Repair manual
Wiring diagrams
Ford Pickup F150 Repair Manual
Step-by-step repair and maintenance instructions for the Ford Pickup F150 (1996–2012): removal, installation, adjustment, diagnostics and parameter checks with illustrations.
128sections
1721articles
ENManual language
- HVAC System - F150 Pickup 7
- HVAC Control System - General Information -- Excursion & F250-F550 Super Duty 5
- HVAC System - Air Distribution System & Filtering System - Excursion & F250-F550 Super Duty 3
- HVAC System - Heating & Ventilation -- Excursion & F250-F550 Super Duty 3
- HVAC System - Air Conditioning -- Excursion & F250-F550 Super Duty 4
- HVAC Control System - Excursion & F250-F550 Super Duty 4
- Automatic HVAC System - Control Components - Excursion & F250-F550 Super Duty 4
- Automatic Transmission - 4R70E/4R75E -- F150 8
- Automatic Transmission - 4R100 - Excursion & F250-F550 Super Duty 6
- Automatic Transmission - 5R110W (Torqshift(r)) - Excursion & F250-F550 Super Duty 6
- Automatic Transmission Cooling System - Excursion & F250-F550 Super Duty 4
- Automatic Transmission External Controls -- Excursion & F250-F550 Super Duty 4
- GEAR RATIO
- RANGE SELECTION
- Park
- Reverse
- Neutral
- Overdrive
- Second Position - 2nd Gear
- First Position
- Upshifts
- Downshifts
- Coastdown
- Kickdown
- Geartrain
- Input Shaft
- Output Shaft
- Overdrive System
- Center Support and Intermediate/Overdrive Clutch Cylinder
- Forward Drive System
- Low and Reverse Drive System
- Apply Components
- One-Way Clutch-Overdrive
- One-Way Clutch Intermediate
- One-Way Clutch Low-Reverse
- Mass Air Flow (MAF) Sensor
- Throttle Position (TP) Sensor
- Intake Air Temperature (IAT) Sensor
- Powertrain Control Module (PCM)
- Transmission Control Switch (TCS), Transmission Control Indicator Lamp (TCIL)
- Coast Clutch Solenoid (CCS)
- Electronic Pressure Control (EPC) Solenoid
- Shift Solenoids SSA and SSB
- Anti-Lock Brake Speed Sensor
- Turbine Shaft Speed (TSS) Sensor
- Output Shaft Speed (OSS) Sensor
- Digital Transmission Range (TR) Sensor
- Brake Pedal Position (BPP) Switch
- Electronic Ignition (EI) System
- Distributor Ignition (DI) System
- Air Conditioning (A/C) Clutch
- Manifold Absolute Pressure (MAP) Sensor
- Know/Understand the Concern
- Verification of Condition
- Determine Customer Concern
- Shift Linkage Check
- Check TSBs
- Before Pinpoint Tests
- Rotunda Transmission Tester
- PINPOINT TESTS
- Shift Solenoid Failure Mode Chart Always OFF
- Shift Solenoid Failure Mode Chart Always ON
- Engine Idle Speed Check
- Stall Speed Chart
- Engagement Concern: Harsh Forward Only
- Engagement Concern: Delayed/Soft Forward Only
- Shift Concerns: Feel - Soft/Slipping (Some/All)
- Shift Concerns: Feel - Harsh (Some/All)
- Material
- Removal
- Removal and Installation
- Installation
- Item 5: Shifter Bezel Removal Note
- Item 6: Overdrive Cancel Button Removal Note
- Item 14: Shifter Assembly Removal Note
- Item 15: Brake Shift Interlock Actuator Removal Note
- Item 14: Shifter Assembly Installation Note
- Item 6: Overdrive Cancel Button Installation Note
- Item 14: Shift Cable Installation Note
- Transmission - 4x2
- Transmission - 4x4
- PRESSURE CHART A
- PRESSURE CHART B
- PRESSURE CHART C
- PRESSURE CHART D
- STALL SPEED
- SHIFT SPEEDS
- GEAR RATIO
- RANGE SELECTION
- Park
- Reverse
- Neutral
- Overdrive
- Third Position - 3rd Gear
- Second Position - 2nd Gear
- First Position - Manual Low Gear
- Tow Haul
- SHIFT PATTERNS
- Upshifts
- Downshifts
- Coastdown
- Kickdown
- Grade Braking
- Power Take-Off (PTO)
- GEARTRAIN
- Input Shaft
- Output Shaft
- Overdrive and Coast Clutch System
- Center Support and Intermediate Clutch
- Forward Drive System
- Low and Reverse Drive System
- APPLY COMPONENTS
- Overdrive One Way Clutch (OWC) Mechanical Diode
- Low/Reverse Mechanical Diode
- Remote Filter
- Transmission Output Shaft Speed (OSS) Sensor
- Engine Coolant Temperature (ECT) Sensor
- Intake Air Temperature Sensor (IAT)
- Accelerator Pedal Position (APP) Sensor
- Turbine Shaft Speed (TSS) Sensor and Intermediate Shaft Speed Sensor
- Brake Pedal Position (BPP) Switch
- Powertrain Control Module (PCM)
- Tow Haul Switch
- Transmission Control Indicator Lamp (TCIL)
- 4x4 Low Switch
- Line Pressure Control Solenoid (PC-A)
- Pressure Switches (PS-A, PS-B, PS-C, PS-D, PS-E)
- Shift Solenoid Pressure Control Solenoids (SSPC-A, SSPC-B, SSPC-C, SSPC-D, SSPC-E)
- Line Pressure Relief Valve
- Know/Understand the Concern
- Verify the Condition
- Determine Customer Concern
- Shift Speeds - Diesel
- Shift Speeds - Gasoline
- Shift Linkage Check
- Check TSBs and OASIS
- Before Pinpoint Tests
- Procedure
- OSC For Transmission - Service Bay Mode
- OSC For Transmission - Drive Mode
- Using Output State Control (OSC) and Monitoring PIDs
- PID Chart
- P0730_Status
- Engine Idle Speed Check
