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Some 2006-2007 Freestar and Monterey vehicles may experience a melted or damaged spark plug electrode, malfunction indicator lamp (MIL) with diagnostic trouble codes (DTC’s) P030X, rough idle, engine knock/ping on acceleration. Pre-ignition (which yields these symptoms) may be caused by water entering the powertrain control module (PCM). ACTION: Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE 1. Remove PCM from vehicle. Refer to Workshop Manual (WSM), Section 303-14. 2. Remove the PCM cover by carefully bending back the four (4) retaining clips holding the galvanized metal cover to the top plate. (Figure 1) Figure 1 – Article 07-14-1 3. Look for evidence of water within the PCM (liquid water, rust, water stains or deposits). (Figure 2) If found – obtain a replacement PCM before continuing on to Step 4. If no water is found, continue on to step 4 with the vehicle’s original PCM. Figure 2 – Article 07-14-1 4. Set the PCM top plate in a clean, dry location where the circuitry will be protected from damage. 5. With the PCM cover removed, drill a 1/4″ hole on each of the four (4) corners of the PCM cover. Get as close to the corner as possible. (Figure 3) Figure 3 – Article 07-14-1 6. De-burr the edges on both inside and outside surfaces. (Figure 3) Be sure to vacuum off all chips and wipe off all metal dust and any machining oil. 7. Clean the surfaces of the PCM cover with Motorcraft ZC-21 (Metal Surface Cleaner) or equivalent. Also clean the edges of the PCM top plate. The metal surfaces must be completely clean before proceeding to Step 8. 8. Apply Motorcraft TA-29 Ultra Silicone Sealant to all edges depicted. (Figure 4, 5, 6, 7) Proceed directly to Step 9 – do not let the sealant skin over. NOTE: Motorcraft TA-32 can NOT be used since its constituents may damage the PCM circuitry.

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Getting started 1. Apply the handbrake. 2. Place chocks under the front wheels and engage 1st gear. Remove the Brake Caliper 6. The brake caliper needs to be removed to allow the brake disc to be removed. Working under the car remove the clip securing the brake hose in place. 3. Loosen the rear wheel nuts using a 19mm wheel wrench with the car on the ground. 4. Jack up the car and support safely using axle stands or ramps. Preferably jack up both sides at the same time, as it makes it easier to balance the handbrake action at the end. This will free the hose and pipe. Carefully slip the pipe fitting out of the bracket. 7. Remove the caliper lower fixing bolt (16mm socket). 5. Remove the road wheel. 8. Remove the plastic cap over the upper fixing bolt. Remove the Brake Disc 11. Loosen the brake disc holding screw using a T-30 Torx bit. 9. Use a 6mm allan key to remove the upper fixing bolt. 12. Release the hand brake and remove the brake disc. If this proves difficult, it may be necessary loosen the brake adjuster. To do this, remove the rubber plug…. 10. The caliper will now be loose and can be carefully lifted away from the disc, taking care to route the brake pipe gently to avoid strain. Support the caliper from the suspension spring using string or ties. …and turn the adjuster with a screwdriver inserted through the hole. The disc has been removed here to show the teeth on the adjuster.

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To prevent damage, ensure steering wfieel and spiral cable DO NOT rotate before or during reassembly. SRS warning lamp Airbag Operation • Switch ignition ON. a SRS warning lamp illuminates. D Lamp extinguishes after approximately 6 seconds. • If not: Refer to Self-diagnosis section. D SRS control module fault memory can only be checked using diagnostic equipment connected to the data link connector (DLC). Disarm the system /0\ ^ ^ ^ J ^ ^ ^ / When Fascia/instrument panel removal or replacement. Front seat belt removal or replacement. Front seat repair or replacement. Repair wor1< around SRS components, especially airbag and pretensioners. • SRS component removal or replacement. D Steering wheel/column repair or replacement. • Welding operations. • • • o How n Ensure ignition switched OFF. o Remove ignition key. • Disconnect battery earth lead. Make sure accidental reconnection is not possible. • Wait 10 minutes tiefore commencing work. Arm the system : ^ How n Ensure ignition switched OFF. D Reconnect battery earth lead. D Keep clear of deployment area. D Switcti ignition ON. • Check SRS warning lamp operation.

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Relay location on the thirteen position auxiliary relay panel, above relay panel: 1 – Auxiliary Emergency Flasher Relay (404) 2 – Relay for Motor Remote Unlock Rear Lid (79) 3 – Starting Interlock Relay (53) (185) (465) 4 – Fog Light Relay (53) 5 – Control Module for Multi-function Steering Wheel (450) 6 – Control Module for Multi-function Steering Wheel (450) 7 – Daytime Running Lights Change-over Relay (173), from April 1999 8 – Daytime Running Lights Change-over Relay (173), through March 1999 9 – Dual Horn Auxiliary Relay (53) 10 – Glow Plug Relay (180) 10 – Warning Lamp Auxiliary Relay (200) 11 – Park/Neutral Position (PNP) Relay (175) 12 – Power Supply (Terminal 30, B+) Relay (109) Relay Panel: 1 – Dual Horn Relay (53) 2 – Load Reduction Relay (18) (100) 4 – Fuel Pump (FP) Relay (409) V – Wiper/Washer Intermittent Relay (192) (377) (389) VI – Wiper/Washer Intermittent Relay (192) (377) (389) NOTE Number in parentheses ( ) indicates production control number stamped on relay housing.

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FORD: 1980-86 LTD 1980-92 CROWN VICTORIA 1980-93 MUSTANG, THUNDERBIRD LINCOLN-MERCURY: 1980-86 MARQUIS 1980-87 CONTINENTAL 1980-92 GRAND MARQUIS, TOWN CAR 1980-93 COUGAR 1984-92 MARK VII LIGHT TRUCK: 1980-93 BRONCO, ECONOLINE, F-150 This TSB article is being republished because of the occasional need for the information it contains. Originally published as TSB 83-13-10 in June of 1983, this article is not easily locatable in many dealerships today; the model application has been updated. Also, The Service Manual contains this information. ISSUE: A no 3-4 upshift condition or a slipping 4th gear may result from ^ Direct clutch checkball leaking ^ Missing plug in end of output shaft ^ Case bore wear ^ Leakage at O/D band servo piston and/or case bore ^ Seal leakage at 3-4 accumulator piston ^ Blocked hydraulic circuit condition ^ Improper valve body attaching bolt torque ^ Leaking governor circuit ^ Torque converter damper/hub malfunction ACTION: Road test, diagnose and repair the transmission as required. Refer to the following diagnostic and repair procedure for service details.