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ISSUE Some 2003 F250-550 Super Duty and Excursion vehicles equipped with a 6.0L Powerstroke engine, may exhibit a difficult to remove or replace air filter assembly during service. ACTION The following procedure has been provided to assist with air filter removal or installation during service. SERVICE PROCEDURE Filter Removal 1. Release 4 toggle clamps located on top of assembly (Figure 1). 2. Lift inlet slightly, enough to disengage the 2 tabs on the bottom of the inlet cover from the 2 windows on bottom of the filter inlet, and push it forward toward front of vehicle as shown in Figures 2 and 3. 4. Pull outlet cover up enough to disengage the 2 tabs on the outlet cover and the filters 2 windows located at the bottom of the clean side. At this step, the MAFS may contact the degas bottle while pulling the cover up but this should not create a problem. Push cover slightly away from filter and down as in Figure 5. 5. Pull filter upward to disengage its 2 legs from grommets (Figure 6). It is easiest to rock the filter forward/aft while pulling it up. Filter Installation 1. Use the guide on the filter to align its legs to the grommet during its installation as shown in Figure 7, making sure filter is fully seated on the cradle. 2. Attach inlet cover to filter using the 2 clamps on inlet side, making sure that tabs are seated inside the windows (Figure 8).

repair manual covers Ford Super Duty F-250 and Super Duty F-350 pickup trucks 1999-2006, and Ford Excursion SUVs 2000-2005. Covers 2WD and 4WD with gasoline and diesel engines.
What’s Inside?
Introduction: About this manual | Introduction | Vehicle identification numbers | Maintenance techniques, tools and working facilities | Buying parts | Jacking and towing | Anti-theft audio system | Booster battery (jump) starting | Conversion factors | Automotive chemicals and lubricants | Safety first! | Troubleshooting

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Some 2008-2009 F-Super Duty vehicles with a build date before 11/06/08, and equipped with DATC (Dual Automatic Temperature Control) may exhibit a side-to-side temperature difference greater than 15 degrees Fahrenheit (8.3 degrees Celsius). A temperature difference of less than 15 degrees Fahrenheit (8.3 degrees Celsius) would be considered normal and no repair attempt should be made. Also, it is not necessary to replace the EATC control head or the HVAC. If equipped with manual climate control, vehicles may exhibit periods where the cabin temperature cannot be maintained with the control knob. Some customers may also complain the heat cannot be reduced without rotating the control knob well into the Cool/Blue range. ACTION Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE Check Actuator Activity: DATC systems may be monitored with the IDS PID ($9910 and $9911 ). Manual A/C systems may be observed through the right side of the instrument panel with the glove compartment door positioned downward. Erratic PID activity or an actuator that appears to be erratically hunting for correct position during the condition should be replaced. Refer to Workshop Manual, Section 412-01, for removal and installation details. The ignition key must be off when replacing the actuator, energizing the actuator before installation on the HVAC case will cause the part to become mis-positioned and correct orientation will be lost. Incorrect actuator operation may result.

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Some 2005-2007 F-Super Duty vehicles may exhibit a speedometer and/or tachometer indicator issue. Symptoms may include intermittent, large inaccuracies, or jumping/bouncing/erratic pointers. ACTION Refer to the Service Procedure. SERVICE PROCEDURE 1. Verify there are no diagnostic trouble codes (DTCs). If there are DTCs present, follow the appropriate procedure in the Workshop Manual to clear the DTC and resolve the concern. 2. Confirm that the axle ratio and tire size are properly configured in the ABS module. 3. For a speedometer related concern, If no DTCs are present, the issue may be with any of the following components: • Cluster • ABS Module • ABS Speed Sensor • Vehicle Wiring • If the symptom is a continuous (non-intermittent) large inaccuracy, ensure that the axle ratio and tire size are properly configured in the ABS module. To identify the cluster as the root cause: 1. Monitor the vehicle speed sensor (VSS) PID in the powertrain control module (PCM), and the speedometer needle position while stopped. 2. If the speedometer displays 5 MPH (8 Km/h) or more, and the VSS PID indicates zero, replace the instrument cluster. 3. With an assistant observing the diagnostic tool, drive the vehicle at 20, 40, and 60 MPH (32, 64, and 97 Km/h) as indicated on the diagnostic tool, and record the value indicated by the speedometer. 4. If the speed indicated on the diagnostic tool versus speedometer readings vary by more than ± 5 MPH, (8 Km/h) replace the instrument cluster. ABS Module Concern To identify if the ABS Module is the root cause, refer to diagnostic procedures in the Workshop Manual. For any customer complaints of jumping/bouncing/erratic speedometers, a wiring concern may exist which is severe enough to interrupt the signal, but not severe enough to totally open/short the circuit.

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Some 2003-2005 Excursion, 2003-2007 F-Super Duty and 2004-2008 E-Series vehicles equipped with a 6.0L engine may exhibit a misfire, lack of power, buck / jerk, excessive smoke or crank / no start. There are several potential causes for these symptoms. ACTION Follow the Service Procedure steps to correct the condition. LOW OR NEGATIVE FUEL PRESSURE If normal diagnostics lead to an injector concern, use the following diagnostics to confirm the cause of injector failure and / or to rule out other conditions which may cause the same symptoms as a failed injector. Low Or Negative Fuel Pressure Internal injector damage can be caused by lack of fuel system supply pressure. Restricted fuel filters and / or fuel line(s), or an inoperative fuel pump can create a low or negative fuel supply pressure. Low or negative pressures may hinder the return stroke of the injector intensifier plunger to its rest position, leading to internal injector damage. To diagnose for low or negative fuel pressure and to confirm if any injectors have been damaged: 1. Perform standard diagnostic procedures including verification of supply fuel pressure using the Powertrain Controls / Emissions Diagnosis (PC/ED) Performance Diagnostic Procedure – Fuel System Delivery Test 10a. This test uses Diesel Fuel Flow Tester 310-193 to verify proper fuel pressure while simulating wide open throttle (WOT) (full load) fuel flow. 2. Repair causes for low pressure on the supply side of the fuel system. 3. Diagnose for failed injector(s) only after rectifying fuel supply pressure. 4. Recheck the fuel pressure after repairs by repeating the Fuel System Delivery Test 10a.