- Stall Speed Chart
- Some/All Shifts Missing
- Timing Concerns - Erratic/Hunting (Some/All)
- Driveability Concerns
- Unexpected Elevated Idle Speed
- Transmission Failure Mode Effects Management (FMEM), Shift Concerns: Erratic/Hunting or Erratic Scheduling
- Material
- All transmissions
- Body System - Exterior
- Insulation
- Liquid Butyl Sealer
- Caulking Cord
- Weatherstrip Adhesive
- Silicone Lubricant
- Exterior Rear View Mirror
- Heated Exterior Rear View Mirror
- Auto Dimming Mirror
- Glass, Frames and Mechanisms
- Rear Window Defrost
- Rear Sliding Window
- Wipers and Washers
- Leaks
- Rear View Mirrors
- Possible Causes — Part 1
- Possible Causes — Part 2
- Window Grid Wire Repair
- Lead Terminal Repair
- Windshield Reseal
- Fender
- Cowl Panel Grille
- Pickup Bed
- Tailgate Lift Assist Torsion Rod
- Exterior Mirror
- Interior Mirror
- Door Window Glass - Front
- Door Window Glass - Rear, SuperCab
- Door Window Glass - Rear, SuperCrew
- Rear Window Glass
- Window Control Switch - Front
- Window Control Switch - Rear
- Windshield Glass
- Front Bumper
- Rear Bumper
- Charging System - Generators & Regulators - Excursion, F250-F550 Super Duty (Gasoline) 5
- Charging System - Generators & Regulators -- Excursion & F250-F550 Super Duty (Diesel with Single Generator) 5
- Generators & Regulators -- F250-F550 Super Duty (Diesel with Dual Generators) 9
- Generators & Regulators - F150 Pickup 7
- Battery, Mounting and Cables -- Excursion & F250-F550 Super Duty 3
- Rear Drive Axle/differential - Dana 80 -- F350 Super Duty 2
- Wheel Hubs & Bearings - Full Floating Axle - Dana -- F350-F550 Super Duty 3
- Rear Drive Axle/differential - Ford 10.50-INCH Ring Gear -- Excursion & F250-F350 Super Duty 3
- Wheel Hubs & Bearings - Full Floating Axle - Ford -- Excursion & F250-F350 Super Duty 3
- Front Drive Axle/differential -- Excursion & F250-F550 Super Duty 2
- Driveline System - General Information -- F150 2
Disc Brakes & Drum Brakes - Blackwood, F150 Heritage Pickup & F150 Pickup: Removal & Installation
10 subsections- REMOVAL & INSTALLATION
- Removal & Installation (Fixed Pedals With A/T)
- Removal & Installation (Fixed Pedals With M/T)
- Removal & Installation (Adjustable Pedals)
- Removal (2WD)
- Installation
- Removal & Installation (Control)
- Removal & Installation (Front Cable & Conduit)
- Removal & Installation (Rear Cable & Conduit)
- Removal - Parking Brake Shoes (Rear Disc)
- Anti-Theft System - F150 Pickup 4
- Handles, Locks, Latches and Entry Systems - F150 Pickup 5
- Anti-Theft- Pats System - Excursion & F250-F550 Super Duty 3
- Handles, Locks, Latches & Entry Systems -- Excursion & F250-F550 Super Duty 4
- Remote Keyless Entry System Transmitter Programming Procedures 2
- Passive Anti-Theft System Job Aid 3
- Item 2: Differential Pinion Shaft Lock Bolt Assembly
- Item 6: Differential Pinion Side Gear Disassembly
- Item 7: Differential Clutch Pack Disassembly
- Item 7: Differential Clutch Pack Assembly
- Item 3: Differential Clutch Spring Assembly
- Item 1: Differential Pinion Shaft Lock Bolt Assembly
- Items 3 and 4: Differential Case and Differential Bearing Shim Disassembly
- Item 14: Differential Bearing Disassembly
- Item 16: Rear Axle Drive Pinion Flange Disassembly
- Item 18: Rear Axle Drive Pinion Oil Seal Disassembly
- Item 21: Differential Drive Pinion Collapsible Spacer Disassembly
- Item 23: Inner Pinion Bearing Disassembly
- Item 25 and 26: Inner and Outer Pinion Bearing Cup Disassembly
- Item 29 and 30: Rear Axle Bearing Oil Seal and Rear Axle Shaft Bearing Disassembly
- Item 30: Rear Axle Shaft Bearing Assembly
- Item 29: Rear Axle Bearing Oil Seal Assembly
- Item 25 and 26: Outer and Inner Pinion Bearing Cup Assembly
- Item 23: Inner Pinion Bearing Assembly
- Item 21: Differential Drive Pinion Collapsible Spacer Assembly
- Item 18: Rear Axle Drive Pinion Oil Seal Assembly
- Item 16: Rear Axle Drive Pinion Flange Assembly
- Item 15: Drive Pinion Nut Assembly
- Item 14: Differential Bearing Assembly
- Items 25 and 26: Inner and Outer Pinion Bearing Cup Disassembly
- Item 21: Drive Pinion Collapsible Spacer Assembly
- Item 16: Rear Axle Pinion Flange Assembly
- Item 15: Pinion Nut Assembly
- Item 4: Differential Bearing Shim Assembly
- Item 16: Drive Pinion Flange Disassembly
- Item 18: Rear Axle Drive Pinion Seal Disassembly
- Item 26: Outer Pinion Bearing Cup Assembly
- Item 25: Inner Pinion Bearing Cup Assembly
- Item 18: Rear Axle Drive Pinion Seal Assembly
- Item 16: Drive Pinion Flange Assembly
- Item 1: Nut and Retainer Assembly Removal
- Item 2: Rear Disc Brake Caliper Assembly Removal
- Item 3: Rear Axle Brake Line Retainer Removal
- Item 4: Rear Axle Assembly Removal
- Item 5: Rear Axle U -bolt Assembly Removal
- Item 5: Rear Axle U -bolt Assembly Installation
- Item 4: Rear Axle Assembly Installation
