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ISSUE Some 2003-2005 Lincoln LS and Thunderbird vehicles, equipped with a bolt-on wheel speed sensor, may exhibit the ABS and traction control or advance trac warning lamp illuminated, with DTC C1145 and/or C1155 stored in the ABS module. ACTION Refer to the following Service Procedure. SERVICE PROCEDURE 1. Per the DTC, replace the appropriate front wheel speed sensor. Refer to Workshop Manual Section 206-09. Apply a thin film of XG-3-A (Motorcraft Silicone Brake Caliper Grease and Dielectric Compound) to the O-ring, and the portion of the sensor which is located in the bearing cap. This includes coating the sides and the end of the sensor cylinder (Figure 1). 2. Vent the front bearing cap by drilling two (2) 1/16? diameter holes along outside edge of the cap, in locations shown on Figure 2 (illustrates driver’s side bearing cap). Drill in approximately the 4 and 5 o’clock positions on the driver’s side of vehicle, and the 7 and 8 o’clock positions on the passenger side of vehicle. CAUTION THE BEARING CAP IS ONLY 1/8? THICK, STOP DRILLING IMMEDIATELY WHEN THE DRILL BIT BREAKS THROUGH THE CAP. CAUTION THE DRILL SHOULD BE HELD PERPENDICULAR TO THE SURFACE NOT AT AN ANGLE, TO AVOID POTENTIAL DAMAGE TO ABS INDICATOR RING. 3. Inspect the opposite side wheel speed sensor, verify that a new sensor is installed, and the vent holes are drilled. The new sensor can be identified by “blue tape” added to the sensor cable between the third and fourth barrel grommets (counting from the bearing toward the connector). Replace the sensor if it is NOT current, and drill vent holes in the bearing cap if it is NOT already vented.

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WARNING: Do not use any fluid other than clean brake fluid meeting manufacturer’s specification. Additionally, do not use brake fluid that has been previously drained. Following these instructions will help prevent system contamination, brake component damage and the risk of serious personal injury. WARNING: Carefully read cautionary information on product label. For EMERGENCY MEDICAL INFORMATION seek medical advice. In the USA or Canada on Ford/Motorcraft products call: 1-800-959-3673. For additional information, consult the product Material Safety Data Sheet (MSDS) if available. Failure to follow these instructions may result in serious personal injury. WARNING: Always install new brake shoes or pads at both ends of an axle to reduce the possibility of brakes pulling vehicle to one side. Failure to follow this instruction may result in uneven braking and serious personal injury. NOTICE: Do not spill brake fluid onto painted or plastic surfaces or damage to surface may occur. If brake fluid is spilled onto a painted or plastic surface, immediately wash the surface with water. 1. Check the brake fluid level in the brake master cylinder reservoir. If required, remove the fluid until the brake master cylinder reservoir is half full. 2. Remove the wheel and tire. For additional information, refer to Section 204-04. 3. NOTICE: Do not allow the brake caliper to hang by the flexible brake hose or damage to the hose may occur. Remove the 2 brake caliper guide pin caps and bolts and position the caliper and brake pad assembly aside. Support the caliper using mechanic’s wire. Remove and discard the guide pin bushings. Inspect the guide pin threads for damage, install new guide pin(s) as necessary. 4. Remove the brake pads from the caliper. 5. Inspect the brake pads for wear or contamination and install new pads as necessary. For additional information, refer to General Procedures in Section 206-00. 6. Using a C-clamp and a worn brake pad, press the piston into the caliper. 7. Inspect the brake disc and resurface or install a new brake disc as necessary. For additional information, refer to General Procedures in Section 206-00. Installation 1. Clean, dry and inspect the brake caliper anchor plate. Apply equal amounts of the supplied yellow lubricant to the 4 brake pad contact points on the anchor plate as shown. 2. NOTICE: Do not apply lubricant to guide pin threads or incorrect tightening of the guide pins may result. Install new brake hardware as follows: Apply equal amounts of the supplied white lubricant to the inside of the guide pin bushings. Install the guide pin bushings into the caliper bores. Install the guide pins into the bushings. 3. Install the brake pads to the caliper. 4. Position the caliper onto the anchor plate and install the 2 brake caliper guide pin bolts. To install, tighten to 38 Nm (28 lb-ft). Clean and dry guide pin threads as necessary. 5. Fill the master cylinder with clean, specified brake fluid. 6. Install the wheel and tire. For additional information, refer to Section 204-04. 7. Apply the brake several times to verify correct brake operation.

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ISSUE Some 2003-2006 Expedition and Navigator vehicles equipped with an air suspension may exhibit an air suspension height sensor linkage arm disengaging from the suspension ball stud or height sensor rotating arm. This concern typically occurs with the rear sensor (Figure 1) but may occur with the front sensors as well. If this occurs, the symptom will typically be the vehicle leaning to one side, the vehicle sitting too low/high, a harsh ride, and/or an inoperative air suspension. In addition, this concern may result in diagnostic trouble code (DTC) C1725 (air suspension front pneumatic failure) or C1726 (air suspension rear pneumatic failure). ACTION When a linkage arm becomes disengaged, do not re-attach the arm and do not replace the sensor unless broken. Instead, install a revised linkage arm on all three (3) sensor assemblies, even if they have not detached from the ball stud.Refer to the following Service Procedure. SERVICE PROCEDURE NOTE IF THE SENSOR ASSEMBLY NEEDS TO BE REPLACED FOR ANY DAMAGE/FAILURE OTHER THAN THE ONE DESCRIBED IN THIS TSB, THE REPLACEMENT ASSEMBLY IS SUPPLIED WITH A NEW STYLE LINKAGE ARM, SO THERE IS NO NEED TO ORDER ADDITIONAL LINKAGES FOR THE SERVICE REPAIR. 1. Replace linkage arms on all three (3) sensor assemblies following Workshop Manual (WSM), Section 204-05. 2. Discard the old linkage arms.

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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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LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS FORD: 2002-2004 Mustang, 2003-2004 Expedition 2004 F-150 LINCOLN: 2003 Navigator MERCURY: 2002-2004 Motmtaineer This article supersedes TSB 06-02-16 to update the Service Procedure. ISSUE Some 2003-2004 Expedition, 2003 Navigator, 2004 F-150 vehicles equipped with a 9.75″ or 8.8″ limited slip rear axle, and 2002-2004 Explorer 4dr, Mountaineer, 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 4X4 vehicles, the sensation may appear to be originating from the iront axle or the steering gear. ACTION First verify the condition. On 4X4 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 veriñed to be in the rear axle, replace the limited slip clutch pack. SERVICE PROCEDURE