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FORD: LINCOLN: 2002-2005 Crown Victoria, Mustang, Explorer 2002-2005 Town Car 2003-2005 Expedition 2003-2005 Navigator 2004-2005 F-150 MERCURY: 2002-2005 Grand Marquis, Mountaineer This article supersedes TSB 04-17-5 to update the model year and vehicle line coverage. ISSUE Some 2003-2005 Expedition/Navigator, 2004-2005 F-150 vehicles equipped with a 9.75? or 8.8? limited slip rear axle, and 2002-2005 Explorer 4dr, Mountaineer, Crown Victoria, Grand Marquis, Town Car, and Mustang vehicles equipped with 8.8? limited slip rear axle, may exhibit a chatter, shudder, a binding sensation, or a vibration during low speed turns. On 4×4 vehicles, the sensation may appear to be originating from the front axle or the steering gear. ACTION First verify the condition. On 4×4 trucks ensure that the vehicle is in 2WD, to isolate the rear axle. On all vehicles, turn the wheel fully right (or fully left) and then accelerate the vehicle. If the condition is verified to be in the rear axle, replace the limited slip clutch pack. SERVICE PROCEDURE

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Material 1. 2. 3. 4. With the vehicle in NEUTRAL, position it on a hoist. Remove the fan shroud. Remove the accessory drive belt. Remove the parts in the order indicated in the illustration and table.5. To install. reverse the removal procedure. 6. To install, reverse the removal procedure. Item 1: Crankshaft Pulley Bolt Removal Note 1. Remove the bolts and position the power steering cooler aside. 2. CAUTION: This bolt is torque-to-yield and cannot be reused. Using the special tool to hold the crankshaft pulley. remove and discard the damper bolt. Item 2: Crankshaft Pulley Removal Note 1. Using the special tool and two 8 mm (0.31 inch) x 1.25 x 100 mm bolts, remove the crankshaft pulley. Item 3: Front Crankshaft Seal Removal Note 1. Using the special tool, remove the crankshaft front seal. Item 3: Front Crankshaft Seal Installation Note 1. Using the special tool, install the crankshaft front seal.

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NOTE:Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure. Special Service Tools: Timing Tool, Camshaft Alignment T94P-6256-CH Timing Peg, Crankshaft Position T97P-6000-A Cam Sprocket Holding/Removing Tool T74P-6256-B CAUTION: The maximum amount by which the engine management system will adjust the camshaft timing (VCT control unit) is limited to two degrees. As a result of this an extremely high degree of accuracy is required for any work which affects the valve timing. Note: The locations of engine mountings and engine support insulators are described looking from the transaxle to the engine. Note: Operation steps which only apply to certain model variants and therefore do not apply to all vehicles are clearly marked with the statement (if necessary). Installation

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NOTE:Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure. NOTE: For additional information refer to TSB# 99-25-4 Installation All Vehicles 1. NOTE: Rotate the crankshaft clockwise. Rotate the crankshaft to TDC on cylinder No. 1. 2. NOTE: Cylinders No. 1 and No. 4 are at TDC when the Woodruff key points straight up. Remove the blanking plug, completely screw in the special tool and auto-align the crankshaft to TDC. 3. Position cylinder No. 4 to “valves overlap” and install the special tool. 1. Hold the camshafts by the hexagon using an open-ended wrench and turn them in the direction of engine rotation. 2. Slide the special tool onto the ends of both camshafts. 4. CAUTION: Do not kink the timing belt (do not bend the timing belt less than a diameter of 35 mm). CAUTION: Do not rotate the crankshaft; as necessary check that it is still resting against the timing pin. NOTE: Design with lower idler pulley shown (built up to 06/1999). NOTE: The lug of the belt tensioner should not be hooked in the sheet metal cover during timing belt installation. Position a new timing belt in place. – Starting from the crankshaft timing belt pulley and working counterclockwise, position the timing belt in place while keeping it under tension.

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NOTE:Ford does not provide camshaft gear timing marks, or information to perform timing belt service without the special tools shown in this procedure. REMOVAL 1. Drain the engine cooling system. 2. Remove the intake manifold. 3. Remove the exhaust manifold. 4. Remove the camshafts. 5. Install the center engine front cover. 6. Install the front engine support insulator. 7. Remove the three bar support. 8. Remove the power steering pulley cover. 9. Remove the power steering pump pulley. 10. Remove the bolts and position the power steering pump out of the way. 11. Remove the power steering pump bracket. 12. Remove the generator bracket. 13. Remove the bolts and position the thermostat housing out of the way. 14. Remove the cylinder head. – Remove the bolts in the indicated sequence. – Remove and discard the head gasket. 15. Check the cylinder head for distortion. INSTALLATION