- Item 3: Rear Axle Brake Line Retainer Installation
- Item 2: Rear Disc Brake Caliper Assembly Installation
- Item 1: Nut and Retainer Assembly Installation
- Removal
- Item 1: Universal Joint Flange Bolt Installation
- Item 2: Driveshaft Flange Yoke Removal
- Item 4: Driveshaft Slip Yoke Removal
- Item 6: Driveshaft Removal
- Item 10: Coupling Shaft Removal
- Item 10: Coupling Shaft Installation
- Items 7 and 9: Driveshaft Slip Yoke Boot Clamps Installation
- Item 6: Driveshaft Installation
- Item 4: Driveshaft Slip Yoke Installation
- Item 3: Driveshaft Center Bearing Bolts Installation
- Items 1 and 2: Driveshaft Flange Yoke Bolts and Driveshaft Flange Yoke Installation
- Removal and Installation
- Items 1 and 2: Driveshaft Flange Bolts Removal
- Items 6 and 8: Large and Small Boot Clamp Removal
- Item 7: Slip Yoke Boot Installation
- Items 6 and 8: Large and Small Boot Clamp Installation
- Item 4: Universal Joint Spider Installation
- Item 3: Universal Joint Snap Ring Installation
- Item 2: Front Driveshaft Flange Bolt Installation
- Item 1: Rear Driveshaft Flange Bolt Installation
- Item 2: Rear Disc Brake Caliper Removal
- Item 7: Differential Pinion Shaft Removal
- Item 8: U-washer Removal
- Item 10 and 11: Wheel Bearing Oil Seal and Axle Shaft Bearing Removal
- Item 8: U-washer Installation
- Item 5: Differential Housing Cover Installation
- Item 2: Rear Disc Brake Caliper Installation
- Item 1: Rear Disc Brake Caliper Bolts Installation
- Item 3: Tie-Rod End Nut Removal
- Item 5: Integrated Wheel End Disconnect Retaining Bolts Removal
- Item 7: Front Axle Halfshaft Removal
- Item 8: Integrated Wheel End Disconnect Removal
- Item 7: Front Axle Halfshaft Installation
- Item 5: Integrated Wheel End Disconnect Retaining Bolts Installation
- Item 4: Rear Pinion Oil Seal Removal
- Item 4: Rear Pinion Oil Seal Installation
- Item 3: Pinion Oil Seal Installation
- Item 2: Pinion Flange Installation
- Item 1: Pinion Nut and Washer Installation
- Incorrect Drive Belt Installation
- Item 1: Accessory Drive Belt Removal Note
- Item 3: EGR System Module to Exhaust Manifold Tube Removal Note
- Item 7: EGR System Module Gasket Installation Note
- Item 1: Positive Crankcase Ventilation (PCV) Hose Quick-Release Fitting Removal Note
- Item 1: PCV Hose Quick-Release Fitting Installation Note
- Removal and Installation
- Item 12: EGR Tube Removal Note
- Item 15: Fuel Tube Spring Lock Coupling Removal Note
- Items 5 and 16: Vapor Management Valve (VMV) Tube and Positive Crankshaft Ventilation (PCV) Tube Quick-Release Fitting Removal Note
- Item 17: Accessory Drive Belt Removal Note
- Item 38: Intake Manifold Bolts Removal Note
- Items 16 and 5: VMV Tube and PCV Tube Quick-Release Fitting Installation Note
- Item 4: Oil Level Indicator Bolt Removal Note
- Item 5: Crankcase Ventilation Tube Quick-Release Fitting Removal Note
- Item 11: LH Valve Cover Removal Note
- Item 5: Crankcase Ventilation Tube Quick-Release Fitting Installation Note
- Item 1: Positive Crankcase Ventilation (PCV) Tube Quick-Release Fitting Removal Note
- Items 2 and 3: Transmission Fluid Level Indicator Tube and Bolt Removal Note
- Item 1: PCV Tube Quick-Release Fitting Installation Note
- Items 2 and 3: Crankshaft Pulley Bolt and Washer Removal Note
- Items 3 and 2: Crankshaft Pulley Bolt and Washer Installation Note
- Item 2: Crankshaft Pulley Bolt Removal Note
- Items 1-16: Timing Drive Components Removal Note
- Items 2-5: Valve Spring Retainer Keys, Valve Spring Retainer, Valve Springs, and Valve Stem Seals Removal Note
- Item 14: Hydraulic Lash Adjuster Removal Note
- Item 14: Hydraulic Lash Adjuster Installation Note
- Items 3 and 4: Exhaust Manifold Nuts and Exhaust Manifold Installation Note
- Items 4 and 5: Exhaust Manifold Nuts and Exhaust Manifold Installation Note
- Items 1 and 2: Exhaust Manifold Nuts and Exhaust Manifold Installation Note
- Items 8 and 9: Oil Filter Adapter Gasket Removal Note
- Item 4: Oil Pan Removal Note
- Items 10-6: Oil Pump, Oil Pump Screen and Pickup Tube and Bolts Installation Note
- Item 8: Crankshaft Rear Seal Retainer Plate Installation Note
- Item 5: Crankshaft Rear Seal Installation Note
- Item 4: Crankshaft Oil Slinger Installation Note
- Item 1: Flexplate Bolt Installation Note
- Item 2: LH Engine Support Insulator Bolt Installation Note
- Code Information
- Induction System
- Valve Train
- Positive Crankcase Ventilation System
- Oil Pump
- Belt Tensioner - Mechanical
- Belt Tensioner - Dynamics
- Positive Crankcase Ventilation (PCV) Valve
- Intake Manifold
- Valve Cover RH
- Valve Cover LH
- Crankshaft Pulley and Crankshaft Seal
- Engine Front Cover
- Timing Drive Components
- Camshaft, Valve Springs and Valve Seals - LH
- Camshaft, Valve Springs and Valve Seals - RH
- Camshaft Roller Follower and Hydraulic Lash Adjuster
- Exhaust Manifold LH
