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Draining 1. Bring the engine to normal operating temperature and turn the engine off. With the cooling system under pressure, inspect cooling system hoses and clamped hose connections for leaks, excessive deterioration or contact wear. Inspect radiator installation retention. Note any discrepancies and proceed. 2. WARNING: Never remove the pressure relief cap while the engine is operating or when the cooling system is hot. Failure to follow these instructions can result in damage to the cooling system or engine or personal injury. To avoid having scalding hot coolant or steam blow out of the degas bottle when removing the pressure relief cap, wait until the engine has cooled, then wrap a thick cloth around the pressure relief cap and turn it slowly. Step back while the pressure is released from the cooling system. When you are sure all the pressure has been released, (still with a cloth) turn and remove the pressure relief cap. CAUTION: The coolant must be recovered in a suitable, clean container for reuse. If the coolant is contaminated, it must be recycled or disposed of correctly and replaced. CAUTION: Some vehicle cooling systems are filled with Motorcraft Premium Engine Coolant VC-4-A (in Oregon VC-5, in Canada CXC-10) or equivalent meeting Ford specification ESE-M97B44-A (green color). Others are filled with Motorcraft Premium Gold Engine Coolant VC-7-A meeting Ford specification WSS-M97B51-A1 (yellow color). Always fill the cooling system with the same coolant that is present in the system. Do not mix coolant types. NOTE: Less than 80 percent of coolant capacity can be removed from the engine. Dirty, rusty or contaminated coolant requires replacement. Drain engine coolant as follows: Open radiator draincock to drain the coolant system. Disconnect radiator overflow hose from radiator filler neck connection. Remove radiator coolant recovery reservoir and empty the fluid. Flush radiator coolant recovery reservoir with clean water. Drain and reinstall radiator coolant recovery reservoir and radiator overflow hose and clamp to radiator filler neck. Correct, repair or install new components found to be inoperative in Step 1. Filling and Bleeding with RADKITPLUS 1. Using the special tool, install the RADKITPLUS and follow the RADKITPLUS manufacturer’s instructions to fill and bleed the cooling system. Filling and Bleeding without RADKITPLUS CAUTION: Engine coolant provides freeze protection, boil protection, cooling efficiency and corrosion protection to the engine and cooling components. In order to obtain these protections, the engine coolant must be maintained at the correct concentration and fluid level in the degas bottle. When adding engine coolant, use a 50/50 mixture of engine coolant and clean, drinkable water. To maintain the integrity of the coolant and the cooling system:

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Customer Concern: Tests/Procedures: Potential Causes: Tech Tips: Loss of engine coolant, and smokes out the tailpipe. No external coolant leaks. 1. If the engine does not appear to be burning the coolant, suspect a leaking Exhaust Gas Recirculation (EGR) cooler. 2. Remove the EGR valve from the intake. Pressurize the cooling system and lift the rear end of the vehicle. Look for any coolant to puddle in the intake where the EGR mounts. If any coolant is seen, replace the EGR cooler. 3. If no leaks are seen with the EGR removed, drain the coolant level down and pressurize the cooling system. Then with a stethoscope and long hose, listen for air in the exhaust or in the intake where the EGR mounts. If present, again replace the EGR cooler. Exhaust Gas Recirculation (EGR) Cooler NOTE: refer to Ford Technical Service Bulletin (TSB) 09-8-3 for tips on addressing cooling system problems. It is generally recommended to also replace the oil cooler heat exchanger if an EGR cooler failure has occurred.

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Some 2003-2007 F-Super Duty, 2003-2005 Excursion and 2004-2008 E-Series vehicles, all equipped with a 6.0L engine, may exhibit: • Coolant venting from the degas bottle cap • No-crank/no-start • Coolant leak • White smoke from tail pipe • Low coolant • Lacks power overheat • No cabin heat The conditions typically occur when operating the vehicle under a load such as trailer towing, uphill driving, or both.SERVICE PROCEDURE Prior to making any repairs, verify the coolant level is not overfull. The new coolant fill level is at the “MIN” line of the degas bottle cold. Overfilled coolant levels will cause coolant to vent from the degas bottle cap. NOTE A FLOW CHART OF THIS PROCEDURE CAN BE FOUND AT THE END OF THE TSB. (FIGURES 9-11) Complete All Steps In Order As Outlined 1. Testing the degas bottle and pressure cap for proper operation of the pressure cap and its seal to the degas bottle: a. Do not remove the pressure cap. b. Install a pressure tester in-line with the degas bottle hose using Rotunda 014-R1068 adapter. (Figure 1)

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Removal (Bronco & F150) 1. Using Torx Bit (T-25), remove 5 bolts from cap assembly. Remove cap assembly. See Fig. 5 . DO NOT drop spring, ball bearing, bearing race or spring retainer. 2. Remove rubber sealing ring and seal bridge retainer. Remove retainer ring by closing ends with needle nose pliers while pulling hub lock from wheel hub. 3. If wheel hub and spindle are to be removed, remove “C” washer from stub shaft groove. Remove splined spacer from axle shaft. Remove wheel bearing lock nuts and lock washer. Exploded View Of Automatic Locking Hub (Bronco & F150) Exploded View Of Automatic Locking Hub (Explorer & Ranger) Removing Manual Locking Hub (Bronco & F150) Exploded View Of Manual Locking Hub (Explorer & Ranger)

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Subject: Models: Low Engine Coolant Level Indicator Always On (Diagnose Low Coolant Level System Operation/Check Sensor for Oil Contamination) 2000-2002 Buick Century, Regal 2000-2001 Chevrolet Lumina 2000-2002 Chevrolet Impala, Monte Carlo 2000-2002 Pontiac Grand Prix 2000-2002 Oldsmobile Intrigue Condition Some customers may comment that the low engine coolant level indicator is always illuminated. Cause The cause of this condition may be due to engine oil contaminating the coolant. Possible sources of oil contamination are internal engine leaks, improper service procedures, or the addition of some types of anti-leak additives to the cooling system. Once in the coolant, the oil leaves deposits on the level sensor creating an insulating film. This film results in a false activation of the coolant level indicator. Correction Diagnose low coolant level system operation and check the sensor for oil contamination using the procedure listed below. Important: No coolant supplements should be used in GM cooling systems, other than what is approved and recommended by GM. The use of “aftermarket” over-the-counter sealing and cooling supplements may affect the operation of the low coolant level sensor. Discoloration of the coolant recovery bottle is normal and does not necessarily indicate that coolant contamination is present. Flush cooling system only when instructed by this bulletin. 1. Verify that the coolant is at proper level in the radiator and the coolant recovery bottle. If the coolant is low, add proper amount of 50/50 water and DEX-COOL® mixture. If the low coolant light operates properly, diagnose the cooling system for loss of coolant as outlined in SI. DO NOT proceed further with this bulletin. 2. Remove the low coolant level sensor. Refer to Coolant Level Module Replacement in the Engine Cooling sub-section. 3. With the key on, the engine off and the coolant level sensor disconnected from the vehicle wiring harness, observe the low coolant light: • Light is on — Chassis wiring or instrument cluster concern. Follow the appropriate diagnostic information in SI. • Light is out — Proceed to Step 4.