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ISSUE Some 2002-2005 Explorer 4dr/Mountaineer and 2003-2005 Aviator vehicles may exhibit a noise from the rear wheel hub bearings. Previous service procedures required service replacement of the wheel hub bearing assembly, base part (1109). This new service procedure allows replacement at a lower service level of the wheel bearing, base part (1215) to repair the noise condition. ACTION Replace the rear hub bearing and wheel bearing retainer ring. Refer to the following Service Procedure. SERVICE PROCEDURE NOTE HAVE AN ASSISTANT PRESS THE BRAKE PEDAL TO KEEP THE AXLE FROM TURNING. 1. Remove the axle-to-wheel hub retainer nut and washer (Figure 1). Discard the nut. When reinstalling at end of procedure, tighten to 203 lb-ft (275 N•m).Figure 1 – Article 05-25-8 2. Remove the bolt and disconnect the wheel speed sensor (Figure 2). To install, tighten to 71 lb-in (8 N•m).

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ISSUE Some 2002-2006 Explorer/Mountaineer and 2003-2005 Aviator vehicles may exhibit a customer complaint of the fuel gauge being slow to read full after refueling, the malfunction indicator lamp (MIL) on with diagnostic trouble code (DTC) P0463, instrument cluster DTC B1201, and/or the fuel gauge dropping to empty. This may be due to the fuel level sender assembly sending incorrect data to the instrument cluster and/or powertrain control module (PCM). ACTION Refer to the following General Information for a description of two (2) modes of fuel gauge operation prior to following the TSB Service Procedure. This brief explanation of current fuel gauge strategy will help ensure the correct diagnosis is made. The fuel gauge on these vehicles has several distinct modes of operation. The difference in the various modes is the speed at which the fuel gauge pointer moves in relationship to fuel level input from the fuel level sender. After reviewing the General Information, refer to the TSB Service Procedure. GENERAL INFORMATION Fuel gauge strategy provides several modes of operation. One being referred to as Fast Acquire Mode and another as Slosh Mode. The time for the fuel gauge pointer to move from “E” to “F” can be 2 seconds, 17 minutes or 55 minutes depending on build date and which mode the fuel gauge is in.

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Various 1997-2008 vehicles equipped with either 4 wheel drive or all wheel drive and equipped with control trac may exhibit a shudder on acceleration/deceleration, binding in slow speed turns or noise from the front driveline and/or transfer case. The shudder/binding will occur with the vehicle being operated in the awd/auto 4×4 mode. The shudder/binding may be due to incorrect tire circumference or improper tire inflation pressures. ACTION: Follow the Service Procedure steps to correct the condition. SERVICE PROCEDURE NOTE: THIS DOES NOT APPLY TO 2006-2008 MOUNTAINEER WITH A 4.0L ENGINE OR 2007-2008 EXPLORER AND SPORT TRAC WITH 20 INCH WHEELS. Review the tire label for correct tire size and tire inflation pressures located at the B-Pillar of the driver’s door. If the tire size does not match the label, this procedure does not apply, follow normal Workshop Manual (WSM) diagnostics. If the tire size is correct, ensure tire pressures are within specifications. Raise the vehicle on the hoist, refer to Workshop Manual, Section 100-02. Disconnect all wiring going to the transfer case and road test. Is the shudder/binding present? a. If the shudder/binding is still present, do not contine with this procedure, continue with WSM normal diagnostic for 4X4. b. If the shudder/binding is gone, proceed to Step 7. 7. Raise the vehicle on the hoist and reconnect all the wiring previously disconnected. 8. Using a tailor’s tape or flexible measuring tape and measure the circumference of all four (4) tires and record the measurements. (Figure 1) 1. 2. 3. 4. 5. 6. 10. If the difference between these two averages is greater than 1/2″ (12.7 mm), front to back or side to side, replace the smallest circumference tire(s) and remeasure the tire averages. Refer to WSM, Section 204-04 for tire replacement.

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ISSUE Some 2004-2008 F-150, 2006-2008 Mark LT, 2005-2008 F-Super Duty, Expedition, and Navigator, with 5.4L 3-V engine; 2005-2008 Mustang, 2006-2008 Explorer, Mountaineer, and 2007-2008 Explorer Sport Trac with 4.6L 3-V engine; 2005-2008 F-Super Duty, 2006-2008 and F-Stripped Chassis, with 6.8L 3-V engine may experience difficulty with spark plug removal. This may cause damage to the spark plug and leave part of the spark plug in the cylinder head. Affected engine build dates are as follows: 5.4L 3-V and 6.8L 3-V before 10/9/07, 4.6L 3-V before 11/30/07. ACTION Refer to the following Service Procedure for techniques to remove the spark plugs and extract broken spark plugs. SERVICE PROCEDURE The engine build date can be read on the left hand cam cover information sticker. To remove spark plugs without damage, it is necessary to adhere exactly to this procedure before removal is attempted. CAUTION DO NOT REMOVE PLUGS WHEN THE ENGINE IS WARM OR HOT. THE ENGINE MUST BE AT ROOM TEMPERATURE WHEN PERFORMING SPARK PLUG SERVICE. REMOVING THE SPARK PLUGS FROM A WARM/HOT ENGINE INCREASES THE CHANCE THE THREADS COULD BE DAMAGED. Spark Plug Removal Procedure 1. Remove the coil-on-plug assemblies and thoroughly blow out the spark plug wells and surrounding valve cover area with compressed air. 2. Back out the spark plugs no more than 1/8 to 1/4 of a turn. Using Motorcraft(R) Carburetor Tune-Up Cleaner, fill the spark plug well just above where the jamb nut hex sits (1/2 – 3/4 teaspoon). A minimum period of 15 minutes of soak time is required. The cleaner will wick down to the ground electrode shield and soften the carbon deposits in this time. DO NOT WORK the spark plug back and forth at this point. NOTE COMPLETELY REVIEW THE PRODUCT LABEL FOR THE MOTORCRAFT CARBURETOR TUNE-UP CLEANER PRODUCT – USE AT ROOM TEMPERATURE AND SHAKE WELL.

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All vehicles 1. Remove the ignition switch lock cylinder. For additional information, refer to Ignition Switch Lock Cylinder—Functional Lock Cylinder or Ignition Switch Lock Cylinder—Non-Functional Lock Cylinder in this section. 2. Remove the air bag sliding contact. For additional information, refer to Section 501-20B. 3. Remove the steering column (3C529). For additional information, refer to Column in this section. 4. CAUTION: Carefully note the position of the steering column lock gear, bearing and retainer prior to removal. Remove the bearing retainer (3C610). 5. Remove the steering column lock housing bearing (3E700).6. Remove the steering column lock gear (3E717). Vehicles with tilt steering columns 7. Remove the shock absorber electronic steering sensor (18B015). 1. Disconnect the electrical connector. 2. Remove the screws. 3. Remove the shock absorber electronic steering sensor. 8. Remove the sensor ring. 1. Remove the steering column lower bearing spring. 2. Remove the sensor ring. Vehicles with fixed steering columns 9. Remove the snap ring from the bottom of the steering column shaft. All vehicles 10. Remove the steering column bearing tolerance ring (3L539) from the steering column shaft.Vehicles with tilt steering columns 11. Remove the two lock cylinder housing pivot screws. Vehicles with fixed steering columns 12. Remove the two lock cylinder housing screws and the steering column spacer (3C549). All vehicles WARNING: The steering column position spring is under tension and can come out with great force. Remove the steering column lock cylinder housing (3511) and the steering column shaft from the steering actuator housing (3F723). 1. Pry up on the steering column locking levers (3B661) using a shop fabricated tool.