- Exhaust Manifold RH
- Oil Filter Adapter
- Oil Level Indicator and Tube
- Oil Pan, Oil Pump, Oil Pump Screen and Pickup Tube
- Flexplate or Flywheel and Crankshaft Rear Seal
- Engine Support Insulators
- Cylinder Heads
- Cylinder Head
- Piston
- Incorrect Drive Belt Installation
- Item 2: Heated PCV Intake Fitting Tube Quick Release Fitting Removal Note
- Item 2: Heated PCV Intake Fitting Tube Quick Release Fitting Installation Note
- Items 5 and 13: Positive Crankcase Ventilation (PCV) Tube and Vapor Management Valve (VMV) Tube Quick-Release Fitting Removal Note
- Item 6: Fuel Supply Tube Spring Lock Coupling Removal Note
- Item 15: Engine Coolant Crossover Assembly Bolts Removal Note
- Items 23 and 24: Intake Manifold Gaskets Removal Note
- Items 14, 22-24: Intake Manifold Bolts, Intake Manifold and Gaskets Installation Note
- Items 5 and 13: PCV Tube and VMV Tube Quick-Release Fitting Installation Note
- Item 4: Crankcase Vent Tube Quick-Release Fitting Removal Note
- Item 4: Crankcase Vent Tube Quick-Release Fitting Installation Note
- Item 3: A/C Compressor Manifold Tube O-Ring Seal Installation Note
- Item 3: Power Steering Reservoir Assembly Removal Note
- Item 4: Positive Crankcase Ventilation (PCV) Tube Removal Note
- Item 6: Oil Level Indicator and Tube Removal Note
- Item 10: LH Valve Cover Bolts Removal Note
- Items 11 and 12: LH Valve Cover Gasket and Valve Cover Installation Note
- Item 4: PCV Tube Installation Note
- Item 1: Accessory Drive Belt Removal Note
- Item 2: Crankshaft Pulley Bolt Removal Note
- Item 4: Crankshaft Pulley Removal Note
- Item 5: Crankshaft Seal Removal Note
- Item 20: RH Radio Ignition Interference Capacitor Nut Removal Note
- Items 21: RH Radio Ignition Interference Capacitor Removal Note
- Items 23: LH Radio Ignition Interference Capacitor Removal Note
- Item 28: Power Steering Pump Bolts Removal Note
- Items 23: LH Radio Ignition Interference Capacitor Installation Note
- Items 21: RH Radio Ignition Interference Capacitor Installation Note
- Item 20: RH Radio Ignition Interference Capacitor Nut Installation Note
- Item 4: Crankshaft Pulley Installation Note
- Items 17-20: LH and RH Camshaft Phaser Sprocket Assembly and Bolt Removal Note
- Items 21-26: Variable Camshaft Timing (VCT) Housing and Bolts Installation Note
- Items 5-8: LH Camshaft Bearing Cap Bolts, Bearing Caps, and Camshaft Removal Note
- Item 4: Valve Seal Installation Note
- Items 5-8: RH Camshaft Bearing Cap Bolts, Bearing Caps, and Camshaft Removal Note
- Item 2: Hydraulic Lash Adjuster Removal Note
- Item 1: Camshaft Roller Followers Installation Note
- Items 2 and 4: Heated Oxygen Sensor (HO2S) Removal Note
- Item 9: LH Dual Converter Y-pipe Assembly Removal Note
- Items 11 and 12: LH Exhaust Manifold and Gasket Removal Note
- Item 8: Oil Filter Adapter Installation Note
- Item 4: Oil Pan Removal Note
- Items 10-6: Oil Pump, Oil Pump Screen and Pickup Tube and Bolts Installation Note
- Item 4: Crankshaft Oil Slinger Removal Note
- Item 5: Crankshaft Rear Seal Removal Note
- Item 7: Crankshaft Rear Seal Retainer Plate Installation Note
- Item 5: Crankshaft Rear Seal Installation Note
- Item 4: Crankshaft Oil Slinger Installation Note
- Item 8: Fuel Pulse Damper Vacuum Connector Removal Note
- VECI Decal
- Engine/Evaporative Emission System Information
- VECI Acronym Definitions
- Catalyst Efficiency Monitor
- Switch Ratio Method
- Index Ratio Method
- Comprehensive Component Monitor
- Evaporative Emission (EVAP) Leak Check Monitor
- Exhaust Gas Recirculation (EGR) System Monitor - Delta Pressure Feedback (DPFE) EGR and EGR System Module (ESM) EGR
- Electric Exhaust Gas Recirculation (EEGR) System Monitor
- Fuel System Monitor
- Heated Oxygen Sensor (HO2S) Monitor
- Misfire Detection Monitor
- Low Data Rate System
- High Data Rate System
- Generic Misfire Processing
- Profile Correction
- PCV System Monitor
- Secondary Air Injection (AIR) System Monitor-Electric Secondary Air Injection Pump System
- Thermostat Monitor
- Malfunction Indicator Lamp (MIL)
- Modifications to OBD Vehicles
- Multiplexing
- Multiplexing Implementation
- Standard Corporate Protocol (SCP)
- High Speed - Controller Area Network (HS-CAN)
- Flash Electrically Erasable Programmable Read Only Memory
- Idle Air Trim
- Short Term Fuel Trim
- Long Term Fuel Trim
- Failure Mode Effects Management
- Engine RPM/Vehicle Speed Limiter
- Powertrain Control Module
- Natural Gas (NG) Vehicle Module
- Constant Control Relay Module
- Fuel Pump Driver Module
- Generic Electronic Module
- Keep Alive Memory (KAM)
- Integrated Electronic Ignition System
- Vehicle Buffered Power (VBPWR)
- Vehicle Power (VPWR)
- Vehicle Reference Voltage (VREF)
- Mass Air Flow Return
- Signal Return
- Power Ground
- Gold Plated Pins
- PCM Inputs
- Air Conditioning Cycling Switch
