Haynes Ford Pick-Ups & Bronco 1980 to 1995 Automotive Repair Manual [36058] 1563921529, 9781563921520

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Ford

Pick-ups & Bronco Automotive

Repair

Manual by Mark Christman, John B Raffa —~and John H Haynes Member of the Guild of Motoring Writers

Models covered: F-100, F-150, F-250, F-350 and Bronco with 300 cu in

(4.9L) inline six-cylinder, 232 cu in V6, and 255, 302 (5.0L), 351 (5.8L), 400 and 460 cu in (7.5L) V8 engines Manual and automatic transmissions Two-wheel drive and four-wheel drive, 1980 thru 1995 Does not include diesel engine or Super Duty vehicles

(8x3 an 880)

a

ab A

AUTOMOTINIE

PARTS & ACCES SORIES VIEMBER

Haynes Publishing Group _Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA

ABCDE FGHIJ KL

Acknowledgements We are grateful to the Champion Spark Plug Company, who supplied the illustrations of various spark plug conditions, and to the Ford Motor Company for their assistance with technical information and certain illustrations. Wiring diagrams were provided by Mitchell International.

© Haynes North America, Inc. 1995 With permission from J.H. Haynes & Co. Ltd.

A book in the Haynes Automotive Repair Manual Series Printed in the U.S.A. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, recording or by any information storage or retrieval system, without permission in writing from the copyright holder.

ISBN 1 56392 152 9 Library of Congress Catalog Card Number 95-076872 While every attempt is made to ensure that the information in this manual is correct, no liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

94-416

About this manual

Introduction to the Ford Pick-ups and Bronco Vehicle identification numbers

Buying parts Maintenance techniques, tools and working facilities

Jacking and towing Booster battery (jump) starting

SOoe0900 t

Automotive chemicals and lubricants

Safety first! Conversion factors

Troubleshooting

s°00006 “-ODOAN oes ok ot NO RD

N

Chapter 1 Tune-up and routine maintenance

Chapter 2

1-1

PartA

Inline six-cylinder engine

2A-1

V8 engines

2B-1

V6 engine

2C-1

Chapter 2

2D

PartD

General engine overhaul procedures

2D-1

Chapter 3 Cooling, heating and air conditioning systems

3-1

Chapter 4 Fuel and exhaust systems

4-1

Chapter 5 Engine electrical systems

5-1

Chapter 6 Emissions control systems

Chapter 7

PartA

Manual transmission

Chapter 7

TA-1

7B

PartB

Automatic transmission

Chapter 7

6-1

7B-1

PartC

Transfer case

7C

7C-1

Chapter 8 Clutch and driveline

8-1

Suspension and steering systems

10-1

Body

44-

—_

Chassis electrical system

12-

—_

Wiring diagrams

12-22

Index

IND-1

IND

Haynes mechanic, author and photographer with Ford F250 pick-up

0-5

About this manual Its purpose The purpose of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; it provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its labor and overhead costs. An added benefit is the sense of satisfaction and accomplishment that you feel after doing the job yourself.

Using the manual The manual is divided into Chapters. Each Chapter is divided into numbered Sections, which are headed in bold type between horizontal

lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used in illustration captions pinpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the illustration refers to Section 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text, are not normally repeated. When it’s necessary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the word “Chapter” apply to Sections and/or paragraphs in the same Chapter. For example, "see Section 8” means in

the same Chapter.

.

References to the left or right side of the vehicle assume you are sitting in the driver's seat, facing forward. Even though we have prepared this manual with extreme care, neither the publisher nor the author can accept responsibility for any

errors in, or omissions from, the information given.

NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand.

CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Caution is found. Not heeding a Caution can result in damage to the assembly being worked on.

WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Warning is found. Not heeding a Warning can result in personal injury.

Introduction to the Ford F-series and Bronco The F-series and Bronco models are conventional front-engine, rear-wheel drive vehicles. Over the years of production covered by this manual, engine options include the 309 cu. in. (4.9L) inline six-cylinder engine, the 232 cu. in. V6 engine and the 255 cu. in., 302 cu. in. (5.0L), 351 cu. in. (5.8L), 400 and 460 (7.5L) V8 engines. Power is transmitted through either manual or automatic transmission to a driveshaft and solid rear axle on two-wheel drive (2WD) models. On four-wheel drive (4WD) models, a transfer case transfers power to the front axle by way of a driveshaft. Transmissions used include a four-speed manual, two different five-speed overdrive manu-

als, a three-speed automatic and two different four-speed overdrive automatics. Three different transfer cases are available - two manual shift and one electronic shift. All 2WD models use twin I-beam independent front suspension with coil springs and radius arms. 4WD models (except F350) use a similar independent front suspension with a two-piece front driveaxle assembly, coil springs and radius arms (except F250). F250 4WD models use leaf springs instead of coil springs on its independent front suspension. F350 4WD models use a solid front axle and leaf springs. All models use semi-elliptical leaf springs at the rear. All models are equipped with front disc and rear drum brakes.

Vehicle identification numbers Modifications are a continuing and unpublicized process in vehicle manufacturing. Since spare parts lists and manuals are compiled on a numerical basis, the individual vehicle numbers are necessary to correctly identify the component required.

Vehicle Identification Number (VIN) This very important identification number is stamped on a plate attached to the dashboard inside the windshield on the driver’s side of the vehicle (see illustrations). The VIN also appears on the Vehicle Certificate of Title and Registration. It contains information such as where and when the vehicle was

manufactured,

the model

year and

the body style.

Vehicle Certification Label The Vehicle Certification Label is attached to the driver’s side door pillar (see illustration). Information on this label includes the

The Vehicle Identification Number (VIN) is visible through the driver’s side of the windshield

SAMPLE VIN NUMBER

Nia (2 1

2

3

4

5

67

05e0 a

8

9

Position 1, 2, and 3 — Manufacturer, Make and Type

6

Position 10 — Model Year

(World Manufacturer Identifier)

7

Position 11 — Assembly Plant

8

Position 12 —

Position.-4 — Brake System/GVWR Position 5, 6, and 7 —

Model or. Line, Series, Chassis, Cab Type Position 8 — Engine Type — Why or Position 9 — Check Digit

is reached, then changes to a constant 'B” and so on

9

Position 13 through 17 —

Vehicle Identification Number details —_—_—_—

Constant “A” until sequence number of 99,999

Sequence number — 00001

begins at

Vehicle identification numbers

‘

:

1506KG

0-7

MFD. BY FORD MOTOR CO. IN U.S.A. GVWR: 6600 LB/2994 KG REAR GAWR: 4004 LB WITH 1816KG TIRES LT 215/85R 16D

g

TIRES

THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFFECT ON THE DATE OF MANUFACTURE SHOWN ABOVE VIN: 1FTEF2Z5H5PLA00000 F0083

©O©6© OOO @®

(A) (B) (C) (D) (E) (F) (G) (H)

SPRING 2029

(A)(B)(C)(D)

05

19

a)

a8

19

QD

@

@3

The Certification label is located on the left front door post

71 | Name and location of manufacture 2 Date of manufacture 3 Front Gross Axle Weight Rating in pounds (LB) and

kilograms (KG) 4 _ Front tire size 5 Front rim size 6 Front tire cold psi 7 Gross Vehicle Weight Rating in pounds (LB) and kilograms (KG) 8 Rear Gross Axle Weight Rating in pounds (LB) and kilograms (KG) 9 Rear tire size 10 ~+=Rear rim size 11. ~+~Rear tire cold psi 12 Vehicle Identification Number (VIN) A World manufacturer identifier B Brake type and Gross Vehicle Weight Rating (GVWR) class C Model or line, series chassis cab or body type D Engine type E Check digit

24 25

F Mode/year G Assembly plant code H Sequential serial number Type vehicle Exterior paint codes (two sets of figures designates a two-tone) Wheelbase in inches Model code and GVW Interior trim, seat and body/cab type Transmission code Rear axle code Front axle code (if so equipped) District/special order codes External body type stripe code Suspension identification codes A Auxiliary/option usage code (front) B Front spring code C A auxiliary/option usage code (rear) D Rear spring code Front axle accessory reserve capacity in pounds Total accessory reserve capacity in pounds

Engine identification label name of the manufacturer, the month and year of production, the Gross Vehicle Weight Rating (GVWR), the Gross Axle Weight Rating (GAWR) and other vehicle specific information. Some of the information is in the form of codes, requiring a conversion chart to obtain the desired information. Included are the conversions for the rear axle ratio and transmission type codes (see illustrations).

Engine number The engine number is stamped onto a machined pad on the external surface of the engine block. There’s also an identification label that’s usually on the valve cover (see illustration).

The engine identification label can usually be found on the valve cover

Buying parts Replacement parts are available from many sources, which generally fall into one of two categories - authorized dealer parts departments and independent retail auto parts stores. Our advice concerning these parts is as follows: Retail auto parts stores: Good auto parts stores will stock frequently needed components which wear out relatively fast, such as clutch components, exhaust systems, brake parts, tune-up parts, etc. These stores often supply new or reconditioned parts on an exchange basis, which can save a considerable amount of money. Discount auto

parts stores are often very good places to buy materials and parts needed for general vehicle maintenance such as oil, grease, filters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell

tools and general accessories, have convenient hours, charge lower prices and can often be found not far from home. Authorized dealer parts department: This is the best source for

parts which are unique to the vehicle and not generally available elsewhere (Such as major engine parts, transmission parts, trim pieces, etc.). Warranty information:

\f the vehicle is still covered

under war-

ranty, be sure that any replacement parts purchased - regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along for positive identification.

Maintenance techniques, tools and working facilities Maintenance techniques There are a number of techniques involved in maintenance and repair that will. be referred to throughout this manual. Application of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the various tasks properly, which will ensure that the repair job is thorough and complete.

Fasteners Fasteners are nuts, bolts, studs and screws used to hold two or

more parts together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type, either a lockwasher, locknut, locking tab or thread adhesive. All threaded fasteners should be clean and straight, with undamaged threads and undamaged corners on the hex head where the wrench fits. Develop the habit of replacing all damaged nuts and bolts with new ones. Special locknuts with nylon or fiber inserts can only be

used once. If they are removed, they lose their locking ability and must be replaced with new ones. Rusted nuts and bolts should be treated with a penetrating fluid to ease removal and prevent breakage. Some mechanics use turpentine in a spout-type oil can, which works quite well. After applying the rust penetrant, let it work for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners may have to be chiseled or sawed off or removed with a special nut breaker, available at tool stores. If a bolt or stud breaks off in an assembly, it can be drilled and removed with a special tool commonly available for this purpose. Most automotive machine shops can perform this task, as well as other repair procedures, such as the repair of threaded holes that have been stripped out. Flat washers and lockwashers, when removed from an assembly,

should always be replaced exactly as removed. Replace any damaged washers with new ones. Never use a lockwasher on any soft metal surface (such as aluminum), thin sheet metal or plastic.

Maintenance techniques, tools and working facilities SS

SE

SS

Fastener sizes For a number of reasons, automobile manufacturers are making wider and wider use of metric fasteners. Therefore, it is important to be able to tell the difference between standard (sometimes called U.S. or SAE) and metric hardware, since they cannot be interchanged. All bolts, whether standard or metric, are sized according to diam-

eter, thread pitch and length. For example, a standard 1/2 - 13 x 1 bolt is 1/2 inch in diameter, has 13 threads per inch and is 1 inch long. An M12 - 1.75 x 25 metric bolt is 12 mm in diameter, has a thread pitch of 1.75 mm (the distance between threads) and is 25 mm long. The two bolts are nearly identical, and easily confused, but they are not interchangeable. In addition to the differences in diameter, thread pitch and length, metric and standard bolts can also be distinguished by examining the bolt heads. To begin with, the distance across the flats on a standard bolt head is measured in inches, while the same dimension on a metric

bolt is sized in millimeters (the same is true for nuts). As a result, a standard wrench should not be used on a metric bolt and a_ metric

gg

SS SS

SSS

SSS SS

SS

0-9 SESS

wrench should not be used on a standard bolt. Also, most standard bolts have slashes radiating out from the center of the head to denote the grade or strength of the bolt, which is an indication of the amount of torque that can be applied to it. The greater the number of slashes, the greater the strength of the bolt. Grades 0 through 5 are commonly used on automobiles. Metric bolts have a property class (grade) number, rather than

a slash,

molded

into their heads

to indicate

one side, while metric nuts are marked with a number. The greater the

number of dots, or the higher the number, the greater the strength of the nut. Metric studs are also marked on their ends according to property class (grade). Larger studs are numbered (the same as metric bolts), while smaller studs carry a geometric code to denote grade.

Grade 8

Grade1 or 2

Bolt strength markings (top - standard/SAE/USS; bottom - metric)

ar

ss Hex a

B

Standard hex nut strength markings

poverty Metric hex nut strength markings

bolt

strength. In this case, the higher the number, the stronger the bolt. Property class numbers 8.8, 9.8 and 10.9 are commonly used on automobiles. Strength markings can also be used to distinguish standard hex nuts from metric hex nuts. Many standard nuts have dots stamped into

a ©

© Metric stud length markings

©)

Maintenance techniques, tools and working facilities

0-10 SES

SS

FS

ES

RS

EST

PE

SE

ESTA

SS SEM SS SE

AS

It should be noted that many fasteners, especially Grades 0 through 2, have no distinguishing marks on them. When such is the case, the only way to determine whether it is standard or metric is to measure the thread pitch or compare it to a known fastener of the same size.1993 Standard fasteners are often referred to as SAE, as opposed to metric. However,

it should be noted that SAE technically refers to a

non-metric fine thread fastener only. Coarse thread non-metric fasteners are referred to as USS sizes. Since fasteners of the same size (both standard and metric) may have different strength ratings, be sure to reinstall any bolts, studs or nuts removed from your vehicle in their original locations. Also, when replacing a fastener with a new one, make sure that the new one has a strength rating equal to or greater than the original.

SS

Tightening sequences and procedures Most threaded fasteners should be tightened to a specific torque value (torque is the twisting force applied te a threaded component such as a nut or bolt). Overtightening the fastener can weaken it and cause it to break, while undertightening can cause it to eventually come loose. Bolts, screws and studs, depending on the material they are made of and their thread diameters, have specific torque values, many of which are noted in the Specifications at the beginning of each Chapter. Be sure to follow the torque recommendations closely. For fasteners not assigned a specific torque, a general torque value chart is presented here as a guide. These torque values are for dry (unlubricated) fasteners threaded into steel or cast iron (not aluminum). As was previously mentioned, the size and grade of a fastener determine the amount of torque that can safely be applied to it. The figures listed

Metric thread sizes

Standard (SAE and USS) bolt dimensions/grade marks

G L T D

Grade marks (bolt length) Length (in inches) Thread pitch (number of threads per inch) Nominal diameter (in inches)

SS

I ET

Ft-lbs

Nm

paces

6 to9

9to 12

a ee elacdees ee eee eee

14 28 50 80

Sieaursiee th ee Mele co pee ee

5to8 12 to 18 22 to 33 25 to 35

7 to 10 17 to 24 30 to 44 34 to 47

ee ead 2 Ree Se aes eee eth poet eee So oe Ce eere Se

6 to9 12 to 14 to 22 to 27 to 40 to 40 to 55 to

9to 12 17 to 24 19 to 27 30 to 43 37 to 51 55 to 74 55 to 81 75 to 108

to to to to

21 40 71 140

18 20 32 38 55 60 80

19 to 28 38 to 54 68 to 96 109 to 154

Metric bolt dimensions/grade marks Property class (bolt strength) Length (in millimeters) Thread pitch (distance between threads in millimeters) 20 OSE Diameter

Maintenance techniques, tools and working facilities here are approximate for Grade 2 and Grade 3 fasteners. Higher grades can tolerate higher torque values. Fasteners laid out in a pattern, such as cylinder head bolts, oil

pan bolts, differential cover bolts, etc., must be loosened or tightened

in sequence to avoid warping the component. This sequence will normally be shown in the appropriate Chapter. If a specific pattern is not given, the following procedures can be used to prevent warping. Initially, the bolts or nuts should be assembled finger-tight only.

0-11

Hose removal tips Warning: /f the vehicle is equipped with air conditioning, do not disconnect any of the A/C hoses without first having the system depressurized by a dealer service department or a service station. Hose removal precautions closely parallel gasket removal precautions. Avoid scratching or gouging the surface that the hose mates against or the connection may leak. This is especially true for radiator

Next, they should be tightened one full turn each, in a criss-cross or di-

hoses. Because of various chemical reactions, the rubber in hoses can bond itself to the metal spigot that the hose fits over. To remove a

to the first one and tighten them all one-half turn, following the same

hose, first loosen the hose clamps that secure it to the spigot. Then, with slip-joint pliers, grab the hose at the clamp and rotate it around the spigot. Work it back and forth until it is completely free, then pull it off. Silicone or other lubricants will ease removal if they can be applied between the hose and the outside of the spigot. Apply the same lubricant to the inside of the hose and the outside of the spigot to simplify installation. As a last resort (and if the hose is to be replaced with a new one anyway), the rubber can be slit with a knife and the hose peeled from

agonal pattern. After each one has been tightened one full turn, return

pattern. Finally, tighten each of them one-quarter turn at a time until each fastener has been tightened to the proper torque. To loosen and remove the fasteners, the procedure would be reversed.

