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NOTE: Hydraulic valve lifters are used; no valve adjustment is required. When valve and/or valve seat is machined, valve clearance is reduced and may cause improper valve operation. Different length push rods are available for correcting clearance. Valve lifter must be collapsed to check valve clearance. 1. With valve cover removed, position piston No. 1 at TDC of compression stroke. Completely collapse cylinder No. 1 intake valve lifter and hold valve lifter collapsed. Using feeler gauge, measure clearance between rocker arm and valve stem. 2. Clearance should be within specification. Refer to COLLAPSED VALVE LIFTER CLEARANCE table. Replace push rod, if necessary, to obtain correct clearance. 3. Position crankshaft as specified. See, in this article, VALVE CLEARANCE CHECKING SEQUENCE table, and check appropriate valves. Replace push rods if clearance is not within specification. 4. If push rod(s) is replaced, ensure corresponding cylinder piston is below TDC. It will be necessary to loosen or remove rocker arm to replace push rod. CAUTION: DO NOT operate or crank engine after installing push rod until valve lifter has leaked down to normal operating position. COLLAPSED VALVE LIFTER CLEARANCE

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1. Remove the bolt and the camshaft position (CMP) sensor. 2. Remove the bolts, the rocker arm seats, and the rocker arms. 2. Remove the bolts, the rocker arm seats, and the rocker arms. 3. NOTE: Always return the valve tappets to their original tappet bores unless they are being replaced. Remove the valve tappet(s). 1. Remove the valve tappet guide plate retainers. 2. Remove the valve tappet guide plates. 3. Remove the valve tappets. Remove the bolts and the engine lifting eye. 5. Remove the (A) bolts and the (B) camshaft thrust plate. 6. Use Oil Seal Remover to remove the camshaft front seal. 7. NOTE: The camshaft can be removed in either direction. Remove the camshaft. 8. NOTE: Identify all parts with respect to the cylinder from which they were removed and whether the valve is an intake valve or an exhaust valve. Use (A) Valve Spring Compressor to compress the valve springs. While the valve spring is compressed, remove the (B) valve span” retainer key. 9. Slowly remove the valve spring compressor tool. 10. Remove the valves valve spring retainer and the valve spring. 11. Remove the valves. 12. Remove and discard the valve stem seals. Assembly

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1. If equipped, turn the air suspension switch OFF. 2. Disconnect battery ground cable. 3. Raise and support the vehicle; refer to Section 100-02. 4. Drain transmission fluid and remove the transmission fluid pan and filter; refer to Transmission Fluid Drain and Refill in this section. 5. CAUTION: Do not pull on the plastic lead frame. This may cause damage to the connector ends. Carefully pry up on the locking tabs to disconnect the sensors. Disconnect the molded lead frame from the sensors. Disconnect the molded lead frame from the sensors. 1. Disconnect the shift solenoid SSA/SS1 and SSB/SS2. 2. Disconnect the torque converter clutch (TCC). 3. Disconnect the electronic pressure control (EPC) solenoid. 4. Disconnect the bulkhead inter connector. 6. Remove the shift solenoid and the torque converter clutch (TCC) solenoid. 1. Remove the bolts. 2. Remove the shift solenoid and the torque converter clutch (TCC) solenoid. 7. Remove the manual control valve detent lever spring (7A261) 1. Remove the bolt. 2. Remove the manual control valve detent lever spring 8. Remove the 23 valve body to case bolts. 9. Remove the main control valve body (7A100) Installation 1. NOTE: Make sure that the drive pin of the manual valve detent lever assembly engages the manual valve in the proper location prior to installing the bolts. Position the main control valve body gasket and main control valve body using the two alignment bolts as a guide. 2. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 3. NOTE: The main control valve body bolts will be tightened in later steps. Loosely install the bolts. 4. Install the manual control valve detent lever spring. 1. Position the manual control valve detent lever spring. 2. Install the bolt.

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1. Remove the torque converter clutch (TCC) solenoid and the shift solenoid. 1. Remove the retaining bolt. 2. Remove the shift solenoid. 3. Remove the TCC solenoid. 2. Remove the 2 reinforcement plates. 1. Remove the bolts. 2. Remove the plates. 3. Remove the separator plate and discard the gaskets. 4. NOTE: Note the location of the eight coasting booster valve shuttle balls for assembly. Remove the 8 coasting booster valve shuttle balls. 5. Remove the converter drain back valve and solenoid pressure supply screen. 6. Remove the main control valve body cover plate. 1. Remove the 13 main control valve body cover plate bolts. 2. Remove the main control valve body cover plate. Assembly NOTE: Inspect the shift solenoid O-rings and TCC solenoid O-rings for damage. 1. Install the valve body cover plate. 1. Position the valve body cover plate gasket and cover plate. 2. Loosely install the 2 guide pin bolts. 3. Loosely install the remaining bolts. 2. Tighten all the bolts in the sequence shown. 3. Install the 8 coasting booster valve shuttle balls.

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ENGINE – 4.0L OHV – CARBON KNOCK ON ACCELERATION NOISE – CARBON KNOCK ON ACCELERATION – VEHICLES EQUIPPED WITH 4.0L OHV ENGINE ONLY FORD: 1990-1997 AEROSTAR 1990-2000 EXPLORER, RANGER ISSUE Some vehicles equipped with the 4.0L OHV engine may exhibit an engine noise which may be perceived by the customer as a piston/connecting rod bearing knock. This carbon knock is heard only under load during the drive cycle. Carbon knock is a customer drive duty-cycle phenomenon that cannot be repaired with an engine exchange. This may be caused by carbon build-up within the combustion chamber. ACTION Verify condition. If normal diagnostics fail to correct the condition, de-carbon the combustion chamber to help quiet the carbon knock noise. Refer to the following Service Procedure for details. SERVICE PROCEDURE Use Motorcraft Carburetor Tune-up Cleaner PM-3. Carbon removal: a. Disconnect canister purge line from throttle body. b. Attach a vacuum line to the canister purge port. c. At hot engine idle, allow the engine to ingest 1/2 to 2/3 of a can of Motorcraft Carburetor Tune-up Cleaner. Use caution not to ingest too quickly due to potential hydro-lock issues. d Shut engine off and allow it to soak for one hour. e. Start engine, allow engine to ingest the remainder of the Motorcraft Carburetor Tune-up Gleaner. f. Remove vacuum line and re-install canister purge line. g. Road test vehicle at 3500 RPM for 2-3 miles. h. Repeat above procedure two times for a total of three times. i. Change oil and filter.