- Air Conditioning Evaporator Temperature Sensor
- Air Conditioning Pressure Sensor
- Air Conditioning High Pressure Switch
- Brake Pedal Position Switch
- Brake Pressure Applied/Brake Deactivator Switch
- Camshaft Position Sensor
- Clutch Pedal Position Switch
- Crankshaft Position Sensor (Integrated Ignition Systems)
- Cylinder Head Temperature Sensor
- Differential Pressure Feedback EGR Sensor
- Engine Coolant Temperature Sensor
- Engine Fuel Temperature Sensor
- Engine Oil Temperature Sensor
- Fuel Level Input
- Fuel Tank Pressure Sensor
- Fuel Rail Pressure Sensor
- Generator Monitor (Gen Mon)
- Heated Oxygen Sensor
- Intake Air Temperature Sensor
- Intake Manifold Runner Control
- Intake Manifold Swirl Control
- Intake Manifold Tuning Valve
- Knock Sensor
- Mass Air Flow Sensor
- Output Shaft Speed Sensor
- Power Steering Pressure Switch
- Power Steering Pressure Sensor
- Power Take-Off Switch and Circuit
- Thermal Manifold Absolute Pressure Sensor
- Throttle Position Sensor
- Transmission Control Switch
- Vehicle Speed Sensor
- 4x4 Mode Switch
- PCM Outputs
- Canister Vent Solenoid
- Coil Pack
- Coil On Plug
- Engine Crank/Engine Running
- CMP FMEM
- Electric EGR System (EEGR)
- EGR System Module (ESM)
- EGR Vacuum Regulator Solenoid
- Electric Secondary Air Injection Pump
- Evaporative Emission Canister Purge Valve
- Fan Control
- Fuel Cap Off Indicator Lamp
- Fuel Injectors
- Fuel Pressure Regulator Control Solenoid
- Generator Communication (Gen Com)
- High Fan Control
- Idle Air Control Solenoid
- Low Fan Control
- Medium Fan Control
- Secondary Air Injection Bypass Solenoid
- Transmission Control Indicator Lamp
- Wide Open Throttle A/C Cut-Off (WAC)
- Vapor Management Valve (VMV)
- Powertrain Control Module - Vehicle Speed Output (VSO)
- Crankshaft Position Sensor
- Returnable Fuel System
- Mechanical Returnless Fuel System
- Electronic Returnless Fuel System
- Fuel Pump and Reservoir
- Fuel Pump Module
- Fuel Filters
- Fuel Injector
- Fuel Pressure Regulator
- Fuel Rail Pulse Damper
- Inertia Fuel Shutoff (IFS) Switch
- Natural Gas Fuel System
- Fuel Rail
- Fuel Injector(s)
- High Pressure Fuel Filter
- Fuel Lines and Fittings
- Fuel Tank Shutoff Valve
- Fuel Rail Shut-Off Valve
- Differential Pressure Feedback EGR System
- Tube Mounted Differential Pressure Feedback EGR Sensor
- Exhaust Gas Recirculation Valve
- Highlights of the Electric System
- Hardware
- Enhanced Evaporative Emission (EVAP) System
- EVAP Canister Purge Valve
- Intake Manifold Runner Control (IMRC) Electric Actuated System
- Intake Manifold Swirl Control (IMSC) Vacuum Actuated System
- Intake Manifold Tuning Valve (IMTV)
- Throttle Body System Hardware
- Idle Air Control Valve
- Throttle Body Housing
- Electric Secondary Air Injection System
- Electric AIR Pump
- AIR Bypass Solenoid
- AIR Diverter Valve
- Variable Cam Timing
- Catalytic Converter
- Light Off Catalyst
- Three-Way Catalyst (TWC) Conversion Efficiency
- Exhaust System
- Underbody Catalyst
- Three-Way Catalytic Converter
- Exhaust Manifold/Runners
- Exhaust Pipes
- Heated Oxygen Sensors (HO2S)
- Muffler
- Supercharger Bypass System
- Intercooler System
- Electronic Throttle Body (ETB)
- Accelerator Pedal Position Sensors (APPS)
- Electronic Throttle Control System Strategy
- Accelerator and Throttle Position Sensor Inputs
- Throttle Plate Position Controller (TPPC) Outputs
- Engine Performance Diagnostic Routine Outline - General Information
- Engine Performance Safety Precautions
- Parasitic Load Explanation & Test Procedures - General Information 2
- Waveforms - Injector Pattern Tutorial - General Information 2
- Electrostatic Discharge Warning - General Information
- State Emission Standards - Diesel
- Material
- Engine Oil Leaks
- Engine Oil Leaks - Fluorescent Oil Additive Method
- Leakage Points - Underhood
- Leakage Points - Under Engine - With Vehicle on Hoist
- Leakage Points - With Transmission and Flywheel Removed
- Compression Pressure Limit Chart
- Cylinder Leakage Detection
- Excessive Engine Oil Consumption
- Valve Train Analysis - Engine Off - Valve Cover Removed
- Valve Train Analysis - Engine Off, Camshaft Roller Followers and Hydraulic Lash Adjusters, Overhead Camshaft
- 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
- Valve Train Analysis - Engine Off, Valves and Cylinder Head
- Valve Train Analysis - Engine Running
- Valve Train Analysis - Engine Running, Valves and Cylinder Head
- Valve Train Analysis - Engine Running, Camshaft Lobe Lift
- Camshaft Journal - Clearance, Plastigage Method
- Camshaft End Play
- Camshaft Lobe Lift
- Camshaft Runout
- Crankshaft End Play
- Crankshaft Runout
- Piston - to Cylinder Bore Clearance
- Piston - Selection
- Piston - Ring End Gap
- Connecting Rod - Cleaning
- Connecting Rod - Bearing Journal Clearance
- Valve Stem to Valve Guide Clearance