Component disassembly Component disassembly should be done with care and purpose to help ensure that the parts go back together properly. Always keep track of the sequence in which parts are removed. Make note of special characteristics or marks on parts that can be installed more than one way, such as a grooved thrust washer on a shaft. It is a good idea to lay the disassembled parts out on a clean surface in the order that they were removed. It may also be helpful to make sketches or take instant photos of components before removal. When removing fasteners from a component, keep track of their locations. Sometimes threading a bolt back in a part, or putting the washers and nut back on a stud, can prevent mix-ups later. If nuts and bolts cannot be returned to their original locations, they should be kept in a compartmented box or a series of small boxes. A cupcake or muffin tin is ideal for this purpose, since each cavity can hold the bolts and nuts from a particular area (i.e. oil pan bolts, valve cover bolts, engine mount bolts, etc.). A pan of this type is especially helpful when working on assemblies with very small parts, such as the carburetor, alternator, valve train or interior dash and trim pieces. The cavities can be marked with paint or tape to identify the contents. Whenever wiring looms, harnesses or connectors are separated, it is a good idea to identify the two halves with numbered pieces of masking tape so they can be easily reconnected.

the spigot. If this must be done, be careful that the metal connection is

not damaged. If a hose clamp is broken or damaged, do not reuse it. Wire-type clamps usually weaken with age, so it is a good idea to replace them with screw-type clamps whenever a hose is removed.

Tools A selection of good tools is a basic requirement for anyone who plans to maintain and repair his or her own vehicle. For the owner who has few tools, the initial investment might seem pair, it is a wise one.

Gasket sealing surfaces Throughout any vehicle, gaskets are used to seal the mating surfaces between two parts and keep lubricants, fluids, vacuum or pressure contained in an assembly. Many times these gaskets are coated with a liquid or paste-type gasket sealing compound before assembly. Age, heat and pressure can sometimes cause the two parts to stick together so tightly that they are very difficult to separate. Often, the assembly can be loosened by striking it with a soft-face hammer near the mating surfaces. A regular hammer can be used if a block of wood is placed between the hammer and the part. Do not hammer on cast parts or parts that could be easily damaged. With any particularly stubborn part, always recheck to make sure that every fastener has been removed.

Avoid using a screwdriver or bar to pry apart an assembly, as they can easily mar the gasket sealing surfaces of the parts, which must remain smooth. If prying is absolutely necessary, use an old broom handle, but keep in mind that extra clean up will be necessary if the wood splinters. After the parts are separated, the old gasket must be carefully scraped off and the gasket surfaces cleaned. Stubborn gasket material can be soaked with rust penetrant or treated with a special chemical to soften it so it can be easily scraped off. A scraper can be fashioned from a piece of copper tubing by flattening and sharpening one end. Copper is recommended because it is usually softer than the surfaces to be scraped, which reduces the chance of gouging the part. Some gaskets can be removed with a wire brush, but regardless of the method used, the mating surfaces must be left clean and smooth. If for some reason the gasket surface is gouged, then a gasket sealer thick enough to fill scratches will have to be used during reassembly of the components. For most applications, a non-drying (or semi-drying) gas-

ket sealer should be used.

high, but when com-

pared to the spiraling costs of professional auto maintenance and re-

Dial indicator set

Hand-operated vacuum pump

Timing light

Compression gauge with spark plug hole adapter

Damper/steering wheel puller

General purpose puller

Hydraulic lifter removal tool

Valve spring compressor

Valve spring compressor

Ridge reamer

Piston ring groove cleaning tool

Ring removal/installation tool

Maintenance techniques, tools and working facilities

Ring compressor

Cylinder hone

Brake hold-down spring tool

Brake cylinder hone

Clutch plate alignment tool

Tap and die set

To help the owner decide which tools are needed to perform the tasks detailed in this manual, the following tool lists are offered: Maintenance and minor repair, Repair/overhaul and Special. The newcomer to practical mechanics should start off with the maintenance and minor repair tool kit, which is adequate for the simpler jobs performed on a vehicle. Then, as confidence and experience grow, the owner can tackle more difficult tasks, buying additional tools as they are needed. Eventually the basic kit will be expanded into the repair and overhaul tool set. Over a period of time, the experienced do-it-yourselfer will assemble a tool set complete enough for most re-

pair and overhaul procedures and will add tools from the special category when it is felt that the expense is justified by the frequency of use.

Maintenance and minor repair tool kit The tools in this list should be considered the minimum required for performance of routine maintenance, servicing and minor repair work. We recommend the purchase of combination wrenches (boxend and open-end combined in one wrench). While more expensive than open end wrenches, they offer the advantages of both types of wrench. Combination wrench set (1/4-inch to 1 inch or 6 mm to 19 mm) Adjustable wrench, 8 inch Spark plug wrench with rubber insert Spark plug gap adjusting tool Feeler gauge set Brake bleeder wrench

Standard screwdriver (5/16-inch x 6 inch) Phillips screwdriver (No. 2 x 6 inch) Combination pliers - 6 inch Hacksaw and assortment of blades Tire pressure gauge Grease gun Oil can Fine emery cloth Wire brush -

0-13

Battery post and cable cleaning tool Oil filter wrench Funnel (medium size) Safety goggles Jackstands (2) Drain pan Note: /f basic tune-ups are going to be part of routine maintenance, it will be necessary to purchase a good quality stroboscopic timing light and combination tachometer/dwell meter. Although they are included in the list of special tools, it is mentioned here because they are absolutely necessary for tuning most vehicles properly.

Repair and overhaul tool set These tools are essential for anyone who plans to perform major repairs and are in addition to those in the maintenance and minor repair tool kit. Included is a comprehensive set of sockets which, though expensive, are invaluable because of their versatility, especially when various extensions and drives are available. We recommend the 1/2inch drive over the 3/8-inch drive. Although the larger drive is bulky and more expensive, it has the capacity of accepting a very wide range of large sockets. Ideally, however, the mechanic should have a 3/8-inch drive set and a 1/2-inch drive set. Socket set(s) Reversible ratchet Extension - 10 inch Universal joint Torque wrench (same size drive as sockets) Ball peen hammer - 8 ounce Soft-face hammer (plastic/rubber) Standard screwdriver (1/4-inch x 6 inch) Standard screwdriver (stubby - 5/16-inch) Phillips screwdriver (No. 3 x 8 inch) Phillips screwdriver (stubby - No. 2) Pliers - vise grip Pliers - lineman’s

0-14

Maintenance techniques, tools and working facilities

eee

Pliers - needle nose Pliers - snap-ring (internal and external) Cold chisel - 1/2-inch Scribe Scraper (made from flattened copper tubing) Centerpunch Pin punches (1/16, 1/8, 3/16-inch)

Steel rule/straightedge - 12 inch Allen wrench set (1/8 to 3/8-inch or 4mm to 10 mm) A selection of files Wire brush (large) Jackstands (second set) Jack (scissor or hydraulic type) Note: Another tool which is often useful is an electric drill with a chuck capacity of 3/8-inch and a set of good quality drill bits

Special tools The tools in this list include those which are not used regularly, are expensive to buy, or which need to be used in accordance with their manufacturer’s instructions. Unless these tools will be used frequently, it is not very economical to purchase many of them. A consideration would be to split the cost and use between yourself and a friend or friends. In addition, most of these tools can be obtained from a tool rental shop on a temporary basis. This list primarily contains only those tools and instruments widely available to the public, and not those special tools produced by the vehicle manufacturer for distribution to dealer service departments. Occasionally, references to the manufacturer’s special tools are included in the text of this manual. Generally, an alternative method of doing the job without the special tool is offered. However, sometimes there is no alternative to their use. Where this is the case, and the tool cannot be purchased or borrowed, the work should be turned over to the dealer

service department or an automotive repair shop. Valve spring compressor Piston ring groove cleaning tool Piston ring compressor Piston ring installation tool Cylinder compression gauge Cylinder ridge reamer Cylinder surfacing hone Cylinder bore gauge Micrometers and/or dial calipers Hydraulic lifter removal tool Balljoint separator Universal-type puller Impact screwdriver Dial indicator set Stroboscopic timing light (inductive pick-up) Hand operated vacuum/pressure pump Tachometer/dwell meter Universal electrical multimeter Cable hoist Brake spring removal and installation tools Floor jack

Buying tools For the do-it-yourselfer who is just starting to get involved in vehicle maintenance and repair, there are a number of options available when purchasing tools. If maintenance and minor repair is the extent of the work to be done, the purchase of individual tools is satisfactory. If, on the other hand, extensive work is planned, it would be a good idea to purchase a modest tool set from one of the large retail chain stores. A set can usually be bought at a substantial savings over the individual

tool prices, and they often come with a tool box. As additional tools are needed, add-on sets, individual tools and a larger tool box can be pur-

chased to expand the tool selection. Building a tool set gradually allows the cost of the tools to be spread over a longer period of time and gives the mechanic the freedom to choose only those tools that will actually be used. Tool stores will often be the only source of some of the special tools that are needed, but regardless of where tools are bought, try to avoid cheap ones, especially when buying screwdrivers and sockets, because they won't last very long. The expense involved in replacing cheap tools will eventually be greater than the initial cost of quality tools.

Care and maintenance of tools Good tools are expensive, so it makes sense to treat them with respect. Keep them clean and in usable condition and store them properly when not in use. Always wipe off any dirt, grease or metal chips before putting them away. Never leave tools lying around in the

work area. Upon completion of a job, always check closely under the hood for tools that may have been left there so they won’t get lost during a test drive. Some tools, such as screwdrivers, pliers, wrenches and sockets, can be hung on a panel mounted on the garage or workshop wall, while others should be kept in a too! box or tray. Measuring instruments, gauges, meters, etc. must be carefully stored where they cannot be damaged by weather or impact from other tools. When tools are used with care and stored properly, they will last a very long time. Even with the best of care, though, tools will wear out if used frequently. When a tool is damaged or worn out, replace it. Subsequent jobs will be safer and more enjoyable if you do.

Working facilities Not to be overlooked when discussing tools is the workshop. If anything more than routine maintenance is to be carried out, some sort of suitable work area is essential. It is understood, and appreciated, that many home mechanics do not have a good workshop or garage available, and end up removing an engine or doing major repairs outside. It is recommended, however, that the overhaul or repair be completed under the cover of a roof. A clean, flat workbench or table of comfortable working height is an absolute necessity. The workbench should be equipped with a vise that has a jaw opening of at least four inches. As mentioned previously, some clean, dry storage space is also required for tools, as well as the lubricants, fluids, cleaning solvents, etc. which soon become necessary. Sometimes waste oil and fluids, drained from the engine or cooling system during normal maintenance or repairs, present a disposal problem. To avoid pouring them on the ground or into a sewage system, pour the used fiuids into large containers, seal them with caps and take them to an authorized disposal site or recycling center. Plastic jugs, such as old antifreeze containers, are ideal for this purpose. Always keep a supply of old newspapers and clean rags. available. Old towels are excellent for mopping up spills. Many mechanics use rolls of paper towels for most work because they are readily available and disposable. To help keep the area under the vehicle clean, a large cardboard box can be cut open and flattened to protect the garage or shop floor. Whenever working over a painted surface, such as when leaning over a fender to service something under the hood, always cover it

with an old blanket or bedspread to protect the finish. Vinyl covered pads, made especially for this purpose, are available at auto parts stores.

0-15

Jacking and towing Jacking The jack supplied with the vehicle should be used for raising the vehicle during a tire change or when placing jackstands under the frame. Under no circumstances should work be performed beneath the vehicle or the engine started while a jack is being used as the only.means of support.

Wheel removal (all models) All vehicles are supplied with a screw-type jack (sometimes called a "bottle jack") which is placed under the axle tube or radius arm nearest to the wheel being changed. The vehicle should be on level ground with the wheels blocked and the transmission in Park (automatic) or

Reverse (manual). On 4-wheel drive vehicles, the transfer case must be engaged in gear, not neutral. Pry off the hub cap (if equipped) using the tapered end of the lug wrench. Loosen the wheel nuts one-half turn and leave them in place until the wheel is raised off the ground. Place the jack under the axle tube or radius arm (see illustration). Insert the wrench handle into the jack and turn the jackscrew clockwise until the wheel is raised off the ground. Remove the wheel nuts and pull off the wheel. Remove any corrosion, dirt or foreign material present on the mounting surfaces of the hub, drum or rotor that contacts the wheel. Warning: /nstalling wheels without proper metal-to-metal contact can cause the wheel lug nuts to loosen and allow the wheel to come off the vehicle while the vehicle is in motion.

REAR AXLE

FRONT AXLE

F-100, F-150,

F-150 (4x4),

ALL F-SERIES

F-250 (4x4) F-350 (4x4)

Pick-up truck jacking points

REAR AXLE

FRONT AXLE

Bronco jacking points

8 LUG WHEEL

5 LUG WHEEL Wheel lug nut tightening sequence

Jacking points and wheel lug nut tightening sequence

0-16

Jacking and towing

Wheel installation (single rear wheel models)

WHEEL

Position the wheel (or spare) on the hub and rotor or the axle flange and drum assembly. Install the lug nuts, making sure the cone ends of the nuts face inwards and properly seat in the wheel. Tighten the lug nuts until snug. Lower the vehicle by turning the jackscrew counterclockwise. Remove the jack and tighten the nuts in a diagonal pattern to the torque listed in the Chapter 1 Specifications, or securely if using the supplied lug wrench. Install the hubcap by placing it into position and using the heel of your hand or a rubber mallet to seat it. Warning: /f replacement is due to a roadside emergency, verify proper torque of the wheel lug nuts using a torque wrench as soon as possible and again after 500 miles.

LOCATING

WHEEL PIN IS INSERTED INTO HUB

Front wheel installation (dual rear wheel models) Warning: Later models equipped with dual rear wheels use special two-piece swiveling lug nuts on the front and rear wheels. Do not attempt to use cone-shaped one-piece lug nuts on these models. Do not attempt to use early mode! wheels on later models, or vice-versa, as

F

the lug nut seats are different. Use of improper lug nuts or wheels can

OEGRAE

cause the lug nuts to loosen and allow the wheel to come off the vehi-

PIECE SWIVELING)

Ne:

cle while the vehicle is in motion.

LOCATING

HOLE IN WHEEL

HUB PIN IS INSERTED

MAIN VIEW

THROUGH WHEEL

Mount the front wheel on the hub and align the wheel-to-hub alignment pins (see illustration). Install the lug nuts and tighten until snug. Lower the vehicle by turning the jackscrew counterclockwise. Remove the jack and tighten the nuts in a diagonal pattern to the torque listed in the Chapter 1 Specifications, or securely if using the supplied lug wrench. Install the hubcap by placing it into position and using the heel of your hand or a rubber mallet to seat it. Warning: /f replacement is due to a roadside emergency, verify proper torque of the wheel lug nuts using a torque wrench as soon as possible and again af-

Li aber SWIVELING LUG NUT

ter 500 miles.

Rear wheel installation (dual rear wheel models) Warning: Later models

equipped with dual rear wheels use special

Front wheel installation details - dual rear wheel models

LOCATING HOLE IN_ DRUM

LOCATING PIN IN WHEEL WHEEL PIN IS INSERTED INTO DRUM HOLE

LOCATING PIN

es| : ae

IN DRUM a

oe

OUTSIDE WHEEL


=,

=

\

SNAP

'

Shes THRUST

THRUST WASUER

Pere PLATE

WASHER RETAINER

THRUST

RING

WASHER

was?

WASHER

ASSEMBLY

BEARING

INDICATOR SWITCH

;

(

KC)

GAN

PLANETARY GEAR

THRUST

FOUR-WHEEL DRIVE

~ .

PLATE

BOLT

BEARING 6 eee NEEDLE

THRUST

BEARING

F

WASHER

THRUST WASHER

THICK i

ETURUSTL Tie NEEDLE

BEARINGS SELECTOR

SHIFT

THRUST

BEARING

~

‘

ASSEMBLY

@

WASHER

THIN

PoPPET_—ehy

THRUST WASHER (THICK)

PLUNGER FRONT OUTPUT SHAFT DRIVE GEAR

POPPET SPRING

OIL PUMP HOUSING

SEPARATORS

WASHER REAR OUTPUT SHAFT ORIVE GEAR (SPROCKET)

REAR OUTPUT SHAFT

SPROCKET CARRIER NEEDLE BEARINGS

-

Con

WASHER OIL SEAL

THRUST WASHER

VENT PLUG BOLT

SNAP RING SPEEDOMETER DRIVE GEAR OIL PUMP

REAR OUTPUT YOKE

ee

BEARING

REAR BEARING RETAINER

ASSEMBLY

DRAIN

PLUG

REAR CASE HALF

vacner___

+)

COLLECTOR

3.1a

ed view New Process (NP) 208 transfer case - explod

Note: The catalytic _Unbolt the heat shield from the transfer case. 8 when working in careful Be converter is located beside the heat shield. high temperatures. ely extrem tes genera ter conver the this area, since and tie them securely Disconnect the front and rear driveshafts 9 8). er Chapt (see way out of the transmission jack. 10 Support the transfer case with a

Installation

41.

