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2004-2005 F-150, 2005 Excursion, and 2005-2008 F-Super Duty vehicles may exhibit rust stains on the edges of the front bumper center vent and fog lamp openings. PROCEDURE NOTE USE PROTECTIVE GLOVES FOR APPLYING BOTH THE MOTORCRAFT® CUSTOM BRIGHT METAL CLEANER AND THE ANTI-CORROSION COATING. Hoist vehicle until bumper is at working level. Follow all safety precautions as outlined in the Workshop Manual (WSM), Section 501-19. Remove two (2) push pins on license plate bracket and remove bracket. Disconnect fog lamp wiring at fog lamps (if equipped). Remove fog lamp wiring retaining clips off fog lamp brackets one (1) per side. Disconnect engine block heater retaining clip from bumper if vehicle is equipped. Remove air deflector flap attachment pins from lower shelf of bumper if equipped. Remove the front bumper corner bracket bolts as shown in WSM, Section 501-19. NOTE THE AID OF AN ASSISTANT IS REQUIRED TO REMOVE THE FRONT BUMPER. Remove the four (4) front bumper retaining bolts as shown in WSM, Section 501-19: Bumpers. Remove the front bumper from the vehicle. Remove fog lamp/bracket (if equipped). 10. Clean excessive dirt from an area of 2? (50 mm) around all 3 cutouts on the inside of the bumper. 11. Clean the red rust stains from the inside edges of the center vent and fog lamp openings with Motorcraft® Custom Bright Metal Cleaner. 12. Install masking tape to all three (3) openings. (Figure 1)

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FORD: 2004-2005 F-150 This article supersedes TSB 06-15-11 to update the vehicle model years. ISSUE Some 2004-2005 F-150, 2005 Excursion, and 2005-2008 F-Super Duty vehicles may exhibit rust stains on the edges of the front bumper center vent and fog lamp openings. ACTION Follow the Service Procedure steps to correct the condition. 2005 Excursion 2005-2008 F-Super Duty 2. Remove two (2) push pins on license plate bracket and remove bracket. 3. Disconnect fog lamp wiring at fog lamps (if equipped). 4. Remove fog lamp wiring retaining clips off fog lamp brackets one (1) per side. 5. Disconnect engine block heater retaining clip from bumper if vehicle is equipped. 6. Remove air deflector flap attachment pins from lower shelf of bumper if equipped. 7. Remove the front bumper corner bracket bolts as shown in WSM, Section 501-19. NOTE THE AID OF AN ASSISTANT IS REQUIRED TO REMOVE THE FRONT BUMPER. 8. Remove the four (4) front bumper retaining bolts as shown in WSM, Section 501-19: Bumpers. Remove the front bumper from the vehicle. 9. Remove fog lamp/bracket (if equipped). 10. Clean excessive dirt from an area of 2? (50 mm) around all 3 cutouts on the inside of the bumper. 11. Clean the red rust stains from the inside edges of the center vent and fog lamp openings with Motorcraft® Custom Bright Metal Cleaner. 12. Install masking tape to all three (3) openings. (Figure 1)

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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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2005 Mustang 2004-2005 F-150 2005 Expedition, F-250, F-350 Some vehicles equipped with a 4.6L 3-valve or 5.4L 3-valve engine may exhibit a ticking and / or knocking noise after reaching normal operating temperature, or a rattle upon starting. The noise may be described as ticks, taps, knocks, or thumps. In some cases the noise may be a normal characteristic of these engines. In other cases the noise may require further investigation. Sorting out and defining the noise as reported by the customer is important to successfully diagnose and / or repair the condition. ACTION Before starting diagnosis, it is critical to determine the specific engine noise the customer is concerned with. The customer should be interviewed to get their detailed perception and description of the noise, and to determine if the noise occurs at idle or above idle speed, and if the engine is cold, hot, or both. Attempt to duplicate the noise, and determine the source of the symptom. Refer to the following Service Procedure to help determine the source of the noise and if a repair is needed. SERVICE PROCEDURE

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FORD: 2004-2005 F-150; 2005 Expedition, F-Super Duty LINCOLN: 2005 Navigator ISSUE NOTE: This article supersedes TSB 06-5-9 to update the vehicle lines and model years. Some 2004-2005 F-150 and 2005 F-Super Duty, Expedition, and Navigator vehicles with a 5.4L 3- valve engine may experience difficulty with spark plug removal which may cause damage to the spark plug and leave part of the spark plug in the cylinder head. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE GENERAL SPARK PLUG REMOVAL To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. 1. Make sure the engine is warm (hand touch after cooling down).