- Valve Spring Strength
- Valve - Seat Inspection
- Cylinder Head Distortion
- Cylinder Bore - Cleaning
- Crankshaft Main Bearing Journal - Clearance
- Material
- Engine Oil Leaks
- Engine Oil Leaks-Fluorescent Oil Additive Method
- Leakage Points-Underhood
- Leakage Points-Under Engine-With Vehicle on Hoist
- Leakage Points-With Transmission and Flywheel Removed
- Compression Pressure Limit Chart
- Cylinder Leakage Detection
- Excessive Engine Oil Consumption
- Valve Train Analysis-Engine Off-Valve Cover Removed
- Valve Train Analysis-Engine Off, Camshaft Roller Followers and Hydraulic Lash Adjusters, Overhead Camshaft
- 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
- Valve Train Analysis-Engine Off, Valves and Cylinder Head
- Valve Train Analysis-Engine Running, Valves and Cylinder Head
- Valve Train Analysis-Engine Running, Camshaft Lobe Lift
- Sprockets
- Camshaft Journal - Clearance, Plastigage Method
- Camshaft End Play
- Camshaft Lobe Lift
- Camshaft Runout
- Crankshaft Main Bearing Journal - Clearance
- Crankshaft End Play
- Crankshaft Runout
- Piston - to Cylinder Bore Clearance
- Piston - Selection
- Piston - Ring End Gap
- Connecting Rod - Cleaning
- Connecting Rod - Bearing Journal Clearance
- Valve - Stem to Valve Guide Clearance
- Valve - Spring Squareness
- Valve Spring Strength
- Valve and Seat Refacing Measurements
- Cylinder Head - Distortion
- Cylinder Bore - Cleaning
- Entertainment System - F150 Pickup 5
- Entertainment System - General Information -- Excursion & F250-F550 Super Duty 2
- Audio Unit System- Excursion & F250-F550 Super Duty 3
- Antenna System -- Excursion & F250-F550 Super Duty
- Speaker System -- Excursion & F250-F550 Super Duty
- Video System - Excursion & F250-F550 Super Duty
- Headlamps
- Autolamps
- Stoplamps
- Turn Signal/Hazard Lamps
- Parking Lamps
- Fog Lamps
- Reversing Lamps
- Trailer Tow
- Daytime Running Lamps (DRL)
- Possible Causes
- Turn Signal and Hazard Lamps
- Parking, Rear and License Lamps
- Trailer Lamps
- Daytime Running Lamps
- Headlamp Aiming
- Photometric Aiming
- Screen Method Aiming
- Mechanical Aiming
- Material
- Daytime Running Lamp (DRL) Module
- Inspection and Verification
- Symptom Chart
- PINPOINT TEST E: THE HEADLAMPS ARE ON CONTINUOUSLY
- Vehicle Security Module Diagnostic Trouble Code (DTC) Index
- PINPOINT TEST Q: THE PARKING, REAR OR LICENSE LAMPS ARE ON CONTINUOUSLY
- PINPOINT TEST S: THE FOG LAMPS ARE ON CONTINUOUSLY
- PINPOINT TEST U: THE REVERSING LAMPS ARE ON CONTINUOUSLY
- PINPOINT TEST AA: THE DAYTIME RUNNING LAMPS ARE ON WITH THE IGNITION SWITCH OFF
- Fuel System - F150 Pickup 5
- Fuel System & Engine Controls - 5.4L (2V) - Excursion & F250-F350 Super Duty 3
- Fuel System & Engine Controls - 6.8L -- Excursion & F250-F550 Super Duty 3
- Fuel System - General Information - Gasoline & Diesel -- Excursion & F250-F550 Super Duty 3
- Fuel Tank & Fuel Lines - Gasoline & Diesel -- Excursion & F250-F550 Super Duty 3
- Fuel System & Engine Controls - 6.0L Diesel - Excursion & F250-F550 Super Duty 2
- Information, Gauges and Warning Devices System - F150 Pickup 4
- Body System - Interior - F150 Pickup 6
- Instrument Cluster System & Panel Illumination - Excursion & F250-F550 Super Duty 2
- Instrument Cluster System -- Excursion & F250-F550 Super Duty 3
- Information Center -- Excursion & F250-F550 Super Duty 6
- Instrument Panel & Console -- Excursion & F250-F550 Super Duty
- Hood
- Door, Front
- Door, Rear, SuperCab
- Door, Rear, Crew Cab, Excursion
- Tri-Back Door System
- Liftgate
- Cargo Doors
- Keyless Entry
- Locks, Latches and Entry Systems - Non Module Controlled
- Locks, Latches and Entry Systems - Module Controlled
- Power Locks
- Power Unlock Inhibit
- Deactivating/Activating Power Door Unlock Switch Inhibit
- Autolock
- Autolock Enable/Disable - Using the Hardwired Keyless Entry Keypad
- Autolock Enable/Disable - Using the Ignition Switch
- Smart Unlocking
- Remote Transmitter Lock/Unlocking Control - Unlocking
- Remote Transmitter Lock/Unlocking Control - Locking
- Panic Alarm
- Keyless Entry Keypad
- Programming Personal Codes
- Anti-Scan Feature
- Unlocking the Doors with the Keyless Entry Keypad System
- Locking the Doors with the Keyless Entry Keypad System
- Wireless Keyless Entry Keypad Remastering (F-Super Duty vehicles built before 12/03 only)
- Remote Transmitter Programming
HVAC Control System - General Information -- Excursion & F250-F550 Super Duty: Diagnosis
10 subsections- Electronic Automatic Temperature Control Module - Diagnostic Methods
- Electronic Automatic Temperature Control Module Self-Test
- Diagnostic Trouble Code Index
- ELECTRONIC AUTOMATIC TEMPERATURE CONTROL (EATC) MODULE DIAGNOSTIC TROUBLE CODE (DTC) INDEX
- PINPOINT TEST J: THE A/C DOES NOT OPERATE/DOES NOT OPERATE CORRECTLY
- Heater Core - Pressure Test
- A/C Evaporator/Condenser Core - On Vehicle Leak Test
- A/C Compressor - External Leak Test
- Visual inspection
- Diagnostic Table
- Climate Control System
- Heat Transfer
- Latent Heat of Vaporization
- Relative Humidity
- Effects of Pressure on Boiling or Condensation
- Compressor Anti-Slugging Strategy
- The Refrigerant Cycle
- Electronic Manual Temperature Control System
- Electronic Automatic Temperature Control System
- MAX A/C
- PANEL
- PANEL/FLOOR
- OFF
- FLOOR
- FLOOR/DEFROST
- DEFROST
- AUTO
- Air Distribution
- Heating and Ventilation
- Heater Core
- Blower Motor
- Heater Core and Evaporator Core Housing
- Air Conditioning
- A/C Compressor Pressure Relief Valve
- Condenser Core
- Refrigerant Lines
- Evaporator Core
- Evaporator Core Orifice Tube
- Suction Accumulator
- Air Conditioning (A/C) Cycling Switch
- High Pressure Cutoff Switch
- Electronic Manual Temperature Control
- Control System Inputs
- Blower Motor Switch
- Control System Outputs
- Blower Motor Resistor
- Temperature Blend Door Actuator
- Mode Door Actuators
- Electronic Automatic Temperature Control
- EATC Module
- Steering Wheel Audio/Climate Control Switch
- In-Vehicle Temperature Sensor
- Solar Radiation Sensor
- Ambient Temperature Sensor
- Blower Motor Speed Control
- Electronic Automatic Temperature Control Module - Retrieve Continuous DTCs
- Possible Causes
- Heater Core-Plugged
- Air Conditioning (A/C) System Check - Retail Procedure
- Material
- Disconnect
- Connect
- Procedure 1 - Ambient Temperature At or Below 38°C (100°F)
- Procedure 2 - Ambient Temperature Above 38°C (100°F)
- Electronic Leak Detection
- Fluorescent Dye Leak Detection
- Fluorescent Dye Detection
- Fluorescent Dye Injection - Using an A/C Refrigerant Center and Dye Injector
- Fluorescent Dye Injection - Using a Dye Injector Loop Kit
- Air Conditioning (A/C) System Recovery, Evacuation and Charging
- Refrigerant System Recovery
- Refrigerant System Evacuation Using an R-134a Service Center
- Refrigerant System Evacuation Using an R-134a Manifold Gauge Set
- Refrigerant System Charging Using an R-134a Service Center
- Refrigerant System Charging
- Refrigerant Oil Adding
- Oil Injection Using a Dye/Lubricant Injector
- Contaminated Refrigerant Handling
- Air Conditioning (A/C) Odor Treatment
- A/C Odor Treatment
- Air Conditioning (A/C) Compressor
- Air Conditioning (A/C) Compressor Shaft Seal
- Evaporator Core Orifice
- Condenser to Evaporator Line
- Instrument Cluster and Panel Illumination
- Instrument Cluster
- Instrument Cluster Module Configuration
- Message Center
- Integrated Circuit Display
- Speedometer
- Tachometer
- Odometer/Trip Odometer
- Fuel Gauge
- Temperature Gauge
- Oil Pressure Gauge
- Voltage Gauge
- Air Bag Warning Indicator
- Anti-Lock Brake System (ABS) Warning Indicator
- BRAKE Warning Indicator
- Charging System Warning Indicator
- Door Ajar Warning Indicator
- Safety Belt Warning Indicator
- Electronic Throttle Control Indicator
- High Beam Indicator
- RH and LH Turn Indicators
- Malfunction Indicator Lamp (MIL)
- Speed Control Indicator
- 4x4 HIGH and 4x4 LOW Indicators
- Information Displays
- Setup Displays
- Warning Messages
- Horn
- Horn switches
- Horn relay
- Parking Aid
- Possible Causes
- Normal Conditions
- Safety Belt Warning Chime
- Belt Minder
- Door Ajar Warning Chime
- Key-In-Ignition Warning Chime
- Headlamps Warning Chime
- Air Bag Redundant Chime
- Vehicle Demagnetizing
- Preparation
- Deactivating/Activating
- Instrument Cluster Diagnostic Trouble Code (DTC) Index
- Restraint Control Module Diagnostic Trouble Code (DTC) Index
- ABS Control Module Diagnostic Trouble Code (DTC) Index
- Powertrain Control Module (PCM) Diagnostic Trouble Code (DTC) Index
- Instrument Cluster Self-Diagnostic Mode
- PINPOINT TEST A: NO COMMUNICATION WITH THE INSTRUMENT CLUSTER
- PINPOINT TEST B: INCORRECT FUEL GAUGE INDICATION
- PINPOINT TEST C: INCORRECT VOLTAGE GAUGE INDICATION-MANUAL TRANSMISSION ONLY
- PINPOINT TEST D: INCORRECT OIL PRESSURE GAUGE INDICATION
- PINPOINT TEST E: INCORRECT TEMPERATURE GAUGE INDICATION
- PINPOINT TEST H: THE SPEEDOMETER IS INOPERATIVE
- PINPOINT TEST J: THE DOOR AJAR INDICATOR IS INOPERATIVE (CHIME IS OPERATIVE)/DOES NOT OPERATE CORRECTLY
- PINPOINT TEST K: THE SAFETY BELT WARNING INDICATOR IS INOPERATIVE (CHIME IS OPERATIVE)/DOES NOT OPERATE CORRECTLY
- PINPOINT TEST L: THE ABS WARNING INDICATOR IS NEVER/ALWAYS ON
- PINPOINT TEST M: THE BRAKE WARNING INDICATOR IS NEVER ON
- PINPOINT TEST O: THE CHARGING SYSTEM INDICATOR IS NEVER ON
- PINPOINT TEST P: THE AIR BAG WARNING INDICATOR IS NEVER/ALWAYS ON
- PINPOINT TEST Q: HIGH BEAM INDICATOR IS NEVER ON
- PINPOINT TEST R: THE LH TURN INDICATOR IS NEVER ON
- PINPOINT TEST S: THE RH TURN INDICATOR IS NEVER ON
- PINPOINT TEST T: THE 4X4 HIGH/LOW RANGE INDICATOR IS NEVER/ALWAYS ON-ELECTRONIC
- PINPOINT TEST U: THE 4X4 HIGH/LOW RANGE INDICATOR IS NEVER/ALWAYS ON-MANUAL SHIFT
- PINPOINT TEST X: THE SPEED CONTROL INDICATOR IS NEVER/ALWAYS ON
- PINPOINT TEST Y: THE THEFT INDICATOR IS NEVER/ALWAYS ON
- PINPOINT TEST AC: THE INSTRUMENT CLUSTER IS INOPERATIVE
- Engine System - General Information - F150 Pickup 3
- Engine - 4.6L (2V) - F150 Pickup 5
- Engine - 5.4L (3V) - F150 Pickup 6
- Engine System - General Information -- Excursion & F250-F550 Super Duty 3
- Engine - 5.4L (2V) -- Excursion & F250-F350 Super Duty
- Engine - 6.8L -- Excursion & F250-F550 Super Duty 2
- Engine - 6.0L Diesel -- F250-F550 Super Duty 5
- Front Seats
- Heated Seats
- Second Row Seating
- Occupant Classification Sensor
- Seat Positioning - Seat Control Switch
- Seat Positioning - Memory Feature
- Seats
- Pinpoint Tests
- Possible Causes
- Driver Seat
- Rear Seat
- Front Seat Cushion - Driver
- Front Seat Cushion - Passenger
- Front Seat Backrest - With Seat Integrated Restraints (SIR)
- Front Seat Backrest-Without Seat Integrated Restraints (SIR)
- Front Seat Backrest - 20 Percent
- Starting System - Excursion & F250-F550 Super Duty - Gasoline 6
- Starting System - F150 Pickup 7
- Starting System -- Excursion & F250-550 Super Duty - Diesel 7
- Fuel Charging System , Starting System & Engine Controls - 4.6L (2V) - F150 Pickup 6
- Fuel System, Starting System & Engine Controls - 5.4L (3V) - F150 Pickup 6
- Front Suspension System - 2WD - Excursion, F-250 & F-350 Super Duty 5
- Front Suspension System - 4WD Leaf Spring - Excursion, F250-F550 Super Duty 6
- Front Suspension - 2WD Coil Spring - F150 Pickup 6
- Front Suspension - 4WD Coil Spring - F150 Pickup 6
- Suspension System-General Information - F150 Pickup 5
- Suspension System - General Information - Excursion & F250-F550 Super Duty 4
- Engine Controls - Introduction - Cng, Flex-Fuel & Gasoline 3
- Engine Controls - Introduction - Diesel 3
- Engine Controls - Theory & Operation - 6.0L Diesel 3
- Engine Controls - Diagnostic Methods - 6.0L Diesel 7
- Engine Controls - Symptom Charts -- 6.0L Diesel
- Engine Controls - Diagnostic Subroutines - 6.0L Diesel 3
- Engine Controls - Pinpoint Tests - 6.0L Diesel 3
- Engine Controls - Reference Values - 6.0L Diesel 3
- Engine Controls - Pinpoint Tests - Cng, Flex-Fuel & Gasoline
- Engine Controls - Theory & Operation - Cng, Flex-Fuel & Gasoline 8
- Engine Controls - Diagnostic Methods - Cng, Flex-Fuel & Gasoline 8
- Engine Controls - Symptom Charts - Cng, Flex-Fuel & Gasoline 2
- Engine Controls - Powertrain DTC Charts & Descriptions - Cng, Flex-Fuel & Gasoline
- Inspection and Verification
- 4x4 Module (PCM) Diagnostic Trouble Code (DTC) Index
- Symptom Chart
- PINPOINT TEST A: NO COMMUNICATION WITH THE 4X4 MODULE (PCM)
- PINPOINT TEST B: THE FRONT AXLE DOES NOT ENGAGE/DISENGAGE CORRECTLY/MAKES NOISE IN 2H UNDER HEAVY THROTTLE
- Pinpoint Test C: The Vehicle Does Not Shift Between 2WD And 4WD Modes Correctly
- Pinpoint Test D: The Vehicle Does Not Shift Between 4H And 4L Modes Correctly
- Pinpoint Test E: The 4WD High Does Not Engage At Speed Correctly
- Pinpoint Test F: The 4X4 System Jumps Out Of Gear
- PINPOINT TEST G: STRAIGHTLINE DRIVELINE WIND-UP
- PINPOINT TEST H: MECHANICAL SHIFT ON THE FLY (MSOF) FUNCTIONAL TEST
- Pinpoint Test I: The Instrument Cluster 4L And 4H Indicators Do Not Operate Correctly/Do Not Operate/Flash
- Four-Wheel Drive Systems - Electronic Shift
- Inspection and Verification - Electronic Shift
- PINPOINT TEST J: NO COMMUNICATION WITH THE 4X4 MODULE (PCM)
- Pinpoint Test K: The Front Axle Does Not Engage/Disengage Correctly/Makes Noise In 2H Under Heavy Throttle
- Pinpoint Test L: The Vehicle Does Not Shift Between 2WD And 4WD Modes Correctly
- Pinpoint Test M: The Vehicle Does Not Shift Between 4H And 4L Modes Correctly
- Pinpoint Test N: 4WD Does Not Engage At Speed Correctly
- Pinpoint Test O: The 4X4 System Jumps Out Of Gear
- Pinpoint Test P: Straightline Driveline Wind-Up
- Pinpoint Test Q: Electronic Shift On The Fly (ESOF) Functional Test
- Pinpoint Test R: The Instrument Cluster 4L And 4H Indicators Do Not Operate Correctly/Do Not Operate/Flash
- Item 11: Bolts Disassembly Note
- Item 12: Case Disassembly Note
- Item 27: Output Shaft Disassembly Note
- Item 33: Input Snap Ring Disassembly Note
- Item 41: Snap Ring Disassembly Note
- Item 45: Shift Lever Set Screw Disassembly Note
- Item 50: Shift Shaft Oil Seal Assembly Note
- Item 45: Shift Lever Set Screw Assembly Note
- Item 35: Bushing Assembly Note
- Item 2: Harness Connector Disassembly Note
- Item 8: Bolt Disassembly Note
- Item 24: Rear Output Shaft Disassembly Note
- Item 29: Shift Cam Disassembly Note
- Item 31: Input Snap Ring Disassembly Note
- Item 39: Snap Ring Disassembly Note
- Item 33: Bushing Assembly Note
- Item 3: Bolt Assembly Note