Transfer 3. ae ee ee Refer to illustrations 3.1a, 3.1b and 3.1¢ the source of a Note: Prior to condemning the transfer case as

er case to the transmission Remove the bolts retaining the transf

adapter (see illustration). to the rear, until the input shaft 42 Carefully move the transfer case bly from the vehicle, then reassem the lower and clears the adapter and adapter. case er move the gasket between the transf

Be sure to Installation is the reverse of the removal procedure. 13 quantity of and grade correct the with case check and fill the transfer torque listed this lubricant (see Chapter 1). Tighten the fasteners to the s Specifications. Chapter’s Specifications and any referenced Chapter’

Ce case

- overhaul

7C-4

Chapter 7 PartC

Transfer case SNAP RING

: OlL PUMP PIN PLANETARY GEAR CASE

NEEDLE BEARING

SPRING

Y,

WASHER

PLANETARY GEAR

BEARING RETAINER

NEEDLE BEARING DOWEL

PIN

ara

:

-

FIBER WASHER

REAR

OUTPUT SHAFT

ES

SPACER

WASHER

LOCKING PLATES ANNULUS

GEAR SUN

GEAR

BUSHING

Of.

SNAP

LOCK KEY

RING

= 8 Volts

601(R) - GRD 537(R) - GRD

Harness*4 Harness

> 8 Volts

Servce circuit 532 (open/short) or Main Relay

> 8 Volts

Service circuit 599 (open/short) or MainRelay

Replace ECU

Other

N/A

22 \solation Valve Open or Shorted

Harness*4

1(v) - GRD

> 8 Volts

Servce circuit 532 (open/short) or Main Relay

Left Front Wheel

Harness*4

4(v) - GRD

> 8 Volts

Servce circuit 532 (open/short) or Main Relay

Harness

40(E) - 7(v)

20,000 ohms 5 to 8 ohms 5 to 8 ohms >20,000 ohms

Service Replace Replace Replace

Left Front Wheel

> 8 Volts

Servce circuit 532 (open/short) or Main Relay (open/short) or Main Relay (open) (short)

5 to 8 ohms 5 to 8 ohms >20,000 ohms

Serce circuit 532 Service circuit 496 Service circuit 496 Replace HCU Replace HCU Replace HCU Servce circuit 532 Serve circuit 532 Service circuit 497 Service circuit 497 Replace HCU Replace HCU Replace HCU

GRD GRD - 8(v) - GRD 8(v) 8(v)

> 8 Volts > 8 Volts 20,000 ohms 3 to 6 ohms 3 to 6 ohms

Servee circuit Servce circuit Service circuit Service circuit Replace HCU Replace HCU

532 532 498 498

(open/short) or Main Relay (open/short) or Main Relay (open) (short)

GRD

>20,000 ohms

Replace HCU

GRD GRD - 3(v) - GRD 3(v) 3(v) GRD

> 8 Volts > 8 Volts 20,000 ohms 5 to 8 ohms 5 to 8 ohms >20,000 ohms

Servce circuit Servee circuit Service circuit Service circuit Replace HCU Replace HCU Replace HCU

532 532 499 499

(open/short) or Main Relay (open/short) or Main Relay (open) (short)

GRD GRD - 2(v) - GRD 2(v) 2(v) GRD

> 8 Volts > 8 Volts 20,000 ohms 3 to 6 ohms 3 to 6 ohms >20,000 ohms

Servee circuit Servce circuit Service circuit Service circuit Replace HCU Replace HCU Replace HCU

532 532 510 510

(open/short) or Main Relay (open/short) or Main Relay (open) (short)

24(E) - 521(S) 25(E) - 522(S) 24(E) - GRD 25(E) - GRD 521(S)-522(S) 521(S) - GRD

20,000 ohms 800 to1400 ohms >20,000 ohms

Service Service Service Service Replace Replace

circuit 521 circuit 522 circuit 521 circuit 522 Sensor Sensor

(open) (open) (short) (short)

Harness Harness Harness*1 Harness*1 Component Component

36(E) - 514(S) 23(E) - 516(S) 36(E) - GRD 23(E) - GRD 514(S)-516(S) 514(S) - GRD

20,000 ohms 800 to1400 ohms >20,000 ohms

Service Service Service Service Replace Replace

circuit 514 circuit 516 circuit 514 circuit 516 Sensor Sensor

(open) (open) (short) (short)

Harness Harness Harness*1 Harness*1 Component

22(E) - 518(S) 21(E) - 519(S) 22(E) - GRD 21(E) - GRD 518(S)-519(S)

20,000 ohms 300 to1550 ohms

Service Service Service Service Replace

circuit 518 circuit 519 circuit 518 circuit 519 Sensor

(open) (open) (short) (short)

Component

518(S) - GRD

>20,000 ohms

Harness*4 Harness Harness*1 Component Component Component

4(v) 26(E) 26(E) 1(v) A(v) 6(v) -

Harness*4 Harness*4

1(v) - GRD 4(v) - GRD

Harness Harness*1

34(E) - 5(v) 34(E) - GRD

> 8 Volts 20,000 ohms

Component Component Component

1(v) - 5(v) 4(v) - 5(v) 5(v) - GRD

25 Dump Valve Open or Shorted Right Front Wheel

Harness*4 Harness*4 Harness Harness*1 Component Component Component

1(v) 4(v) 15(E) 15(E) 1(v) A(v) 8(v) -

26 Isolation Valve Open or Shorted Rear Wheels

Harness*4 Harness*4 Harness Harness*1 Component Component Component

1(v) 4(v) 33(E) 33(E) A(v) Av) 3(v) -

27 Dump Valve Open or Shorted Rear Wheels

Harness*4 Harness*4 Harness Harness*1 Component Component Component

1(v) 4(v) 27(B) 27(E) 1(v) 4(v) 2(v) -

31, 35, 41 or 55 Speed Sensor Open or Shorted - Left Front Wheel

Harness Harness Harness*1 Harness*1 Component Component

32, 36, 42 or 56 Speed Sensor Open or Shorted - Right Front Wheel

33, 37, 43 or 57 Speed Sensor Open or Shorted - Rear Wheels

; 24 Isolation Valve Open or Shorted Right Front Wheel

'

5

51, 52 or 53 Dump Valve Hydraulic Malfunction or Sensor Disturbance

GRD - 6(v) - GRD 6(v) 6(v) GRD

\

> 8 Volts

Harness and Component*4 Harness*4 Harness Harness Harness Component*4 Component*4 Harness Harness Harness*1 Harness Component

Jump 534(RP)- 533(RP) 601(R) - GRD 537(R) - GRD 534(RP)-GRD 599(R) - 19(E) 532(R) - GRD*S 539(RP)-GRD*S 539(RP)-29(E) 533(RP) - 4(P) 533(RP) - GRD 1(P) - GRD 2(P) - 3(P)

Motor Runs > 8 Volts > 8 Volts > 8 Volts 8 Volts > 8 Volts 5 ohms

Harness Other

539(RP)-GRD N/A

67 Fluid Return Pump (runs all the time) “4 *2 *3 *4

= = = =

Harness disconnected at component side Brake pedal applied (Brake lights on) Brake pedal off (Brake lights off) Key in RUN position

'

(open/short) or Main Relay (open/short) or Main Relay

(open) (short)

Replace Sensor

See Dealer

N/A

63 Fluid Return Pump (does not run) ‘

Z

circuit 495 (short) HCU HCU HCU

> 8 Volts 20,000 ohms 3 to 6 ohms 3 to 6 ohms >20,000 ohms

1(v) - GRD

Harness*4

23 Dump Valve Open or Shorted

- GRD 7(v) 7(v) GRD

(m) = (v) = (s) = (E) =

:

Harness Harness Harness Harness

connector connector connector connector

at Module at RABS Valve at Speed Sensor at ECU

Perform following tests, if no faults found, Replace HCU Service circuit 601 (open/short) or Fuse Service circuit 537 (open/short) or Fuse Service circuit 534 (open/shorted) or Fuse Service circuit 599 (open) Replace Main Relay Replace Pump Relay Service circuit 539 (open) Service circuit 533 (open) Service circuit 533 (short) Service Harness Ground Replace HCU Service circuit 836 (open) Service circuit 887 (open) Service circuit 886 (open) Service circuit 836 (short) Service circuit 887 (short) Service circuit 886 (short) Replace Accelerometer Replace Accelerometer Service circuit 539 (short) Replace Pump Relay

>20,000 ohms (R) = (RP) (P) = (A) =

Harness connector at Relay Box (Main Relay) = Harness connector at Relay Box (Pump Relay) Harness connector at HCU Pump Motor Harness connector at Accelerometer

*5 = Relay must be installed during measurement

14.21a

ABS system code descriptions and troubleshooting chart

se CiaLantt EERE RENE eee e ec ee

ce

9-22

Chapter 9

Brakes

BRONCO

See EVTM for more details of this circuit

i

HOT IN RUN

HOT AT 4TIMES

(BK)

HOT IN START AND RUN

498

960.

FUSE

(PK)

(BK/LB) 539

(PK/LB)

We) 532

He (O/BK)

(om)

887 ) 836 (om) 499

aa (00) 599 (PK/LG) i

497

519

(W)

(LG/BK)

(GY/BK)

(LG)

HARNESS SIDE 14A464 14A466

ey 523

514 (Y/R)

ee

516

(O/R)

621

462

(T/o)

(Wek)

(P)

522

495 (1)

LE/PK

REAR SENSOR CONNECTOR

(LE/PK)

511

Gee

HARNESS SIDE 14A464

DIAGNOSTIC CONNECTOR

BRONCO

57

510 (T/A) HOT AT ALL TIMES

ECU CONNECTOR

140468

(T/BK)

DIAGNOSTIC CONNECTOR

or

14489

148593

57

(Bk)

i

14A099

539 § PKLB

HARNESS SIDE

140464 14468 UNIT (ECU)

oe

TO

Si4B

YR

§ 523

T/BK ff516

Mi

BA/PKE

836

OW

519

HS

887

ae

521 (1/0) (LEFT) 514

$22 (T/BK) (LEFT) 516

(Y/R) (RIGHT)

(Y/BK) (RIGHT)

HARNESS SIDE

BY

140464

144468

ea)

REA

SENSOR

SENSOR

SENSOR

604

604 (OR)

BR f=] ACCELERATION SWITCH

(om)

532

14.21b

14.21c

component pin identifications (see illustrations 14.21b and 14.21c) 22 Follow the procedure in order from top to bottom, making note of the following: a) Harness continuity checks are always done at connectors at both ends of the harness (not component harness connector) unless specified otherwise. b) Component checks are done at the component connector unless specified otherwise. c) Note *X (X represents a number) callouts for specific set-up or test information. e) Make sure all connections are tight and clean and fuses intact prior to troubleshooting as most problems are as a result of these simple causes. f) = greater than.

ABS component connector pin identifications

DIODE/RESISTOR ELEMENT

coe = pee SS er

15

aa

Anti-lock brake components - removal and installation

Refer to illustrations 15.2a, 15.2b, 15.7, 15.16, 15.22 and 15.43

RABS | and Il RABS Modules 1 Disconnect the cable from the negative battery terminal. 2 On RABS | systems, locate the module in the cab to the right of the brake pedal and under the upper dash panel (see illustration). On RABS II systems, locate the module in the cab directly behind the glove box (see illustration). 3 Disconnect the wiring harness from the module by depressing the plastic tab on the connector and pulling the connector off. 4 Remove the two screws that retain the module to the dash and

MODULE

15.2a The RABS | module is located to the right of the brake pedal under the dash panel - to remove. the module, simply disconnect harness connector and remove the two screws

Chapter 9

Brakes

INSTRUMENT PANEL

| WIRING | ASSEMBLY

COVER

15.2b The RABS II module is located under the glove compartment - to remove the module, simply disconnect the electrical connector and remove the two screws

HOLD DOWN BOLT

FRONT OF VEHICLE

SENSOR

@ Fr

15.16

TUBE

The speed sensor mounts on the rear axle housing

is Perform a systems self-check and verify that the warning light 6 indicating proper operation of the system.

RABS Hydraulic Control Valve (HCV) Locate the RABS Valve on the left frame rail just behind the cross7 member (see illustration). to Disconnect the inlet and outlet brake lines and plug the lines 8 ation. contamin line and _ prevent excess fluid loss Disconnect the wiring harness. 9 the Remove the three nuts (or screws on some models) retaining 40 valve to the frame rail and remove the valve. s to the Installation is the reverse of removal. Tighten the fastener 41. ations. torque listed in this Chapter’s Specific Bleed the hydraulic system (see Section 11). 12

light is Perform a systems self check and ,verify that the warning 13 indicating proper operation of the system.

RABS Speed Sensor

15 146

15.7 To remove the HCV assembly, disconnect the inlet and outlet brake lines and remove the fastening hardware attaching it to the left side frame rail

AXLE HOUSING

remove the module. Installation is the reverse of removal. 5

44 ing.

RABS I! VALVE

ial housLocate the sensor in the upper part of the rear different Disconnect the sensor electrical connector. the sensor from Remove the sensor hold-down bolt and remove

the axle housing (see illustration). 17.

Ifthe sensor is to be reinstalled, inspect and clean the magnetized

sensor pole piece and inspect the O-ring. Replace the defective parts, if required. 48. Installation is the reverse of removal. Tighten the fasteners to the torque listed in this Chapter’s Specifications. Perform a systems self-check and verify that the warning light is 19 indicating proper operation of the system.

RABS Speed Sensor Ring — 20 The sensor ring is part or the rear axle ring gear assembly and requires complete disassembly of the differential to replace. If the ring has damaged teeth, take the vehicle to a professional repair facility.

Four wheel ABS system (Bronco only) Hydraulic Control Unit (HCU)

,

is reWarning: Special Test equipment to actuate the internal valves reto decide you if Therefore, removed. is it if HCU the quired to bleed

place the HCU the braking system will not be safe to drive after installation. It will be necessary to have the vehicle towed to a facility which can properly bleed the HCU. Disconnect the cable from the negative battery terminal. 21 left Locate the HCU in the front of the engine compartment on the 22

9-24

Chapter 9

Brakes

15.22

Four wheel ABS system component locations

Electronic Control Unit (ECU) 1 2 Brake fluid reservoir 5 — Hydraulic Control Unit (HCU) 9 Tube 13 ~ Clip 14 Tube 16 Clip 16 Clip

frame rail (see illustration). 23 Disconnect the electrical connectors (8 pin and 4 pin connectors). 24 Remove the two inlet and three outlet lines and plug the lines to prevent excess fluid loss and line contamination. 25 Remove the three nuts retaining the HCU to the mounting bracket

and remove the HCU. 26 Installation is the reverse of removal. Tighten all fasteners to the torque listed in this Chapter’s Specifications. 27 Have the vehicle towed to a dealer service department or other repair shop for HCU bleeding. 28 Perform a systems self-check and verify that the warning light is indicating proper operation of the system.

20 22

Tube Hose

23

Fender apron

24

Wheel speed sensor

44 Position a new ring on the hub and press the ring onto the hub using an appropriately sized driver. Seat the ring against the hub shoulder. 45 Installation is the reverse of removal. Tighten the fasteners to the torque listed in this Chapters Specifications and any other referenced Chapters. 46 Perform a systems self-check and verifythat the warning light is indicating proper operation of the system.

Speed Sensor Ring (rear) 47 The sensor ring is part or the rear axle ring gear assembly and requires complete disassembly of the differential to replace. If the ring has damaged teeth, take the vehicle to a professional repair facility.

ECU Module 29 Disconnect the cable from the negative battery terminal. 30. Locate the ECU at the left front fender apron (see illustration 15.22). 31. Disconnect the ECU electrical connector. 32 Remove the ECU-to-retaining bracket screws and slide the ECU out of the bracket. 33 Installation is the reverse of removal. 34 Perform a systems self-check and verify that the warning light is indicating proper operation of the system.

Wheel Speed Sensors (front) 35 Locate the right or left sensor mounted on the steering knuckle(s) (see illustration 15.22). 36 Locate the sensor harness connector inside the engine compartment and disconnect the electrical connector. Also separate the sensor harness from the brake hose clips. 37 Remove the sensor hold-down bolt from the knuckle and slide the

16

Parking brake - adjustment

Refer to illustration 16.5a and 16.5b

Tension limiter systems (1980 through 1991) 1 The parking brakes employ a cable system that incorporates a tension limiter. If the parking brake system is in normal operating condition, depressing the parking brake pedal to the floor will automatically set the proper tension and pedal feel. The system relies on a special cinch strap hook (part of the tension limiter) made of a malleable material that will deform at a given tensile load. This deformation is what sets the upper limit of cable tension after each parking brake adjustment is made. Therefore, adjustment should only be done when necessary, because the limiter is a perishable item and must be re-

sensor out. 38 Installation is the reverse of removal. Tighten the fasteners to the

torque listed in this Chapter’s Specifications. 39 Perform a systems self-check and verify that the warning light is indicating proper operation of the system.

Wheel Speed Sensor (rear) 40 The rear sensor is similar to the one on the RABS system. Refer to steps 14 through 19 in this section

Speed Sensor Ring (front) 41 Remove the affected front wheel (see Chapter 1). 42 Remove the caliper, rotor and hub assembly (see Chapters 9 and 8). 43 Using a three-jaw puller, remove the speed ring from the hub (see illustration).

15.43

Remove the ABS front wheel speed sensor ring using a three jaw puller

Chapter 9

9-25

Brakes

38.1mm

(1.5 INCH) MAX.

AFTER INITIAL ADJUSTMENT 22.8mm (0.90 INCH) NOMINAL

:

COUPLING Ca

QUALIZER

e

ee

EQUALIZER NUT B

7

a

LJ

EQUALIZER

—

pa HOOK

TENSION LIMITER HOUSING

F-150-350 AND BRONCO 73.7mm + 3.175mm + .120 INCH)

(2.90 INCH

CABLE TENSION LIMITER ASSEMBLY

16.5a Parking brake system with tension limiter - limiter is located along the

alin

with

the

limiter

housing,

a new

limiter

must

be installed

before

proceeding (see illustration). 6 Grip the limiter housing and tighten the equalizer nut about six turns on the threaded rod or until the cinch strap hook begins to slip (deform) around the housing. This indicates that the parking cable tension has been automatically Set. 7 Inspect the cinch strap hook again. If the stop at the end of the cinch strap hook is in contact with the limiter housing, a new limiter must be installed and the parking brake adjusted again. 8 Release the parking brake and check for rear wheel drag. If drag is excessive, readjust the parking brake as required. 9

Lower the vehicle and check for proper operation of the parking

brake.

INITIAL ADJUSTMENT

Auto tensioned systems (1992 and later) 10 Late model vehicles utilize a system that maintains a constant and proper preload tension on the parking brake cable while in the non-applied state. This static tension allows the driver to always be able to set the proper parking brake pressure in the normal range of travel of the parking brake pedal assembly. It eliminates the need for any adjustment but leaves the ultimate parking brake holding power up to the individuals “feel”. The tension is maintained by a clock spring and cam built into the parking brake pedal assembly. 11 No adjustment is provided for. Check the cables, parking pedal assembly and adjust the rear brakes (see Section 2 or 3) if problems _ are encountered.

17

Brake pedal assembly - removal and installation

Refer to illustrations 17.1, 17.2a and 17.2b 1 On vehicles equipped with a manual transmission, the brake pedal pivots on the clutch pedal shaft, and both pedals are removed as

SPRING

SPRING RETAINER

LEVER

WASHER

SPRING \

+ 3.175mm

(3.10 INCH + .120 INCH)

16.5b When the end of the cinch strap hook reaches the tensioner housing the tensioner assembly must be replaced

frame rail next to the cable equalizer

placed if deformed to its safety stop. 2 Raise vehicle and support it securely on jackstands. 3 Make sure the rear brakes are cold and properly adjusted (see Section 2 or 3). 4 Depress the parking brake pedal all the way to the floor. 5 _ Locate the tension limiter (see illustration) and observe the cinch strap hook. If the stop at the end of the cinch strap hook is in contact

E-150-350 78.7mm

RETAINER

BUSHING

BRACKET

BUSHING

BUSHING

RETAINEF

BUSHING CLUTCH ROO

BUSHING

SPRING WASHER BRACKET

CLUTCH PEDAL STOr BUSHING

BUSHING

FLATWASHER WITH MANUAL TRANSMISSION AND WITH AND WITHOUT POWER BRAKES

PEDAL

CLUTCH PEDAL

17.1

Exploded view of typical brake pedal components manual and automatic transmissions

Chapter 9

9-26

Brakes

>)

BUSHING

FRONT OF VEHICLE

BRACKET

SELF-LOCK

STUD AND WASHER

SPACER

STUD AND WASHER

BRACKET SPACER

SPACER

MASTER CYLINDER

17.2a

described

STOP LAMP SWITCH

Master cylinder and brake switch assembly details - early model manual brake system

in Chapter 7. On automatic transmission

models,

the retaining clip and slide the shaft to the right until the brake pedal and pedal bushings can be removed (see illustration). 2 Disconnect the master cylinder pushrod and brake switch assembly (See Section 18) and remove the pedal (see illustrations). 3. Replace the bushings if worn and install the pedal and pushrod using the reverse of the removal procedure.

18

A BRAKE PEDAL

BOOSTER

remove

cat

a

ADAPTER

Brake light switch - adjustment

1. ‘The brake light switch is located under the dashboard directly above the brake pedal. It is activated by the pedal traveling away from its bottomed position, which releases the plunger and closes an electrical circuit in the system. The switch is mounted in a metal bracket which can be bent to vary its position. 2 _ Make sure the switch is fully seated in its bracket. Use an assistant or a mirror to determine when the brake light circuit is activated. A test light connected to the two terminals of the switch would also provide you with this information. 3. The switch should activate the brake circuit within the first 1/4-

inch of brake pedal travel. ; 4 If the switch does not perform in this manner, bend the mounting bracket up or down to obtain the desired results. Do not bend the bracket down to the point where it is preventing the pedal from returning fully. 5 The factory suggests that a 25-pound or less pull up on the pedal is sufficient to adjust the switch. Again, make sure the brake lights are off when the pedal is at rest.

BOACKET

STOP LAMP

POWER BRAKE WITH MANUAL TRANSMISSION WITHOUT SPEED CONTROL

SWITCH

ADAPTER

gs BRAKE PEDAL

COTTER aN

Ne STOP LAMP SWITCH

SPACER WITH SPEED CONTROL

17.2b

Pedal and brake switch assembly details - power brake systems

10-1

Chapter 10 Steering and suspension systems Contents Section Front coil spring - removal and installation ............::ccssseeesseeeeeseees Front I-beam axle - removal, bushing replacement SLA ALLO lease ten eceeecestiernnccteaeraves serereteets=.7SecsasrarcdveceVadect=sAMICI Front leaf spring - removal and installation.............cccseceeeeneereees Front shock absorbers - removal, inspection and installation ....... Front spindle (2WD) - removal and installation ...........:eeeeseeeeeees Front spindle/knuckle (4WD) - removal and installation................. Front stabilizer bar - removal and installation ...........ccsscceseseeeeeees ccerces: cree sesscaecastcngescusandeseossrsecceeconos GemeraiintOninatiOieamentttietseess Power steering pump - removal and installation............-:sseeeee Power steering system - DICECING...........cccccseceeteeeesseesseteseessseeseees Radius arm - removal and installation...........:::cccccceesseeeeeesneneeeeees Rear leaf spring - removal and installation...........::csceseeseeeseeeseees Rear shock absorbers - removal, inspection and installation........ Rear stabilizer bar - removal and installation ...........:cceseeeeeeeeeeeees

Section 8 Steering damper- removal and installation ...........::cccesesecseeeeeeeees 15 Steering system - general inforMation .........-.ccccceecceeeetteeesteeeeees 16 Steering gearbox - check and adjustMent.............:ccseeseeeenreeenees 17 Steering gearbox - removal and installation ............::eeeeeeeeteee 20 Steering linkage - removal and installation ............::cceseeeeeeeeeees 21 Steering wheel - removal and installation ...........:ccceceeeereeeeeeeees Suspension and steering - iNSPeCtiON .............ceeceeeetees See Chapter 1 Tires and wheels - checking and rotation ............:00:eee See Chapter 1 6 Upper and lower balljoints- removal and installation .............-:0: 22 Wheel alignment - general information ............cc:scceceeseeseereeeeeeens Wheel bearings (front - 2WD) - check, repack and ACHUSTIMMEMNteeretee nce ceeetee ts aa tes teneesaransucnrarceattinexeneteneseneat See Chapter 1 Wheel bearings (4WD) - check, replacement and GNYS 015coss-ceetaar rice ceecache concesee -bcod-cu-oavaccs cocooeEcRe-E See Chapter 8 Xe [UW

2 11 3 7 4 5) 10 1 19 18 9 12 13 14

Ln

na

Specifications

i

Front suspension type NN]I)een

ees ee

PANN(6)ere ;

ene

en arg Renate Ce onercicaseacn ncsqeisaaeee+ronnayorqanaeca fea ag eee oes revoseedacaceersess specs ndecs cvs onasneneneesenws

Rear suspension type (all).............-:::: cesses

Forged or stamped twin I-beam axles with coil springs and telescoping shock absorbers Independent front suspension (IFS) with two-piece front drive axle assembly, leaf or coil springs and telescoping shock absorbers, except F350 monobeam (F350 monobeam has springs and telescoping shock absorbers)

Leaf spring with telescoping shock absorbers

Steering systems Manual TYPO cassesecececscesecssesaccsnsscienscercsscnsnssusoessesanensnseneneneeransvensssnadecesete eet cere ee nen accacetee LUGS ON STEERING GEAR. // MUST BE INSTALLED PRIOR 7’ TO INSULATOR ASSEMBLY.

WORM SHAFT (INPUT SHAFT)

SECTOR SHAFT COVER WORM BEARING ADJUSTER NUT (PRELOAD ADJUSTMENT) SECTOR SHAFT

PITMAN

SECTOR SHAFT ADJUSTING SCREW

SECTOR SHAFT COVER

SECTOR SHAFT.

Integral power steering gearbox components

adjuster nut until all endplay has been removed (see illustration). 13 Using an 11/16-inch socket and an inch-pound torque wrench, carefully turn the worm shaft all the way to the right and then turn it back about one-half turn. 14 Tighten the adjuster nut until the specified worm bearing preload is obtained. , 15 Tighten the adjuster nut locknut to the torque listed in this Chap-

ter’s Specifications. 16 Rotate the worm shaft from stop-to-stop, counting the total number of turns, then turn the shaft back half way, placing the gear on center.

17 Loosen the sector shaft adjuster locknut by turning it in a counterclockwise direction. 18 Turn the sector shaft adjuster screw clockwise to remove all lash between the ball nut and the sector teeth, then tighten the sector shaft locknut to the torque listed in this Chapter’s Specifications. 19 Using an 11/16-inch, 12 point socket and an inch-pound torque wrench, observe the highest reading while the gear is turned through the center position. This is the backlash measurement. 20 Check that the backlash is within the range listed in this Chapter’s Specifications. 21 If necessary, repeat Steps 17 through 19 until the proper backlash is obtained. 22 Reinstall the steering gear. 23

Reinstall the Pitman

Power steering gearbox installation details

from the steering gear. 26 Turn the shaft back 45-degrees from the left stop and attach a torque wrench calibrated in inch-pounds to the steering wheel nut. 27. Rotate the steering gear about one-eighth of a turn and then move it back across the center position several times. Loosen the adjuster locknut and turn the adjuster screw until the specified torque reading is reached when the steering gear is rotated through the overcenter position (see illustration). 28 Hold the screw and tighten the nut. 29 Install the Pitman arm and steering wheel center cover. Reconnect the fluid return line and refill the reservoir. Be sure the Pitman arm retaining nut is tigntened to the torque listed in this Chapter’s Specifications.

HOUSING

16.27

16.24

ARM

arm

and tighten the retaining nut to the

torque listed in this Chapter’s Specifications.

Power steering 24 Remove the Pitman arm (see illustration) and remove the horn pad to gain access to the steering wheel retaining nut (See Section 21). Disconnect and plug the fluid return line at the reservoir. 25 Place the fluid return line in a suitable container and turn the

steering wheel lock-to-lock several times to discharge all of the fluid

17.

Steering gearbox - removal and installation

Warning: On models equipped with airbags, make sure the steering shaft is not turned while the steering gear or box is removed or you could damage the airbag system. To prevent the shaft from turning, turn the ignition key to the lock position before beginning work or run the seat belt through the steering wheel and clip the seat belt into place. Due to possible damage to the air bag system, we recommend only experienced mechanics attempt this procedure.

Manual steering Removal i Raise the front of the vehicle and place it securely on jackstands. 2. Disengage the flex coupling shield from the steering gear input shaft shield and slide it up the intermediate shaft (see illustration 16.4). 3 Disconnect the flex coupling from the intermediate steering shaft flange by removing the attaching bolts. 4 Using an appropriate tie-rod end remover, disconnect the drag link from the Pitman arm. 5 Remove the Pitman arm-to-sector shaft attaching nut and washer. 6 Using an appropriate puller, remove the Pitman arm from the steering gear sector shaft. Caution: Do not hammer on the end of the sector shaft or on the tool 7 While supporting the steering gear, remove the bolts and washers that attach the steering gear to the frame rail. 8 Lower the steering gear assembly out of the vehicle. 9 Remove the coupling-to-gear attaching bolt from the lower half of the flex coupling and remove the coupling from the assembly.

Installation 10 To install the gearbox, position the flex coupling on the input shaft of the steering gear. Note: Be sure to use a new coupling-to-gear attaching bolt and tighten it to the torque listed in this Chapter’s Specifications.

Chapter 10

Steering and suspension systems

10-17 WITH A/C BRACKET

19.3a Power steering pump installation eather ce ‘ details (inline six-cylinder engine)

POWER STEERING

ADJUSTMENT BRACKET

we

P

—_—

pou era ; SONNE C “AN

\\

S

SUPPORT BRACKET

SPACER WITHOUT A/C Q

\

RETURN

:

HOSE

PIVOT Oe”

11 Center the input shaft (the center position is approximately three turns from either stop). 12 Position the steering gear assembly so that the stud bolts on the flex coupling enter the bolt holes in the steering shaft flange and the holes in the mounting bosses of the gearbox match the bolt holes in

the frame rail. 13 While supporting the gearbox in the proper position, install the

gearbox-to-frame rail attaching bolts and washers and tighten the bolts to the torque listed in this Chapter’s Specifications. Note: /f new bolts and washers are required, be sure that they are Grade 9. 14 Connect the drag link to the Pitman arm, install the drag link ball Stud nut and tighten the nut to the torque listed in this Chapter’s Specifications. Install a new cotter pin. 15 Place the Pitman arm on the sector shaft, pointing down. Install the attaching nut and washer and tighten the nut to the torque listed in this Chapter’s Specifications. 16 Attach the flex coupling to the steering shaft flange with the two attaching nuts and tighten the nuts to the torque listed in this Chapter’s Specifications. 17 Snap the flex coupling shield to the steering gear input shaft

shield. 18 Remove the jackstands and lower the vehicle.

Power steering Removal 19 Place a drain pan under the steering gearbox. 20 Disconnect the pressure and return lines from the gearbox and plug the lines and the ports in the gearbox to prevent contamination. 21 Disengage the flex coupling shield from the splash shield (see illustration 16.24). 22 Disconnect the flex coupling at.the steering gearbox by removing the retaining bolt. 23 Raise the front of the vehicle and place it securely on jackstands. 24

Using an appropriate tie-rod end remover, disconnect the tie-rod

from the Pitman arm. 25 Remove the nut and washer attaching the Pitman arm to the sector shaft. 26 Using an appropriate puller, remove the Pitman arm from the sec. tor shaft. Caution: Be very careful not to damage the seals. 2/7 Support the steering gearbox and remove the steering gearboxto-frame rail attaching bolts. 28 Work the steering gearbox free of the flex coupling and remove the steering gearbox from the vehicle. 29 Remove the splash shield from the retaining lugs on the steering gearbox.

Installation 30

To install the gearbox, position the splash shield over the gearbox

lugs. 31 Turn the steering wheel so that the spokes are in the horizontal position. 32 Slide the flex coupling into position on the steering shaft assembly.

33 Center the steering gear input shaft with the index flat facing down (the center position is approximately three turns from either stop). 34 Slide the steering gear input shaft into the flex coupling and the ‘gearbox into place on the frame rail. 35 Install the flex coupling attaching bolt and tighten it to the torque listed in this Chapter’s Specifications.

36 Install the gearbox-to-frame rail attaching bolts and tighten them to the torque listed in this Chapter’s Specifications. 37

Be sure that the wheels are in the straight ahead position, then in-

stall the Pitman arm on the sector shaft. 38 install the Pitman arm attaching washer and nut and tighten the nut to the torque listed in this Chapter’s Specifications. 39 Attach the drag link to the Pitman arm, install the retaining nut and tighten it to the torque listed in this Chapter’s Specifications. Install a new cotter pin. 40 Remove the jackstands and lower the vehicle. 41 Install and tighten the pressure and return lines. Be sure you have removed the plugs from the lines and ports. 42 Snap the flex coupling shield over the hose fittings and the splash shield. 43 Disconnect the coil wire from the distributor. 44 Fill the power steering fluid reservoir, then crank the engine and turn the steering wheel from lock-to-lock to distribute the fluid. 45 Recheck the fluid level and add more if necessary. ‘ 46

Connect the coil wire, start the engine and turn the steering wheel

from side-to-side. 47 \nspect for leaks.

18

Power steering system - bleeding

|

If bubbles are visible in the power steering fluid, the air in the sys-

tem should be bled off. 2 Fill the reservoir as described in Chapter 1. 3 Run the engine until the fluid reaches normal operating temperature (165 to 175-degrees F). : 4 Turn the steering wheel lock-to-lock several times. Note: Do not hold the wheel all the way to the left or right for more than five seconds or you may damage the pump. 5 Recheck the fluid level and add more as necessary.

19

10

Power steering pump - removal and installation

Refer to illustrations 19.3a, 19.3b, 19.3¢, 19.9 and 19.12

Removal 1 Remove the power steering fluid from the pump reservoir by disconnecting the fluid return hose at the reservoir and draining the fluid into a suitable container. 2

Disconnect the pressure hose from the pump.

3 Remove the bolts from illustrations).

the pump

adjustment

bracket

(see

Chapter 10

10-18 4

Steering and suspension systems

Onearly models, loosen the pump enough to allow removal of the

belt from the pulley. On later models with an auto tensioner, place

a 5/8-inch wrench on the tensioner pulley bolt and rotate against spring tension enough to loosen and remove belt. 5 Remove the pump (still attached to the adjustment bracket) from

PRESSURE HOSE

the support bracket and from the vehicle. 6 If the pulley and adjustment bracket are to be removed from the pump, follow Steps 7 through 14. 7 Drain as much fluid as possible from the pump through the filler pipe. 8 Place the pump in a bench vise. 9 Install a pulley removal tool (see illustration). 10 Rotate the tool bolt counterclockwise to remove the pulley, then remove the bolts attaching the adjustment bracket to the pump and remove the bracket.

