge block. Attach throttle cable. Start engine. Check throttle and transmission shift operation.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS