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Ford Training for 1999, 2000, and 2002 MY E350 and F350 with 5.4L SOHC Engine and Automatic Transmission

The following are notes from a training seminar I put together. It includes common symptoms and repairs for Ford E/F350 vehicles. It is not all inclusive and it assumes that the repair person has prior knowledge of the vehicles. Some symptoms and repairs that are suggested may not be appropriate for your application. Sorry for the format.

Ford Training for 1999, 2000, and 2002 MY E350 and F350 with 5.4L SOHC Engine and Automatic Transmission

I. NGS use
A. Connecting to vehicle

1. Plugging in- DLC is under dash on driver side. Use cigar socket as alternate power source.

          2. No communication
   a. Check fuses if NGS does not come on.
    b. Check fuses if no communication with module

NOTE- DLC and cigar lighter socket share the same fuse.

    B. PCM
1. Location

          a. F series-lower dash panel passenger side
          b. E series- lower dash panel driver side. Access from engine compartment.

2. Retrieve/clear codes- Emission related codes are stored when the fault happens the fist time. If the same fault occurs on the next drive cycle the MIL is lit up. It will stay on even if the fault is intermittent. MIL will extinguish if the fault is not present on three consecutive drive cycles.

3. KOEO- Performs checks on certain sensor and actuator circuits. A fault must occur at the time of the test to detect a fault.

4. KOER- Performs checks on certain inputs and outputs. A fault must occur at the time of the test to detect a fault. AFTER the RPM increases actuate BPP, PSP and TCS. Step on the brake pedal, turn the steering wheel one quarter turn and back in either direction and cycle the OD switch.

a. P1780- Normal (for here, will not cause CEL, check engine light, to illuminate).

b. P1288- Engine not warmed up (will not cause CEL to illuminate).

NOTE- Ignore P1000. Drive cycle will not be completed here. Diagnose in order of KOER, KOEO, and then continuous memory. Refer to appropriate PCED for pinpoint tests.

NOTE- If any code does not clear a problem with that component and/or circuit is present. Diagnose these concerns first.

5. PID data monitor/record- Used to view input or output status of a component.
              a. Push “softkey 3” for the definition of the PID. Push “Cancel” to return to PID menu.
6. Output Test Mode-
 Used to turn on actuators associated with the PCM. Monitor PIDS when
executing. It can control state of electric fan. It will briefly energize the fuel pump.
II. EEC controls

  1. A.               PCM
    1. B.               HO2S- Used to determine amount of oxygen in combustion gasses. Compared with monitor to determine catalyst efficiency
      1. Testing via NGS and w/ DVOM- Access via PIDS. Should switch quickly low to high. < or = 0.4v indicates lean. > or = 0.6v indicates rich. Check signal and signal return pins at sensor during KOER to determine if sensor is faulty. Should see a change in voltage greater than 0.5v during or at end of Self Test.
      2. C.               Transmission Control Switch- Wired for OD off all the time. Will indicate P1780 on KOER
        1. D.               Inertia Switch- Located behind right side kick panel. Used to shut fuel off in accident or for diagnostic purposes i.e. compression check.
        2. E.               EGR system- Introduces exhaust gas back into the engine for cooler combustion chamber temps which lowers NOx

1.  During KOER engine should run rough for a moment if operating correctly.

2.  Run rough at idle- EGR valve could be stuck open if all other components check ok. i.e. spark plugs, coils, etc.

3.  EGR passages could be clogged with carbon if components of system check OK but code is present and engine does not run rough when EGR is commanded on.

III. Things to look for

A. Check engine light- P1408- EGR flow out of self-test range.

B. ABS light- wheel speed sensors

C. Air bag light- clock spring.

D. Door hinges- Look for worn bushings on pins and/or cracked spot welds first. Repair as necessary.

1. All doors- Check pinch welds where doors straps cross. The pinch welds can get pushed outwards making the door hard to close and “pop” open. Adjust pinch welds with rubber hammer and relocate door strap. Start with the rear most door on vans and rear most part of cab on trucks. Remove striker until door is close to aligned then install striker. Adjust striker. After all is aligned and adjusted properly and door still does not close properly the door/sheet metal may be sprung where hinges are bolted to the door and body.

2. Front Doors- Check door skin on leading edge. If unfurled, repair first. Remove the inner fender on trucks to adjust. Remove inner and outer fender on vans to adjust.

E. Glycol leak from intake manifold gaskets- Leak from right rear near cylinder four will run down right side of transmission bell housing. Leak from left front will leak into engine valley and/or into cylinder five spark plug well possibly causing misfire. CLEAN AREA AFTER REPAIRING LEAKS, ANY LEAKS!

F. Heaters- Check for shorts and secondary junction boxes. Glycol 20 Ω, Battery- 130 Ω, Trans and engine oil- 190 Ω. 0.0 Ω or OL indicates no resistance or short- heater should be replaced.

G. Shifter lever-Torx bolts at rear of steering column that hold the shift cable bracket to the shift tube. These can become loose. If OK- Remove key cylinder and steering column trim. Move shifter lever by hand and pinpoint excessive movement. If the tube turns, lower the steering column by removing four 13mm nuts. Chances are the bolts holding the straps over the bushings are loose and/or the bushings are worn. Repair as necessary. If movement is detected at the pin that attaches the shift lever to the tube, replace the pin.

H. Front pinion seal- Cut with chisel from right to left on the top side of the pinion. Remove outer part. Cut the inner part the same way as the outer. You can remove both pieces with a t-style seal puller or side cutters.

I. Leaf spring bushings- If front or rear leaf springs are replaced or are removed to replace bushings, new U bolts need to be installed. They are torque to yield and can fail if reused.

J. Shift interlock- Brake lamp and shift interlock circuit must operate properly to shift out of park. If brake lamps are inoperative, diagnose accordingly. To move vehicle if this occurs turn the key cylinder slightly forward to the detent between OFF and RUN. The shifter can then be placed into Neutral and the vehicle can be started.

L. Hard start, no start, long crank, or slow return to idle- This can be due to a faulty idle air control valve. It is located on the rear of the throttle body. Remove connector, breather hose, and two 8mm bolts. This part can be cleaned with parts washing solvent. Soak for a minimum of 15 minutes. Blow dry with compressed air.

NOTE- Clear KAM (Keep Alive Memory) after IAC component is replaced or cleaned. Resets PCM memory default setting and clears adaptive learning strategies related to idle and fuel trim. If KAM reset is unavailable- clear codes and disconnect battery negative terminal for five minutes.

M. Transfer case- VANS ONLY- If you find non ferrous metal in transfer case and have no driveability complaints this is due to a worn out or loose chain hitting a boss inside the t-case. No service is required.

N. Check drag links and tie rods- Use channel locks. Any movement is not acceptable.

O. Misfire Diagnosis- Coils and/or coil boots are likely to break down before spark plugs. This can cause a stumble on hard acceleration or rough idle.

1. The coil resistance between either pin and the coil spring should be between 5.2K & 5.5K Ω.

2. To verify misfire set the Mico brake and service brake. Place the engine in drive or reverse and rev engine to 2000-3000 rpm. To isolate the misfire remove the coil connectors one at a time. If engine runs the same when the connector is removed continue removing one connector at a time. When you locate the faulty cylinder the engine will run the same. If the engine smooths out when you remove the coil connector check the cylinder opposite that one in the firing order. i.e. – if cylinder four coil connector is removed and the engine smooths out check cylinder number seven for fault.

3. 5.4L firing order: 1-3-7-2-6-5-4-8.

4. NOTE– Check for water or glycol in the plug wells. Service accordingly.


Click the respective links below to view and print a repair work order to service your fleet Ford F350 or E350.

400 Hour Service

2000 Hour Service

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