ADJUSTMENT SLOT CLAMP

RETURN

HOSE

GEAR ASSEMBLY CLIP

Installation 11. To install the pump, place the adjustment bracket on the pump and install and tighten the retaining bolts to the torque listed in this Chapter’s Specifications. 12 Thread a pulley installation into the steering pump shaft (see illustration). 13 Rotate the tool nut clockwise to install the pulley on the shaft. Caution: Do not apply in-and-out pressure on the shaft as such pressure will damage the internal pump components. When properly installed, the pulley hub face must be flush within plus or minus 0.010 inch of the end of the pump shaft. 14 Place the pump with the attached pulley and adjustment bracket on the support bracket. 15 Install the bolts connecting the support bracket to the adjustment bracket and tighten them securely. 16 Place the belt on the pulley and adjust the belt tension as

Eines 19.3c

19.3b

Power steering pump installation details typical V8 engine (except 460)

described in Chapter 1. Note: Do not pry against the reservoir. Pressure on the fiberglass reservoir will cause it to crack. 17 Attach the pressure hose to the pump fitting. 18 Connect the return hose to the pump and tighten the clamp. 19 Fill the reservoir and bleed the system (See Section 18). 20 Check for leaks and recheck the fluid level, adding fluid if necessary.

HEX HEAD

LOCK BOLT

PULLEY SUPPORT

Power steering pump

installation details - 460 V8 engine

WITH A/C

BRACKET

\

@Q-

gee

SPACER W/O A/C

= HEX HEAD

i! 19.9 This special tool, designed for removing power steering pulleys, is available at tool stores and some auto parts stores

i

19.12 This special tool, designed for installing the power steering pulley, is available at tool stores and some auto parts stores

s

Chapter 10

Steering and suspension systems

10-19

TIE ROD BALL STUD Lp

d/s oRAG Link

ARG

BALL STUD

—

San

45°

ADJUSTING SLEEVE

20.6 Position the steering linkage clamps within a limit of 45degrees as shown - the threaded portion of the bolts on the right (passengers) side must face the rear, and the threaded portion of the bolts on the left (drivers) side must face the front of the vehicle

ORAG LINK FRONT OF VEHICLE

TIE ROD

ee COTTER PIN

DRAG LINK BALL STUD

20.1

20

TIE ROD BALL STUD

ADJUSTING SLEEVE

Typical steering linkage components - models with a coil spring front end

Steering linkage - removal and installation

Refer to illustrations 20.1 and 20.6 Warning: Ali fasteners in the steering system are important as they could affect the safety of the system. They must be replaced with fasteners of the same part number if replacement is necessary. Never substitute with a replacement part of lesser quality.

Installation 6 and nuts and

1 Steering linkages for Ford pick-ups and Broncos come in many configurations and combinations, depending on driveaxle, suspension type and load carrying capabilities. They are all of a common type and consist of a connecting link with either two ball-type links on either end or one ball-type link and a male or female thread (see illustration). ‘2 If a linkage is bent or if the balljoint end is excessively worn, it must be replaced. 3. Any balljoint end can be removed after the cotter pin and retaining nut are first withdrawn. A “pickle fork” designed for this job is the quickest and easiest method for removing this type of connection. However, the rubber dust seat is usually damaged with this type of tool and the seal should be replaced (even if the joint is being reused). A balljoint end can also be removed with a puller. Use the jaws of the puller to grasp the housing of the component (Pitman arm, sector shaft, spindle arm, etc.). Situate the point of the screw on the center of the balljoint bolt. Tighten the puller to put tension on it and lightly tap

the housing with a brass hammer to help break the joint free. Be careful not to damage either the joint or the housing. lf the threaded end of a linkage component is being removed, first

Install the new component to a depth matching the original part install a retaining nut and new cotter pin. Tighten the bolts and on any clamps to the torque listed in this Chapter’s Specifications have the vehicle’s front end alignment checked. Align the clamps

as shown (see illustration). 21

Removal

4

mark the component so that the threads can be reinserted to the same exact depth. The vehicle will still need an alignment, but the setting will be close to original so the vehicle can be driven to the alignment facility. Unscrew the component after releasing the bolts and nuts of the 5 clamps.

Steering wheel - removal and installation

Refer to illustrations 21.3, 21.4, 21.5, 21.7 and 21.8 Warning: Some later models are equipped with airbags. If your vehicle is equipped with an airbag, DO NOT attempt to remove the steering wheel. Have the procedure performed by a dealer service department

or other qualified repair shop. 1 Park the vehicle with the front wheels in the straight ahead position. 2 __ Disconnect the cable from the negative battery terminal. 3 Remove one screw from the underside of each steering wheel spoke and lift the horn switch assembly (steering wheel pad) off the steering wheel to gain access to the wires beneath (see illustration). Do not remove the horn assembly at this time. 4 On models with cruise control, pinch the J-clip ground wire terminal firmly and pull it out of the hole in the steering wheel (see illustration). Note: Do not pull the ground terminal out of the threaded hole without pinching the terminal clip to relieve the spring retention of the terminal in the threaded hole. 5 Disconnect the horn switch wiring (see illustration). 6 Remove the horn switch assembly. 7 Remove the steering wheel retaining nut (see illustration). Mark

HORN SWITCH

INSERT “J” CLIP GROUND TERMINAL

BRUSH ASSY. MUST BE INSTALLED AS SHOWN FOR SPEED CONTROL ONLY,

HORN BRUSH

21.3

Horn pad installation details terminal with needle-nose pliers

10-20

Chapter 10

Steering and suspension systems

i

21.5 Disconnect the horn wiring

21.7

Remove the steering wheel nut, then mark the relationship

of the steering wheel to the shaft

Verticat . © Gof Vehicle

pz

Camber Angle Front View

Vertical

2 -¢ of Ball Joint Axis

,

21.8 Use a puller to remove the steering wheel from the steering shaft - DON’T beat on the shaft

@Fwo

the relationship of the steering wheel to the shaft to ensure correct positioning of the steering wheel upon installation. 8 Using a steering wheel puller, remove the steering wheel (see illustration). Caution: Do not beat on the shaft in an attempt to remove the wheel. 9 Installation is the reverse of the removal procedure. When attaching the steering wheel to the steering column shaft, place it on the shaft so that the mark and the flat on the wheel are in line with the mark and the flat on the shaft. Tighten the steering wheel retaining nut to the torque listed in this Chapter’s Specifications.

22

Wheel alignment - general information

Refer to illustration 22.1 Note: Since wheel alignment is generally out of the reach of the home mechanic, this section is intended only to familiarize the reader with the

basic terms used and procedures followed during a typical wheel alignment job. In the event that your vehicle needs a wheel alignment check or adjustment, we recommend that the work be done by a reputable wheel alignment shop. 1 The three basic adjustments made when aligning a vehicle’s front end are toe-in, caster and camber (see illustration). 2 _Toe-in is the amount the front wheels are angled in relationship to the centerline of the vehicle. For example, in a vehicle with zero toe-in, the distance measured between the front edges of the wheels is the same as the distance measured between the rear edges of the wheels. The wheels are running parallel with the centerline of the vehicle. Toein is adjusted by lengthening or shortening the tie-rods. Incorrect toe-in will cause tires to wear improperly by making them “scrub” against the road surface. 3 Camber and caster are the angles at which the wheel and suspension upright are inclined to the vertical. Camber is the angle of the wheel in the lateral (side-to-side) plane, while caster is the angle of the wheel

Caster Angle Side View

22.1

A D E G

Typicai alignment details

minus B = caster minus F = toe-in

= C (degrees camber) (measured in degrees) = toe-in (measured in inches (expressed in degrees)

and upright in the longitudinal (fore-and-aft) plane. Camber angle affects the amount of tire tread which contacts the road and compensates for change in the suspension geometry when the vehicle is traveling around curves or over an undulating surface. Caster angle affects the self-centering action of the steering, which governs straight-line stability. 4 Some vehicles covered in this manual have caster and camber angles designed into the front suspension and no provision is available to change them. On other vehicles, provision is made for camber adjustment, but not for caster adjustment. Still others have provisions for adjustment to both caster and camber. For those vehicles with no provision for these adjustments, in extreme cases, certain components may be bent by a shop with the proper equipment in order to correct the caster and camber. In all cases, however, steering alignment work should always be performed by a facility with the proper equipment and experienced personnel.

11-1

Chapter 11

Body

Contents Section BoOclvg-aimealmtemanee mes seven voce sh cateaaacte se tveecchsteereacce sates Bodyirepaltz ial OnGlannage peeccsacseSstcce vcs setae tence hasteet seaessents BOGVAKe Pali anmiMOl GAAG Gres censee sacs cre stereo ev sssy sock st eke na erase ct aeeee Bumpers - removal'and installation ...............c:ccccsscesssesscevesscerennes Door - removal, installation and alignment .............::cccccceseeseeeseees Door glass - replacement and adjustment...............cccccccseeseeseeees Door handle (outside) and lock cylinder Kemovaltanchinstallationtcecscs.ne sh nsat ac coe cnct th ssedcvseseseeon otis Door trim panel - removal and installation .............cccccccssseeeesseeeees Door window regulator - replaceMent ...........:ccescccssscesssseeeesseeeenes Fiberglass roof - removal and installation (Bronco onlly)...............Floor carpet/mat - removal and installation ............c:cccsssceesseeeeeees Generaliiiitonimationteencme cnenttee te Maes cccte ccd an co soirese yates sk cals

Section

2 6 S 18 g 12 10 11 13 19 21 1

Glove box - removal and installation..............c:ccecscssssessesseeesseseees Grill assembly - removal and installation ............c::ccccceeceesseesseeseees Hinges ahd locks, = MainteEMANCe....0:......cc.te.cssasaseecbevecsesesesvaresstente Hood - removal, installation and alignment ............:cc:ccccsccceeseeeneeee Rear window - removal and installation ..........cccccccessesecseesseeseeseesee Tailgate: removal:andiinstallationessctstve cyssiccsetsssteeee eee teens Tailgate glass and regulator - removal and installation (Broncoiomly) aches ee accent ervade aacen eae eae a ee eee Upholstery and carpets - Maintenance...........cccccccccccessceesseseeseeeeees Vent window assembly - removal and installation ..............0.cc000 Vin yltrimestmaintenancesccctcrsite-2--tepeteeametcnceceee canceansne eee nD Windshield and fixed glass - replaceMent .............cccccccccesseceeeeeseees

22 20 7 8 15 16 17 4 14 3 23

Specifications

Torque

Ft Ibs

DOO MINTS COy pl alienware acetone ates ceceeesscatcesesoccpinecessevatecsoapsithedeones Fiberglass roof to body (long screws) (BrONCO).........:eeeteeeeeteeeeeee Fiberglass roof to body (Short screws) (BrONCO) .........ceeceeeseeereeees

17 to 25 7 to 10 13 to 20

EFOMtDUIMDClstOMmalntGre.certrccerescascctudeteavessssL| 1 Accessory &7— CIRCUIT A-3

RUN

START

BATTERY CIRCUIT a3

ACCESSORY

CIRCUIT AA BATTERY CIRCUIT Ba IGNITION CIRCUIT 12

A-1 THROUGH B-5 NO CONTINUITY NO CONTINUITY A-1 AND B-1, A-2 AND B-2, A-3 AND B-3, A4 AND B4, 11 AND B5 I-14 ANDO B-5, I-2 AND B-1, STA AND B-4, P-1 AND GRD, P-2 AND GRD.

as shown Ignition switch circuit continuity checks (later models) - check each combination of pins in the various key positions

12

Chapter 12

12-10

Chassis electrical system IGNITION CYLINDER IN “ON” POSITION

IGNITION SWITCH

IGNITION LOCK

ALIGN PIN WITH SLOT

RETAINING PIN

Location of the lock cylinder retaining pin on an early

10.23a

model non-tilt steering wheel

10.15 When installing the ignition switch, align the switch pin with the slot in the lock/column assembly as shown - make sure both key and switch are in the RUN position

DEPRESS RETAINING

PIN

Replacement Note: The following procedure pertains only to functional lock cylinders for which keys are available or for which keys can be made when the lock cylinder number is known. If the ignition lock is inoperative and the lock cylinder cannot be turned due to a lost or broken key and the key number is not known, or the lock cylinder cap is damaged and/or broken to the extent that the lock cylinder cannot be turned, have the lock cylinder assembly replaced by a dealer service department or other repair shop. Replacement will likely involve installation not only of a new lock cylinder but a new lock cylinder housing as well, a procedure that requires disassembly of the steering column. 19 Detach the cable from the negative terminal of the battery. 20 On early models, remove the steering wheel (refer to Chapter 10). 21

On later models, remove the steering column trim shrouds.

22 Turn the lock key to the Run position. 23 Place a 1/8-inch drill bit in the hole in the casting surrounding the lock cylinder (early models or in the hole in the trim shroud (iater models) (see illustrations). Depress the retaining pin while pulling out on the lock cylinder to remove it from the column housing. 24 Install the lock cylinder by turning it to the Run position and depressing the retaining pin. Insert the lock cylinder into the lock cylinder housing. Make sure that the cylinder is completely seated and aligned in the interlocking washer before turning the key to the Off position. This will permit the retaining pin to extend into the hole. 25 Turn the lock to ensure that the operation is correct in all positions. 26 The remainder of installation is the reverse of removal.

11

Headlight switch - check and replacement

Refer to illustrations 11.1, 11.4, 11.7 and

11.12

Check Note: A se/f-powered test light or onmmeter will be required for the following checks. 1 Refer to the accompanying table and perform continuity checks

TURN IGNITION TO RUN POSITION

10.23b

Location of the lock cylinder retaining pin hole in the trim shroud on later model steering columns

Connect SelfPowered Test Lamp or Ohmmeter to Terminals

TO

TEST

2

If the headlight switch fails any of the above checks, replace it.

Replacement

Will Indicate

38 BK/O (B1) and 15 R/Y (H)

Open Circuit Open Circuit Closed Circuit

Park Lamp Circuit

195 T/W (B2) and 14 BR (R)

Open Circuit Closed Circuit Closed Circuit

Dome Light Circult

54 LG/Y (D1)

Thumbwheel rotated full left (in Detent) Thumbwhee! rotated fully right {Out of Detent)

and

55 BK/PK (D2)

Closed Circuit

Open Circuit

14 BR (R) and 19 LB/R (1)

Thumbwheel rotated left from full right position

Ohmmeter Will Show Smoothly Increasing

Ignition On, Lamps Off

137 Y/BK (IGN) and

Off Park

Closed Circuit Open Circuit

Circuit

484 O/BK

(DN)

Head

Open Circuit

Cluster Dimmer Circuit

19 LB/R (I) and 484 O/BK (DN)

Off Park Head

Open Circuit Closed Circuit Closed Circuit

Panel Light Dimmer Circuit

TERMINAL

©

484 (O/BK)

Resistance _

LOCATIONS

§4 (LG/Y)

55 (BK/PK) 15 (R/Y)

137 (Y/BK) 19 (LB/R)

Early models 3 Disconnect the cable from the negative battery terminal. 4 Remove the knob on the switch by reaching under the dash and pressing the shaft lock tab while pulling the knob and shaft away from the cluster panel (see illustration).

A Good Switch

Headlamp Circuit

between the indicated terminals (see illustration). Early models may have different terminal locations, but wire color has remained the same.

Move Switch to These Positions

38 (BK/O)

11.1

14 (BR)

195 (T/W)

Headlight switch continuity chart

j

Chapter 12

Chassis electrical system

KNOB RELEASE BUTTON

| g

|? IF

“|

13

PIN #30 LT GRN-BLK.

ba

ae

SEs

oo

} RT

GLOW PLUG RLY

Zz

Z| HEapit sw

|

i

=

ct STARTER

—

a

WHT

WH

RED-ORG,

oe

inst CLSTR PIN B}

ee

S|

I

—

Yel, CHOKE RLY

;

ie a

STARTER

RLY

(DURASPARK)

tal9 |

a

STARTER

it) MTRE

“Tee —

INST

PN Stee

EEC POWER RLY

SOL

F

o)

SSS

1

(>?

_ BIK-ORG @

BLU

me CUI [Oita CAB MARKER oo ie | LTS (5 USED) | (Seal

rsiatal SR!

