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FORD: 2005-2008 Mustang 2004-2008 F-150 2005 Excursion 2005-2008 Expedition, F-Super Duty 2006-2008 Explorer, F-53 Motorhome Chassis 2007-2008 Explorer Sport Trac This article supersedes TSB 08-1-9 to update Vehicle Applications, Service Procedure and Part List. ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, Navigator and 2005 Excursion, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 F-Stripped Chassis, and 2005 Excursion, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. LINCOLN: 2005-2008 Navigator 2006-2008 Mark LT MERCURY: 2006-2008 Mountaineer

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Some 2004/2005 F-150 vehicles built before 11/29/2004 may exhibit front brake roughness and or shudder while braking. ACTION Service the rack and pinion, rotors, and caliper assemblies as needed, based on vehicle build date and current part levels installed on the vehicle. Refer to the following Service Procedure. SERVICE PROCEDURE 1. Vehicles built prior to 8/20/2003 require the replacement of the rack and pinion assembly if it has not been replaced. Refer to Workshop Manual, Section 206-03 and 211-02. 2. Determine if the vehicle has the old or new level rotors (Figure 1).WHEN REPLACING THE ROTORS ON 4X2 UNITS, A NEW SPINDLE NUT IS REQUIRED. b. If new level (47 fin) rotors are present, perform one (1) of the following: (1) (2) If rotors are within minimum thickness specifications, machine the rotors using the Rotunda on vehicle brake lathe and the Rotunda adapter kit 201-R0093. Refer to the Workshop Manual, Section 206-00 for the correct on-vehicle brake lathe procedure. If rotors are beyond machinable thickness, the front rotors must be replaced. 3. Install new service fix calipers. NOTE REPLACE CALIPERS WITH NEW SERVICE FIX CALIPER ASSEMBLIES BY REMOVING THE CALIPERS AT THE KNUCKLES. THE SERVICE REPLACEMENT CALIPERS WILL BE PRE-ASSEMBLED WITH ANCHOR, SPRINGS, AND PADS. THE CALIPERS SHOULD BE INSTALLED AS A UNIT WITHOUT DISASSEMBLY.

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2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350 Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking and / or knocking noise after reaching normal operating temperature, or a rattle upon starting. The noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a normal characteristic of these engines. In other cases the noise may require further investigation. Sorting out and defining the noise as reported by the customer is important to successfully diagnose and / or repair the condition. ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer is concerned with. The customer should be interviewed to get their detailed perception and description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the symptom. Refer to the following Service Procedure to help determine the source of the noise and if a repair is needed. SERVICE PROCEDURE

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FORD: Crown Victoria, Taurus Ford GT Mustang Ranger Expedition Explorer This article supersedes TSB 04-25-1 to update the vehicle model years. ISSUE Some vehicles may exhibit a bubbling or blistering under the paint on aluminum body parts. This is due to iron contamination of the aluminum panel. 1. Corrosion should be removed by blasting. Use an aggressive blasting material, such as acrylic (salt grain size). 2. Use a DA sander with 180 grit paper backed abrasive. Only sand and featheredge the damaged area. 3. Mix and apply Ford approved epoxy primer, per the manufacturer’s label instructions. Bake at 140° F (60° C), or use an infra-red lamp for curing. 4. If necessary, mix and apply two-part polyester filler to a slight over crown. Allow polyester filler to cure 20-30 minutes, or mix and apply spray polyester filler two-three (2-3) coats as necessary. Allow to cure per manufacturer’s label instructions. 5. Hand-sand the repair area with 80 grit sand paper to remove excess filler. 6. Finish-sand the repair area with 400 grit sand paper. 7. Mix and apply Ford approved primer/surfacer per manufacturer’s label instructions. Bake at 140° F (60° C) or use infra-red lamp for curing.

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The Crankshaft Position (CKP) sensor is a magnetic generator type sensor. The sensor produces an alternating current signal. The CKP sensor sends the A/C signal to the Powertrain Control Module (PCM) in order to indicate the crankshaft RPM and the position. The PCM uses the CKP sensor signal in order to calculate the following: ^ The ignition sequence ^ The fuel injector sequence ^ Fuel injectors pulse width If the PCM does not receive a CKP sensor signal, the engine will not start. CONDITIONS FOR SETTING THE DTC ^ The engine is cranking. ^ The signal from the CKP sensor is missing for 2 seconds. ACTION TAKEN WHEN THE DTC SETS ^ The PCM illuminates the malfunction indicator lamp (MIL). ^ The PCM records the operating conditions at the time of the diagnostic failure. This information is in the Freeze Frame buffer. CONDITIONS FOR CLEARING THE MIL/DTC The MIL turns OFF after three consecutive trips during which the diagnostic runs, and the fault is not present. A History DTC clears after 40 consecutive warm-up cycles without a fault. Use a scan tool clear the DTC. Disconnect the PCM battery feed in order to clear the DTC