YEL

GRN

6 GA) GLOW PLUG RELAY

Sarene gl

1 ¥

|

pw

GS,

{e--4 RELAY

FUR

(8, rod

PARKLT

[|

«

STARTER

E

[60|GND

LTS RLY YEL-WHT

BU

;

i

MARKER

gl =

TAILLT

BLK-LT GRN

ERA ER ETBYE SS

BS g

B

3

TRAILER LTS RELAY LEFT REAR

2

5

2 Cas

153]

Bice 56} ie hh

LINKS

an

[54

SOL (491)

YEL

ached

HEADLT

aun

EGR ON/OFF

g

I FEEDBACK

He

RED-LT BLU

OK GRN

gf gi cmmsor(Q)

mM] IGN

EEC MODULES

RED

—

T

Sa

Sw (A/T)

DIR/HAZ SW

o

DEST(50 ono £5] Fa

FUSE #1

TRAILER ELECT | BRAKE CTRL

OH 1s

(NEUTRAL SAFETY

DIRLT

Bea

0) Rae

(m/1)

E

[BtK-WHT | [J | er

a aes Sa

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Dk BLU-LT GRNJ4g)

~

AY20 ace cto

A 14-15

BLK-LT GRN Ee) aren fay] raQ|


z e

D

RDstill

RODIGITAL

L) cmt

INST CLSTR

— =

SENS iL > ;

G

woo

YEL- RED

BK-LTGN_,

SPEED

COGCANT (1]2]3] Babe RED- WH. HARES

PARK BRAKE SW

nt

WDO MTR

INST CLSTR

Bel me py

TAILGATE COAT

RIGHT FRONT

Kj,

TGRN- WHT :

DK GRN- LT GRN

DIR/HAZ SW

OIL PRES GA

aa TEMP GA

= AMMETER

ae CONN BLU FUS LINK

TS EES | ILLUM HI LTS (2USED) BEAM

E

INST CLSTR PIN A4 LEFT FNT DIR LT

LFTs DIR

SEAT RTs -DIR__—iBELT

E

BRAKE

oteaw

,

DIR/HAZ SW a

DIR /STOP LT

:

Sia

=< ae

=

=

RT REAR

=

pir /STOP LT RTFNT

& z

r

DIESEL WARNING INO MODULE GLOW PLUG

eaeree a

~

z&

Ziu[FUsE SESE

2

AMPLIFIER

| 1,

Gtowetuc riyj—

18]

19

]

20

_————ee

iis wae

BUZZER

/

WATER

IN FUEL

DIR /HAZ SW

xy ag

=&

al sl

+; =

- ace

i COMPT

BSR

1984 through 1986 F-Series/Bronco wiring diagram (5 of 5) Wiring diagram, Copyright © 1994, Mitchell International, all rights reserved

=F

LICENSE ue

WATER IN FUEL SW

] & REAR

tanit

MARKERLE

|

NOTE: _ _ _ DIESEL ONLY

OVERHEAT [No] 3orem sw

INST PANEL

rea One /STOP LT

LEFT ENT ¢BRN

3| “A Teovet “49 ols — RED-YEL

LT.GRN

a

OVERHEAT

22

| ee

CF

23 de

|

Chapter 12

BATTERY

A/C SYSTEM

BATTERY

PS Rios = | (pteset)

COMPONENT LOCATOR:

LO

f

12-35

Pie a

28

BLK

oF

STARTER

=

ee

y pete ei

===9

GEAR SELECT SW (A/T) CLUTCH INTERLOCK SW (M/T) (GAS)

GLOW PLUG CONTROL (DIESEL)

ELECT CTRL ASSY

MAIN LT SW i

(W/BODY MARKER LTS

Le

FUSE #1 IGNITION SW FUSE #16 TRAILER ELECT BRAKE CTRL EEC PWR RELAY

z

FUS LINKS)

ORG BLKTRAILER LTS RLY (W/ TRAILER), MARKER LTS RLY (W/DUAL REAR WHEELS)

WHT BLK-

WHT YEL-

RADIO NOISE Be

|GAS)

ALTERNATOR (GAS)

LT GRN- RED

SAOKNSUGAOWANWW ONNGDO|$43H00RM =

a] a o

;

HORN

RELAY

WHT- BLK

is\

REGULATOR

* HORN

ALTERNATOR (DIESEL)

SW VIP TEST CONN

HORN RLY

.

IGNITION SWITCH ILLUM LIGHTS ......

ae

CONTROL)

Vaasa ONNMODO@ INFERRED MILEAGE & EXTEN oO m o HORNS USEFUL LIFE MOD ...........200000 i?) INJECTOR BLOWER RELAY . On INST CLUSTER .

INERTIA SWITCH

LY BLKBLU BLK- LT BLU

af

RIGHT HEADLT

.

Zz = m D < > t

B/ ORG. tT atu F

....

HORN SWITCH .. IGNITION COIL

YEL- WHT

[s|

W/O CRUISE CONTROL)

ae -D 22

INST CLUSTER

DIESEL)

WHT YEL-

FUEL SHUT-OFF SOL (DIESEL) FUEL WATER SWW (DIESEL) pe [BOR B-C FUSE BLOCK. A-B 2-3 FUS LINKS ........ .

STARTER RELAY

qj

FUS LINK)

HEADLT

....

GLOW PLUG CONTROL HAZ FLASHER ..... HEATER ............ HEGO SENSOR .

js)

“4

>

RED

A

SW COLD IDLE & ADVANCE SOLS (DIESEL) COOLING FAN MOTOR CRUISE CONTROL .. 7 N= DEFOGGER ........ DIR FLASHER ..... “Mei: = DIR/HAZ SWITCH . DISTRIBUTOR .... DOME LIGHTS... DOME/MAP LIGHTS ............ DOOR CONTROL SWITCH . oommmogeo: DOOR SWITCHES ........ > EEC POWER RELAY EEC SELF TEST CONN... ELECT CTRL ASSY (4.91) .......... B-D ELECT CTRL ASSY (5.0L, 5.8L & 7.5L) .... ELECT SHIFT CTRL . ENG COMPT LIGHT . ENG SPEED SENS (DIESEL) 4WD IND SWITCH . FUEL INJECTORS . NHNNM FUEL LEVEL SEND FUEL PUMP RELAY

L

3

|

1

_! ALTERNATOR ... ANTI-LOCK BRAKES BACK-UP LT SWITCH .. BATIRERWaccccacrcstsvetunuts BEAM SELECT SWITCH . BLOWER MOTOR BRAKE WARN SENS CAB MARKER LTS CARGO LIGHT ...

Chassis electrical system

BLK

a3CYCLING

PRES SW

pe nésisvor re

Bix WHT {] MANIFOLD

DK BLU- LT cent

ine

GRN-YEL ee Ae

En

AesOre wanes ew

i

bhi ee

an VALVE POSITION

BLK WHT| ee BRN- LT GRN

VREF

sonop

sy)

SENS

ect

BRN-LT GRN

ORG-

1

sm

THROTTLE POSITION SENS

—

ur Sect cin Teme

ORG

HEGOG

49} arieven

CLUTCH CYCLING PRES SW

ACC

NDS

CLUTCH INTERLOCK SW (M/T)

AM2

Dk GRN-PPLI |eq, aux] =

'

AMI

1

Cc

RY-YEL t eere

IGN SW

HEATED EXHAUST GAS ©, SENSOR (HEGO)

EVR

a

WHT BLK

THERMACTOR AIR DIVERTER SOL AIR

SPOUT PIP

[56]

sto

Vea

ho

v PWR

SOF

CHECK,

PNK-LT.GRN

ENG LT

PNK- LT GRIN

ENICLTGRN

ae

ae

BYPASS

SOL EGR VENT

OK GRN

IGN GND

=

THERMACTOR

WWHT-RED

;

D

WH

BLK wet 4

HEGO

(e;

AIR

ON)

TANATGRN Sete tesr some L_] hei

D

TAN-

INJ BANK

#1

=——

[58]

ho]

Aone

IGNITION

[39]

INJ BANK #2

=

CASE GND [20]

PWRGNO

PWR GND 4.91 ELECTRONIC CONTROL ASSEMBLY

[59h

[ao]

[60]

SWITCH

Bik

—BLK-LTGRN

=

=

a8

ee

& cu) =|

=

WHT_LT

SHA

come

NOISE

CAPACITOR

BLU

a

IL (GND)

fo

TAN-RED FUEL INJECTORS

E

FUEL INJECTORS

ry

E

4 tix. orc} RED- LT BLU

GEAR SEL SW (A/T) CLUTCH INTERLOCK

Genevel/

SW(M/T)

DISTRIBUTOR

oT

4

I

ve

i

6

!

1987 through 1989 F-Series/Bronco wiring diagram (2 of 7) Wiring diagram, Copyright © 1994, Mitchell International, all rights reserved

7

r

Chapter 12 8

I

Chassis electrical system,

9

]

10

N

:

5

:

2

=

Bi RD-LT $ug

SPEED

WHT

GRN-

SENSOR ~\ ¢-OK

P/S

Fus unx

INERTIA

PRESSURE

sw

IGNITION Sal : BLK-WHT

2 a

BLKKelis

8

xc]

ZS

ee

A

eal BRN

>}xf

1m

FUEL PUMP RELAY

EEC POWER RELAY

aia}

12-37

fea]

:

YEL-RED

pao AIR

SRE SENSOR

RED (\ GRY-WHT tare

ae ISC-BPA

i

AE

erwa RYWHT

Ja

ere

THROTTLE

AIR BYPASS

eee

VALVE

FP

care is, eee] ior PSPS

eee

MAP vss DiF-

SENSOR a BK-WT SENSOR

TT

(5.0Leae

ite

serra D

a

Eee

A 277

—cT

°

stl

Ss

° ° Ac ° e

HEGO

HEGOG ACCS oe AM2 De

‘

aa

[2a]

e

EVR

INPUT CONN

LGRN-YEL

-

SENSOR a > |Heated ot @ @ |ExH Gas ea] BZ ygees SENSOR Gayvel—| Earp |©,(HEGO)

ol IGN SW (A/T) GRY-YEL CLUTCH INTERei WHT-BLK LOCK SW (M/T) ow pk i op oe Fey RED

OKGRN-PPL-{

ESnun fn) cepa

Sa

WHT- BLK.

THERMACTOR RED AIR BYPASS [warrep (9) (TAB) SOLENOID

INFERRED MILEAGE SENS MODULE

EXTENDED USEFUL LIFE &

DK GRN

EGR VACUUM SOL

oy. REGULATOR

hie) Camera

bea

Sue Gh PLL

s aie Se ‘rn IMs See INJ BANK #1

ec TAN-ORG

5.8L}

BLU FUS LINK 9 RED-LTGRN 4gn sw

WHT-LT BLU OK

A deeaast "ea ese 20

GRN-YEL

WHEAT Bt

ae ancrcnnraall

eo

DK

a

a)

INST

CLSTR

NOISE

a

WHIT BLU

Goa

‘ re RNYEL J. __!

Baa (GND)

GRN-YEL

capacitor

troRN | pwr Gnd = [Hla [60}

PWR GND

5.0L, 5.8L &7.5t ELECT CTRL ASSY

LENS

GaN

recy ENOUTpCUTGIN TANAIGRN | StF praca

sel

pia

RESISTOR 1.8KQ CASE GND

—

THERMACTOR

CS) air DIVERTER

CS) AMR DIVERTER,

e

Seow

C

gcse ae eae B7.5L)

Scr |

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[15]

COOLANT

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a

5

:

ACCY

5 re)

3

ae

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OFF

RED-LT BLU

BL

a

:

OFF

am

CLUTCH INTERLOCK SW

START

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OFF

OFF

st

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2

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6] —|

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&

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Start ACCYF

OFF

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d]

oz

al

TEMP SENS

g

Ld

N

i] RED-LT Bi!

REO-LT BLU

IGN COIL

RED-LTGRN

oe

IARED-ATGRN

insr¢—RED-LTGRN/L__(DIESEL}x'7

| 2

CLSTR

|

fists tie HEATER

[pent Btu

re ! ice |pe

Lb

4.90) GR 5 (J

moe BLY

Ue tak e oe P

SENS

| PRED-WHT__-

ele |

DEFOG z|z] ° GO] o

tl z

BLK-WHT /etect SHIFT CONTROL MOD

BLK-WHT 7 anGaTE WINDOW SW

= GRN vl Al © 312) =

BLK-LT

TAN- WHT

HORN RLY

>

LTS

HORNS

RG

Fr

, ru

.

gSRN-ORG

ab

—

t

YEL-LT BLU

—OIR/HAZ ,LT BLU

2

sw

FOG ¢ LT BLU-RED

sf a

SNE OS SW

Al

ANTI-LOCK ,_LT BLU-PNK BRAKE MOD

INST CLSTR

ELECT SHIFT, WHT-peL__| CONTROL

LT BLU-RED oa 4

he

3 Z|

LT BLU-RED

RADIO

TAILGATE WINDOW SW

Lal

1

(GND)

ASHTRAY HLLUM

|

2 2

oa =}

oF

co ed

=

ee oad =

a

BRAKES

LT GRN-YEL

DOOR CTRL sw

_JN\LLGN-Y é= 33= =

POWER WEnOWs> RADIO INTERNAL GOVERNOR

W/SHIELD

a

co

re)

3

FUEL TANK

=

SELSW (DIESEL)

[1 A — HEAD

. RED-YEL/INST.

COMPT LT

n

o a

E B DI

DN Se 5 DIMMER

gare

on

ae R

Es eyal

= = >

Bee BUZZER

ee

iS

| |—

|

t__|iGN

[4

Cc

¥

z

o

Nee

|

x é 3

INTERIOR LTs

D

RED-YEL—

CAE

IPER

1)

ENG

&

Ww:

z a

L-BLK

=

RADIO ve

Oo

35 ay

ax ra}

5

ELECT SHIFT 4wp sw S 3)

LT BLU-RED CIG LTR (BLK

MUM ise

(LT BLU-BLK

rartnee sfppBiK

LT BLU-RED (E BLK I, TR NTR

MOD

| 2

rn) rll Falbay =| 2

teow

CIGLTR

135A = a8

5|5

BLK

YeirBiug

#16

BLK-WHT

2 |

a

HORN SW

a

#15

C

DK BL

yasty

JOA

WIPER/ WASHER SW ILLUM

cTRi ) YEL-LT BU

'W /CRUISE

LTSW

© Jak (E

7 eS 4

B i

BACK-UP

BACK-UP

GEAR SEL SW BLOWER MOTOR

B

Dk BLU

CRUISE

WHT-PPL

uae (Gas

UISE CONTROL RUMP

BLK-PNK

cq| PPL- ORG

4

Wiper WASHER

c

A/T) x

BLK-PNK

8

(FUS LINK)”~y

we

HAZ eee

ELECT suiter CTRL MOD

| PBLK-PNNK

y

!

Gry-veL

s

BLK-LT GRN :

FUS LINK

> & BLU 4 i

5

|

HEGO

val

=

FUEL WATER

COOLANT

RED-LT BL

=

—

TEL

ELECT CONTROL ASSY a REAR DEFOG SW

BLU RED-LT -

DISTRIBUTOR

B

Chassis electrical system

Chapter 12

12-38

(3)

‘3)

(3)

MOTOR

(3)

oe

BLK

LT GRN-BLK RED-BLK ay

Viatere

aon SEL ‘SW —_

W/SHIELD

a

IGN

sw

WIPER

or

MOTOR

BRN ¢RIGHT FRONT MARKER LT SENS TAILLIGHTS

BRN; TRAILER OR MARKER

IGN SW WASHER E

LT RELAY

-WHT

1

me

Sik

-WHT

LEFT FRONT MARKER LT

WINDSHIELD

rs

WASHER MOTOR

ry as.

2&@

o2sfo

Six1sl3

—

Ges 288

3233s

UI conn

| Jit BLu-PNK

[PLLGRN: BUX

yf0fy

SE5O5e

3

TEST

31

=

L

og ERS

«

3

zZ

shia]

3|4}Z

B RED- PNK

22 ww

5g

aeOos

5 ze

z > Zz

«

z

Sug Zukag 332222933

WARN SENS

19 ~

«e = ¢ PIae AteBogen

Lod

Ay

51313

i

SHIFT

2sssssea2

a3]o} a] [2]

DUAL BRAKE

18

eased

33

L [2]3]4[sJo[7]s[9|

12-39

ELECTRONIC SHIFT CONTROL MODULE (4X4)

E 05

=

a)

]

BRAKE MODULE (RABS)

5

IGN *

Chassis electrical system

TRANSFER CASE MOTOR

LT BLU-RED

SHIFT POSTION

TRANSFER CASE

(SHIFT NSOR: MTR ASSY)

. RED- WHT

©

GEAR

SELECT SW

B

te

TRANSFER

1}

ee)

es) a

a

[7

;

yetk-wat

CRUISE CONTROL SERVO ee

%

aeren

MOTOR

®.|

al

Ones

[]

BLK TF

eri

ee

g g

asc sw

—

a BRN-ORG

[]BRN-ORG fl LT GRN-PPL

OFF e BLOWER SW FUSE #9

RED-LT BLU #

c

DK GRN-WHT |_teep- tT Buy [TE Btu.BK

DK CRN WHT

@ tT GRN

CRUISE CONTROL AMPLIFIER

e

ELECT CTRL ASSY

SPEED SENSOR

=

BLK ira BLK

'

fa

ra 5 5

a

a

seen

ak

co

I RESUME

coast| >

HORN

D

»

F|

2 INTERVAL

@)

GOVERNOR

Go

©

A/C COMP

x

C-)

BLK

A/C COMP

CLUTCH

CLUTCH

~

)

C)

as

2

BLOWER MOTOR:

(W/INTERVAL WIPERS

(W/O INTERVAL

E

© 4 9z

=

a

a

FUSE

E

HEATER

&

BLOWER SW

ce)

#9

W/SHIELD WIPER sw |

=

16

BLOWER RESISTORS

WIPER

BLK WASHER MOTOR

|

W/THERMAL LIMITER

MOTOR

17

|

18

1987 through 1989 F-Series/Bronco wiring diagram (5 of 7) Wiring diagram, Copyright © 1994, Mitchell International, all rights reserved

i

19

r

Chassis electrical system

Chapter 12

12-40

YEL- WHT

vott-

fe

METER

2

4g

a

FUEL

ca

GAUGE

{A12 |

F5| | sp 13 a) x

+

t

BLK

(GAS

;

FUEL TANK SEL VALVE (DIESEL),

FUEL TANK SEL SW (GAS W/ DUAL TANKS) OR FUEL LEVEL

gy,

SENDER (GAS, SINGLE TANK)

(ON COM

count

COLNT

temp @ @ SENS | 3

b

Teme

ee

S|

om pres| CAUCE

oF

-—]

:

OlL SENDER

—

=

IND

4wo IND

EG

BUCLT sign BLU

PBLKLLBL

|

tock

BRAKES

aoe

SENS

Ya

iY

Gee

vs

sy

pp-BLk

FUEL FILTER

bibs

| > Ae

C1 park

FUEL

ia BRAKE —

S 3

Hed

LO IND UT

ANTI-

FUEL TANK SEL SW (DIESEL)

oe

SHI

HI IND ir

sw

oa

Lage eh! (DIESEL) B

LEVEL. SENDER

ANTI-

-

tock “emits

gon! INSTRUMENT CLUSTER

FUEL TANK SEL VALVE

oo.

(©)

Tao }OXSRN

(DIESEL)

BRAKE MODULE

oer #18 INST CLSTR

CHING ©

Bo

FASTEN

seav(@)

BELTS

A2

ca

e)rear] LTS G

Sia

(S

Meat core

/IGRN: Bik

rege)

©)

(DIESEL)

INFERRED MILEAGE &

DIR/HAZ

Hea fa PLLGRN: WHT

re ic

(W/DUAL TANKS

FUEL TANK SEL SW (GAS W/DUAL TANKS)

EXTENDED Aree

sw

:

=

paves SENDER

WARNING SWITCH

sw

FUSE #10

e

FUEL

gi «

BEAM SEL

[a4 | LT BLU-RED

oir (©)

ut

>

Yt | A3

eee Onna

c

B

z

BRAKE WARN Gm oo

A

fre)

(W/O ELECT

a

mop|_}|—4 Ay

FUSE #15

RED- WHT

> . 5 ES

TUpieset)

ENG © WARN

2a

{WHT-LT BLU

WB

r—} o ARNING sw >

a

aI

wena RED-YEL

=

OVERHEAT

@&

SENS >| =

fe@ PDK GRN-VEL ) AvaI aan (ESO SPEED eB 7] Dk Biu-ver_ SENSOR UW [ Seuxver Io ane (DIESEL COLNT [] rary PRE (OR WHT-LT BL

A

a

23

]

22

|]

21

1]

20

ant

SensMODULE

conttt ASSEMBLY

Be LT

ete

INSTRUMENT CLUSTER

Hoes FUEL PUMP

DIRECTIONAL/ HAZARD SWITCH [WHT RED y

NORM

=

ry

‘a hd A oS

RERTS

$ cs

‘siceaaed ceaDIESEL)

}HAZ

e

6

pLREO-WHT of Haz | FLSHR

ey

‘a

CONTROL

K

a

ruse 1

Zco)

CRUISE

ANTI-LOCK D

3

[case] CJ

stop LT sw J

¢

| 5 5|

KEY a sw

:

z

=

:

m

RADIO (PARTIAL)

=

BLK-PNK

YEL ra]

Lert REAR LT DIR/STOP

—

ae

5|

pe MAIN eaLT SW ae SNC ay 17 WARNING BUZZER)

em

BRN-LT BL

rrp RN-tT Btu

BRN FUS LINK

9 BRN-LT BLU

eke

*

RED-YEL—

E

GLOW PLUG

CONTROL”

]=

FUSE #5

ds

I

an

=

E

RED-WHT a

auf

BLK-LT.B

oO

FUSE #10 REAR DEFOG

E

SEAT BELT

WINDOW OSRIDDEFOG

IGNITION SW

“T

D

=a

BL

RT REAR DIR/STOP LT

LEFT FNT

Fish

c

GRN-RED __¢ ai TERNATOR

Lil

wat

%

ae

IGN

FUEL WATER

(DIESEL)

SW

20

|

21

1

22

TARING IND

1987 through 1989 F-Series/Bronco wiring diagram (6 of 7) Wiring diagram, Copyright © 1994, Mitchell International, all rights reserved

'

23

BS

Chapter 12 24

Chassis electrical system

25

]

]

26

12-41 i

27

MASTER WINDOW CONTROL SW RIGHT FRONT

RT SIDE BODY MARKER LTS

LEFT FRONT TAILGATE WINDOW Sw WHT-RED

A

TRAILER BRAKE

x)

3 T x Fuse x14 ¢-LLBLU-BLK

5

“

¥

Es

$

FUSE 2 12

a

= a

2

a 316

-]

als

ml

z

a (-GUK-WHT

5

=

x

x

2

=

LIGHT SW’

>

a

|

a

a

TRAILER

RT

FNT

FUSE #14

wdo Sw

BRN

LEFT TAILLTS

ELEC BRAKE CONTROL (NOT SHOWN)

3 5=

ORG-LT BLU

ORG-LT BLU

BLK FUS LINK

ro

a

al

Fi =

DIR/HAZ, Sw

oe

L-)

DIR/ STOP LT

CONN

a

¥

WHT-RED ,REAR BODY MARKER LTS

(EX STYLE SIDE

LICENSE LT

ARTE

LEFT FRONT WINDOW sw | UP MOTOR Nhe) i OM OURSta Nhe,

ORG-LT BLU a LT GRN-ORG | BLK {_]

Pectin

TRAILER BRN CONN B FUSIBLE LINK 'W/ TRAILER) TAILGATE POWER WDO

BRN

MOTOR

TAILGATE

WINDOW UNIT SW

i,

Ww/DUAL h REAR WHEELS) BRN FUSIBLE LINK

im UT GRN-YEL

=

=

BLK- LT BLU

LEFT para hes

MAIN

ELECT

LT sw

CTRL ASSY

REL mat

Ld

it

RIGHT BODY

WARNING BUZZER

USL Ree

MAIN sw

LIGHT

MARKER

INERTIA sw

LTS

‘ ey =

2

LEFT BODY

TROL SW

RT DOOR

Cc

malate

sw

z

>

Faz [o) aS|

> Fe )

REAR BODY MARKER LTS * IN-LINE FUEL PUMP INSTRUMENT CLUSTER =e LT SW

“= x

Z

a

FUEL LEVEL SENDER (GAS, SINGLE TANK)

F150-F350

BLK-PNK ms

aS

2&

ey

BACK-UP |

x

a

BLK-PNK

urs

ahDk BU-YLy z

6 5

4

DOME/MAP LTS

~

(CHASSIS CAB:

ra

D

per can ve

omit

ues3 eMiaieetr |} Nay,

FUEL TANK SELECT SW (GAS W/ DUAL TANKS)

“ Laan!Pie

[Jeb

Reece

)

DIODE

LICENSE LTS

TAILLTS

BRN

DIR /HAZ s

FUEL LEVEL

SENDER (REAR)

~)

ce)

FUEL TANK SELECTOR

BLU BLK-LT GRN-YEL LT BLK-PNK

"

TRAILER CONN

valve (DIESEL)

FUEL LEVEL

SENDER (FRONT)

1R/

STOP LT

gOo} 5

Taalien

=

FUEL LEVEL SENDER (REAR) BLK-GRN-YEL PNK LT

PNK BLKBLU. BLELT REAR

BODY MARKER

BLU BLK-LT

LTS

E

LEFT SIDE BODY MARKER LTS

24

|

25

1

26

1987 through 1989 F-Series/Bronco wiring diagram (7 of 7) Wiring diagram, Copyright © 1994, Mitchell International, all rights reserved

i

27

12

Chapter 12

12-42

Chassis electrical system REO Bw

pistRiBuTOR COMPONENT

CLUTCH INTERLOCK SW (M/T), MANUAL LEVER POSITION gep-iT BLU SENSOR (E40D TRANSMISSION), BACK-UP/NEUTRAL SAFETY SW (C6 OR AOD TRANSMISSION)

eee TERN j=) i 1 las 'e

LOCATOR:

beter

w.----0 1) A/C CLUTCH RESISTOR DIODE ......... E30 RIC: COME CLUTCH ines decvuncdiae seinen E29 A/C/HEATER FUNCTION SELECTOR SW! cscs. ALTERNATOR (DIESEL)

is ALTERNATOR (DIESEL, 165 ALTERNATOR (GAS) ea, .........-0202025 SA HURIT GWAR

:

4) ala

RED

ala alo

(DteESELY—c>

SAFETY SW (A/T) BAUER Yann .tedemnrs BEAM SELECT SW

U

b

SWNUMPERVAIN)) CONN C300........

| veirencn sscnwrevae ne B27 Mon se teta até D 33

D-E 33-35

CRUISE CONTROL DIR FLASHER .. DIR/HAZ SW ... DISTRIBUTOR

ENGINE

20 GA BLU W 30 GA BLU N

FUSE #1

Soe

F-SERIES/BRONCO

14 GAGRNJ

W/ OPTIONS)

7

FUS LINKS)

D-E 24-27

AT. A11, 415 . © 33-34

DOOR SWS... DUAL BRAKE

F-SERIES W/O OPTIONS)

DIR LT

WHT-LT BLU

PODE/RESISTOR, ©i .cigecetdaacetease: B33 £40D TRANSMISSION . £4,69,E12,E17 EEC POWER RELAY .......... A4,A8, A 12 ELECT ENGINE CONTROL

(EECVGCINE mak net Be. cese B-E4 KEECOUSA ESI wea een ces BE 8 B ELECT ENGINE CONTROL (EROUIZSISMM eee ue nee ELECTRONIC SHIFT CONTROL MODULE ENGINE COMPT LT . FLUID LEVEL SW FUEL PUMP RELAY FUEL TANK SELECT SW (DIESEL) dae FUEL TANK SELECT SW(GAS)..,.---.-. FUEL TANK SELECT VALVE (DIESEL) FUEL TANK SENDER (DIESEL) nee FUEL TANK UNIT(GAS FUEL TANK UNIT (SINGLE TANK) ....... a FUEL WATER SW

$s

MORE Rie

CLUTCH INTERLOCK SW (umn MANUAL LEVER POSITI SENSOR (E40D TRANSMISSION), BACK-UP/NEUTRAL SAFETY SW (C6 OR AOD TRANSMISSION)

TRAILER/MARKER LT RELAY

...........

YEL

720 GA BLU M

YEL

[[20GABLUF_f

7 ———“BiK-OnG_/ NCA FUS

YEL-WHT BLK-ORG

FUS LINKS)

LINK)

STARTER RELAY

FUSE #16 TRAILER ELECT BRAKE CTRL

NGA

TRAILER/MARKER

RED

{}

LTS RELAY

(STANDARD}—{_

us

BLK-ORG YEL-LT GRN

(i)

ORG-LT BLU

ALTERNATOR (DIESEL)

tus

[eLne2

=

ms 4 1\ | LT GRN-RED

CHARGE

||

ORG-LT BLU

IND

LINKS)

144GAGRNB_. BLK-ORG 14GAGRNC ~ BLK-ORG 20 GA BLU N

V

TECA

YEL-WHT

POWER RELAY

Plolnli—

LT GRN~BLK RED-BLK

\ BEAM SELECT SW

YEL-WHT

VOLTAGE REGULATOR (DIESEL)

\ a9 RADIO NOISE CAPACITOR

CHARGE IND

GLOW PLUG

CONTROLLER

—{165 A ALTERNATOR

: FUS LINK Z (GLOW PLUG CONTROLLER)

(INST CLSTA)

HEADLIGHT

RED-LT : GRN BLK-ORG

*

LT GRN-RED

C38

WHT-BLK

WHT-BLK MARKER

SYA

YEL

(INST CLSTR)

WHT-BLK

LT

BLK

BRN BLK LT GRN-WHT

WARNING INDS (DIESEL)

{_|

STARTER (DIESEL)

HORNS

ASSY (TECA) (DIESEL)... 2-2 -s B-E 16 VEHICLE SPEED SENSOR... B4, 88,8 12,A16 VOLTAGE REGULATOR (DIESEL) WARNING CHIME MODULE. .

i)

~_14GABLU J

18 GA BRN L 20 GA BLU P

YEL

YEL-LT GRN

D

ga

YEL

SGA BRN G

ruse ene YeL USL 10

ao VELD

TRANSMISSION ELECT CONTROL

WASHER MOTOR. .. WIPER MOTOR,.... WIPER/WASHER SW (INTERVAL) WIPER/WASHER SW (STANDARD) 4WD IND SW

RED-LT BLU RED

HEADLIGHT

(W/ CRUISE CONTROL)

5S suter co. 2 oka feo

}

___LTGAN-RED

CHARGE IND (INST CLSTR)

FUSE BLOCK GLOVE BOX'ET: as coe. s GLOW PLUG CONTROLLER HAZARD FLASHER ............-+-

HORN RELAY HORN RELAY JUMPER... IGN SUPPRESSION RESISTOR .IGNITION COIL... ; IGNITION SW, ILLUM LTS ..... me, INERTIA SW (DUAL ik on eee A3t INERTIA SW (SINGLE TANK) INSTRUMENT CLUSTER .. INTERVAL GOVERNOR .. LEFT DOOR SW ....... LOW VACUUM WARNING (DIESEL). .C31 MAINIDC SW suc. niecc. omeeteanes MANUAL LEVER POSITION SENSOR (MLPS), B 7/B 11/B 15/C 19/4 25 MAP/DOME LTS E33, E35 OVERDRIVE SW. £ 6-7, i/614-15,C18 PARK BRAKE SW B33 POWER DOOR LOCKS . POWER WINDOW SW . RABS SYSTEM, .... RADIO (PARTIAL)... REAR DEFOGGER SW SEAT BELT SW ........ a SELF TEST OUTPUT CONN. C7, C 11, C 15, E19 STARTER RELAY (DIESEL) B-C3 STARTER RELAY (GAS) ; STOPIMSWite hens TAILGATE WINDOW SW TECA POWER RELAY TRAILER CONN ELECT BRAKE OCS AIL TRAILER

ALTERNATOR W/ INTERNAL REGULATOR (GAS)

s

CONTROL), HORN RELAY

oe

LINKZ . FUS FUS LINKS ...

18

MAIN LIGHT SW

HORN RELAY JUMPER (W/O CRUISE

E37

BLK-ORG BLK-ORG

INST CLSTR

rr BRN

ELECT ENGINE CONTROL

CONTROLICONNE

YEL YEL

A

TRAILER ELECT BRAKE CTRL VELSEEO@aLCR ELE BLUM St Sh

0

(DIESEL

COMPT LT

em

STARTER RELAY (GAS)

VEL ©20GA BLU P

YEL

FUEL PUMP RELAY

;

COURTESY LTS...

Vel

TRAILER/MARKER LTS RELAY

CLUTCH INTERLOCK

STARTER motor

RED $I

FUSE #16

CAS MARKER LTS CARGO LT. ..... 4 CIGD Ri ceraen aeeea nares tants : CLUTCH INTERLOCK SW(M/T)..... 0.

eral fal (4, ry

18 GA BRNG 20 GA BAN BLU A Os Ga

YEL YEL Saag

w OD SS REAR DEFOGGERLON(BRONCO)

BACK-UP/NEUTRAL

,

RED-LT BLU

GAS)

=

A

t

3

|

2

|

1

wl

i

MAIN LIGHT SW

|e | Tes

INST CLSTR

DIR LT oon

BLK

1

465 AMP ALTERNATOR W/ INTERNAL REGULATOR [o[o]o]n W/(DIESEL E40D)

\

CHARGE IND

RELAY (DIESEL W/ E40D)

es OK BLU-ORG

DK BLU-ORG BLK

c

ees

war

70 INTERVAL WIPERS)

——

2

| ce

BICENG

\ ear

BLK

Bes

Se

BLK-PNK

9),

{W/ INTERVAL WIPERS) RED

WIPER MOTOR

BLK-PNK WHT

WASHER MOTOR

\

a

a

1

INTERVAL GOVERNOR

DK BLU-ORG

|

BLK-WHT

2

WASHER SW

a

1990 and 1991 F-Series/Bronco wiring diagram (1 of 10) Wiring diagram, Copyright © 1994, Mitchell International, all rights reserved

[cB]

=\|7 |—#*~e—_

Sapaaiaiocn SW (STANDARD)

WIPER/WASHER SW

BLK-WHT

ria

RED. BLK-LT GRN [=[>] >

IGNITION SW Ca

3

ie

Chapter 12

DUAL BRAKE RESISTOR ion sw

WARNING DIODE/ < REO-LT GRN

L— Yeu

;

=

Loe id eo lees

OK GRN-YEL

GRY-ORG 395 |—+

h

INERTIA SW

RED-LT BLU 32 SEDSLTGRNG

STARTER RELAY

@

SPOUT

GDS CRNSYEL

,

© OQ)

ser PNG} SP etwas es

@

~ O26

PNK

uy

et

©

PNK 929 |—

FUEL PUMP

RED-LT GRN

MODULE

ORG-RED 259

at

YEU K

TFI

> (STARTER RELAY)

oe

‘us LINK YEE

al

ater

UT BLU-ORG |} RED

¢REO=LT.GRN

(STARTER RELAY)

A

Chassis electrical system

DISTRIBUTOR

CONN

i}

RED-LT GRN

Zs

A/C CLUTCH RESISTOR DIODE Ae tee

TEES BOWER? RELAY ==

VEHICLE p@; SUK

SPEED [eiGRY-BLK

sensor CRUISE CONTROL

|S

-

PNK-ORG — LT GRN-RED DK GRN-YEL PNK-LT BLU

|

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KNock [epeeee SENSOR | @{CRY-RED

||

Bi

ENA

Bese

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Ba

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PNK-LT GRN

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he

|

i

le

(33:

ARID VERTED ee t

224 TAN-WHT

IDLE SPEED

CONTROL

CANISTER

PWR GND [6o} >i

E40D

SENSOR —, SELF TEST INPUT

BRN-WHT A/C/HEATER

FUNCTION

GRY-REO

SELECTOR SW

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g

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,

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a

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a

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OVERDRIVE

sw | ~

4990 and 1991 F-Series/Bronco wiring diagram (2 of 10) Wiring diagram, Copyright © 1994, Mitchell International, all rights reserved

GPRLORG sFUSE #6

E

EX BRONCO) p

PPL-ORG

REAR on

6 ILLUM

2

“A

iel

t=)

|

PRESSURE (MAP) SENSOR

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o iE | (5] A [

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ee

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Seis \ele}

CONTROL (EEC) (4.9L)

[|

THROTTLE

WHT-RED

ORG-YEL SS1 (E40D ONLY) ) {e2t22/ 780 PPL-YEL

ELECTRONIC ENGINE

D

GRY-WHT

PURGE SOL

i Byte BED eneINJae 555 TAN BANK #4 [58---— INJ BANK#2 (697-70 BUK-WHT E

SENSOR

BRN-WHT

SOL

AS a 358 LT GRN-BLK

a Hee| 295 GRY-ORG

]

IAB) SOE

=

eevee Hye|359. GRY-RED tp =)|a7 355 GRY-WHT 209 WHT-PPL STI |4875 ORG HEGO GND [49] 60 190 WHT-ORG ams [64

Ccsie

BRN-WHT

AIR BYPASS

|41 903 ORG-BLK

ec (E400 ONLY) |5a-~ pe eaeetr _ 924 BRN-ORG

SENSOR

clea EGR VALVE GAN bos POSITION [__BRN-UT

THERMACTOR

aeoN tS

=

olis

GAS OXYGEN

FLASHER

35! 909 PNK Seu eS 925 WHT-YEL

TOT (E40D ONLY) |42}—

EXHAUST

THERMACTOR

Axis < 570 BLK-WHT

OCS (E40D ONLY)

BLK

GRY-YEL ot

EPC (E40D ONLY) [38 D

GERTED

GRY-LT BLU

[|

==

ea

Seared

Cc

= D| AIR CHARGE CL [_Gary-Re0 || Temp sensor

{tt}

CIL (E40D Sain Ey RIN 360 BRN-PNK (

nt

fet LT BLU-ORG [)___—saLT BLU-ORG_

ans co

SZ DX] SELF FN Segr uTeUT

TAN-ORG

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743 GRN-YEL 351 BRN-WHT 252 BRN-LT GRN oS

MANUAL LEVER POSITION SENSOR (PARTIAL) ¢__PNK-LT GRN

pnk-ut eu

Beene dca

NDS/MLP (E40D ONLY)

bate a

INST

18) 315 PPL-ORG

—| bee = Eve (27) PRTATLINIC TENSE

B

Z\z

CLSTR

$82 (E40D ONLY) [18

> ial 926 LT BLU-ORG

os}

/ E40D)

W TEMP SENSOR

Bi

< $ z2

PASE See s 264 WHT-LT BLU

|

aa

| me CS[lier

EDGE PNK-LTGRN 47 SSS ENKS

Key oa] eo

~

Aa colt

TAILLTS

BLK

BLK

A

REAR FUEL TANK

RADIATOR SUPPORT)

4

(GAS)(A 8/A 12/ A 16) (DIESEL)

ENGINE COMPTFUSE BOX

di

BLK

BLK

DK BLU-ORG

FRONT \_ FUEL eR TANK SENDERS

BLK-WHT.

LEFT faa UT

PCM POWER RLY

S

My z

BLK

ee stare as Scaeeee

— ie

a

it BIR

— BIC)

BLK

—

A

S| ¢ |p =

LEFT FRONT , BLK DIR/PARK LT

FUEL PUMP RLY (GAS) (A 8/A 12/ A 16) TRAILER BACK-UP RLY (D48)

B SOA/15A

HEGO SENSOR’ BACK COMPT F/B)

RED-LTGRN

‘

©

STARTER RELAY

F/B)

YEL

=

\

hea

ae

INERTIASW

ORG-RED 259

é

FUSE 0 (ENGINE COMPT F/B)

Rig Seoe omar DK GRN-YEL i i ul

11

i

10

i

9

:

YEL LT BLU-ORG RED

A.

Chassis electrical system

ZNO

se

||

LT BLU-ORG

LT BLU-ORG GRY

||

AIR CHARGE

GRY-REO || Temp SENSOR

[| |)

BNWT GAN 201 BRN-LT vace eve [aep (p71 SE 202

a

914 TAN-ORG

481 GRY-YEL (OR 199 LT BLU-YEL)

NDS/MLP (E40D ONLY) [30

canp [31 = — on Lal

EOP

ONE

EVR

YEE {3608RN-PNK PNK

4

map

SARE

= H Las

yah

(TAD) SOL a4

Ps

GRY- RED

BRN-LT GRN Saar, Se

On

(FAB)SOL IDLE AIR Bvnice

ac al ea

PURGE

oe

[|

SOL

|52

237 ORG-YEL

480 PPL-YEL

ro

"| 924 BRN-ORG

|

a

|58

=

HT

aa

INT PWR BANKGNDG2 71091 =a |60! MODULE

(PCM) (4.9L)

BLK-WHT

le

ee

ees

9

9

.

> |x

9

5

cs

& ES

z

a

z

o

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PRESSURE

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[oI Ke) 817

MISSION CONTROL SOL

MANIFOLD

as

9


|

28 BLK-PNK

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HAZARD

OFF iLgso ns cualHl WHT YEL-RED

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NORMAL

DK BLU-ORG

peel

MOTOR

a

INT

| MOTOR

HAZARD FLASHER

9

>

2

Zz

Us

&

=

°

z

&

=

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2 = a

2 5 2

5

lpr

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re

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/7® (@)_RED-WHT

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i

L| 1g \ ::

IGRREWET DIRINDS _f LEFT eae aees

YELCLT TGR GAN

LT GRN-WHT WHTLLT BLU ORG-LT BLU UTGRN-ORG?

ORNS

(ENGINE COMPT F/B)

FUSE C (ENGINE COMPT F/B)

RED-LT GRN ,OUTSIDE CARGO/HIGH

LEVEL STOP LT (BRONCO)

4WABS CTRL MODULE (BRONCO)

TRAILER CONN

LT GRN¢

CLUTCH INTERLOCK SW (M/T) CLUTCH INTERLOCK SW JUMPER (A/T) CRUISE CTRL SERVO/AMP ASSY (6.8L LIGHTNING)

STGENYS

POM PIN #2

F/B

HORN sw

LT BLU-BLK

sleet WHTEENK

SLIP RING ASSEMBLY /O CRUISE CONTROL) 7 CRUISE CONTROL)

GROUND H FUSE E (ENGINE COMPT FUSE BLOCK)

Ay

RED-LT BLU WHT-PNK LT BLU BLK PPL-ORG DK GRN-ORG

fle cuamaine ASSEMBLY

CLUTCH INTERLOCK SW JUMPER (A/T) STOP LT SW (5.8L LIGHTNING)

DK GRN-ORG

BRAKE i PRES SW

901 GROUND 146 ~.BRAKE RESIN 151 | swin 298 are 848 I] swin

RED-LT GRN 810

CLUTCH INTERLOGK SW (M/T)

ACCES.

28

D

GROUND

fing

NCA

NCA

=

it sToP iTsW

em

HORN

OFF

‘

a ee MULTI-FUNCTION SW

E

FUSEG/S

noe

COAST are CRUISE CONTROL SW ASSEMBLY

RIGHT\ REAR (ee, > DIRLTS

=LT

od

RESUME

Cc

OHMS

SEs nae A, SAME

DK BLU

HORN RELAY

E

4.8K CEM

LT GRN ; RABS MODULE PIN #11 (EX BRONCO)

reer

YEL-UT BLU

ON | NCA

DK GRN

LT GRN-RED

RED-WHT

(INST CLSTR) \ RIGHT

D

SS

LT GRN

See Peal FUSE

ee

WIPER/WASHER SW

Cae

;

i

8

W/SHIELD WIPER

OHMS

3.3K OHMS

sw

GROUND E

CRED eo RABS MOD PIN #12 S DIR FLASHER

INT MIN

OFF og

sw

DIR/HAZARD

N BLK-PNK fa

#13

100K OHMS

WASH

RUN ie ars

Lo

MAX

z

TTA

]

a

i

INTERVAL

oa

©

xs a

GOVERNOR

WIPER

he

SE aa

(C6 OR AOD TRANSMISSION:

MOTOR

14

Cc

GRY-YEL |

PCM PIN #30

BRRERER

GROUND E

REO-LT BLU a

(E40D TRANSMISSIONS

10 (4 G5 OK GAN

12! 13

idee

VV

GRY-YEL

USED

sw

—_

G-G—SED-LT BLU |

IGNITION Sw

RED-LT BLU

CPs BENE WHIT ; 56 DK BLU-ORG 9 |290 DK BLU-WHT

Dera

COMPT F/B)

CRUISE CTRL SERVO/AMP ASSY

a

=

RED-LT BLU , IGNITION

3 — L241 BUK-WHT

FUSE E (ENGINE

LTs

(EX 6.8L LIGHTNING) STOP LT SW

i

STARTER RELAY

ELECTRONIC SHIFT CONTROL MODULE PIN Bi

BACK-UP

RELAY,

2 z

RED-LT BLU

SSTREDEETBLU IGNITION SW r

3

STARTER

COMPT F/B) CRUISE CTRL SERVO/ AMP ASSY

é!

5 o «

GAY-BLK 679

E

BRAKE IN {| SPEED IN

CRUISE CTRL SERVO/ AMPLIFIER ASSY

INST CLSTR

=

|

29

I

30

4992 and later F-Series/Bronco wiring diagram (8 of 13) Wiring diagram, Copyright © 1994, Mitchell International, all rights reserved

i

31

12

12-60

Chapter 12

,

32

Wiis

i

Chassis electrical system

33

|

34

:

L.

4WABS CONTROL MODULE (BRONCO)

Siea

w

wo >

a -ostU

Zh iu

st oeciee,

Sus

G54

peesSecrse2s3 enor ls

= oO

gee euns ce

2

w

giz Fee 3 eee

ee

SP9RS5 USL Rvvas Z7OzGr%r = fezGGoeseeE SSE Ege Geavo0a7rs SaRezzzogeeeOR yy _aoaste Seroeee bueuue aSt=zeczyuzVuneZ

ag oC@cy

SEO Eee ESSE ee tussZGgag-

A

A

EE ek SH ta oH tue Ze Ziceal eer eegy

wyewesS

GeaseeSeresttecoaovoreor

tesa

f2]3 [41616] 718] 9 [10]14]12[13]14[15]16]17]16]19]20]2 1]22[23|24]26]26]27|26|29]30]31]32]23[24]36|36]37]38[39] 40]

g=

Pd elFedbedbededFeded ed Si/4/z/2/O||

I-|_LT BLU-RED

RESET

B

—

BRAKE FLUID , TAN-LT GRN LEVEL SW

a

PS

LT. GRN-BLK =

Fee

PNKCORG;/

(BEHIND BOTTOM

jjj_—SLK-WHT

OF RIGHT COWL

WHT 770 Bs |#4 | SHIFT

#2

“

ELECTRONIC SHIFT CONTROL MODULE (BRONCO)

a

IN BRN-WHT < WHT. eRe PPL-YEL re|

MOTOR POSITION SENSOR -_ mel

NX

BLK-WHT?

| wey

BLK-WHT

| J) SHIFT motor

CleTR

BLK-WHT

ee —a\

RED-LT BLU , CRUISE CTRL SERVO/

SPEED‘ MAGNETIC cLUTCH tts |SENSOR “coiL

AMPLIFIER ASSY

C

ON IND

—

=

| 4 reo-vet WHT=LTGRN ON TAN-WHT

LEFT DOOR SW

FUSE #17 int wap > PCM

LT. GRN-YEL BLK-LT BLU

Lads he

Bee

KY

LT GRN-YEL LT GRN-YEL

ene

LT GRN-YEL

eo { LRED-PNK _¢ CRIME MODULE

(3

OVERDRIVE

saad

LT GRN-YEL

TRANSFER CASE ASSEMBLY

FUSE #8 BLK-LT BLU

Heavier

LEFT

\

SOLID

ricHT (@) BLK

STATE

or

€

| BLU BLK-LT

D

as

SEOUNDIE

LT GRN-YEL

GROUND F

Bee

BEDE NEY

peed Eee SNS ee See Pee eer

a COURTESY

us

FUSE #17 {

RIGHT

(6 ©

RED BLK

8

i RIGHT

re

i

REAR

COURTESY [| LEFT

=

treRNeven -

IGNITION SW

qd_{op

PLUGGED

()) [ae Ree MAP/DOME LTS

GLOVE BOX LT th

E FUEL PTE

gi,

5

LT GRN-YEL

eg (Sea)

RAT IND) © ois

qd

Es D_LtTGRn-Yet =

BLK-LT BLU BLK-LT BLU

CARGO

=

“t

xs

(Py

(W/ MAP LTS)

(F-SERIES

f

=

=LT

PNK Ca

ATTHUPE

{_]

/O MAP LTS)

qd p

BLK-LT BLU

DOME

b> iT

LT GRN-YEL

RIGHT DOOR SW

FRONT DOOR

>)

+

=

BUK-LT BLU

[|

CANCEL SW

B

YEL-WHT 9]

wan

BLK-

PANEL)

ae

BRN-WHT 764 [56 |#3 > POSITION ORG-WHT 763 SENSORS

oo pin #6 z 2A nio

BLK-LTGRN, GROUND H

[At |

-PN ude Mesias FUSE #15 DK GRN , ABS IND (INST CLSTR)

(INST CLSTR) < BEDSENS

id

| a2 |GROUND

SENSE a. 23 |baa SENS RETURN

: STOP LIGHT SW

————_— +, 4X4 HI/LOW IND SW

are

arene

RED-WHT463 (57 ast NEUT SAFETY SW [trea |82 |SPEED SENS FEED SS

(AOD TRANS)

ans

AS

GROUND F

ros EsOD TRANS), BACK-UP/NEUTRAL SAFETY SW LT GRN

IGN RUN & ACCY POWER |AG| Lede a As |

aero |e ee moun BLK 57 SENSO

soutien

ws ORG 778

MANUAL LEVER

seo

A

BLK-WHT 517 [As | BATTERY POWER

FUSE #18

$158) 5/815 1515/4 1515/9) So SI5/Z|s|A/S/S|5/2/ 9/48) 5)5 Sy]

-

[cs | 4x4 IND

Sarre)

ELECTRONIC SHIFT CONTROL SW

‘%S/2/S$/5|3/9/2Z/2/S/¥/Z/2|Z|Z

jal] Lala re

BRN aoe = |C4 |LOW RANGE IND

IND SW

nie (Cm

SISlZSS/S(S|SlSlS E151 3/3

BlZo/a| =

ORG-LTpat BLU 781 |-C3] Low RANGE INPUT

4X4 HI/LOW

GRY.

i]2[3]4[5[6[7 [a9 {so]ss]s2]13}14) BURG TRO. Ks VALVE

L.

S GROUND F

BEDSIEE

pe

(Lg

43

FUSE #10

D WHT-LT BLU 4X4

2Eou GEES EOF EOD

te

LT BLU-RED

7 Blk

Pe

-—°

zootesss

wS5agZ ny s i as a

42

’

7 Teint GANEVEIN

ae |

E

|

auk-ut atu IN fa BLK-PNK ,OUTSIDE CARGO/

> GROUND F

HIGH LEVEL STOP LTS

INSIDE

CARGO LT

LAMPS

40

i

a1

]

42

1992 and later F-Series/Bronco wiring diagram (11 of 13) Wiring diagram, Copyright

© 1994, Mitchell International, all rights reserved

i

43

r

Chapter 12

|

Chassis electrical system

12-63

45

47

FUSE M (ENGINE COMPT F/B)

FUEL GAUGE DEFOGGER GRID

BRN-WHT

(INST CLSTR)

GROUND | (LEFT REAR CORNER

BLK

|| OF CARGO AREA,

TIMING

SZ

NEAR REAR LAMP

CIRCUIT

ASSEMBLY) fee rat

ittum ey) (6

2

GROUND E

PUECTANICUNEY

(GAS

BLK-WHT BLK-WHT DOWN

POWER RGnnac COMPRESSOR

up

BLK-WHT

MOTOR J

al a] g =]

a

7

alc 5

—

GaN

LT BLU-BLK

z