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Accelerator pedal cable -1- connected to accelerator pedal and routed over the Throttle actuator control module cable quadrant. Remove clip -3- from notched section of cable sleeve -4-. Fully depress accelerator pedal to Wide Open Throttle position. Note: Either use a second technician or a mechanical device to depress the accelerator pedal. Vehicles with manual transmission Move notched outer sleeve in or out of grommet -4- (as necessary) until Wide Open Throttle position is just reached. Re-install clip -3- into the first completely exposed notch closest to the top of the grommet. Vehicles with automatic transmission Move outer sleeve in or out of grommet -4- (as necessary) until Wide Open Throttle position is just reached and the kick-down switch clicks audibly. Re-install clip -3- into the first completely exposed notch closest to the top of the grommet. All vehicles Release accelerator pedal (remove mechanical device, if used). After adjusting, check the Closed and Wide open Throttle stops. Vehicles with automatic transmission, adjustment checking Test and auxiliary equipment required Fluke 83 Multimeter VW 1594 Adaptor kit Disconnect 2-pin harness connector from kick-down switch In engine compartment on firewall Connect multimeter between kick-down switch terminals using jumper wires from VW 1594 adaptor kit. Measure resistance across switch. Specified Value: ? Slowly depress accelerator pedal until Wide Open Throttle is reached. If properly adjusted, following conditions will be met: Shortly after kick-down point, resistance must drop to 0 Accelerator pedal must almost be up to the full travel stop

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ISSUE Some vehicles built prior to 12/1/2001 may exhibit the following shift and engagement conditions: • No 2nd Gear • No 3rd Gear • No Engine Braking In Manual 1st. Out of specification pressures controlled by the transmission main control valve body separator plate may be the cause. ACTION Verify the condition, the main control valve body separator plate may need to be updated to the latest level. Refer to the following Service Procedure for details. SERVICE PROCEDURE CAUTION TO BE ADDED OR REPLACED FOR THIS TSB. 1. Verify that one or more of the following conditions exist. • Low Line Pressure While In Drive At WOT • No 2nd And/Or No 3rd Gear • No Engine Braking In Manual 1st • DTC P0732, P0733 Or P1762 2. Install Kit (3L5Z-7M203-JA) to update the main control valve body assembly, refer to the installation procedures found in the kit. 3. Reinstall the main control by continuing to follow the installation steps listed in the Workshop Manual, in-vehicle service, main control valve body. 4. After completing the procedure, verify the condition has been corrected.

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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.

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Santa Fe (2.7L) & Sonata (2.5L) 1. Turn ignition off. Disconnect TP sensor 3-pin connector. Measure resistance between TP sensor terminals No. 2 (Orange wire on Santa Fe, Black/White wire on Sonata) and No. 1 (Yellow/Black wire on Santa Fe, Green/White wire on Sonata). See Fig. 1 . Standard resistance value should be 3500-6500 ohms. If resistance is not as specified, replace TP sensor. If resistance is as specified, go to next step. 2. Measure resistance between TP sensor terminals No. 2 (Orange wire on Santa Fe, Black/White wire on Sonata) and No. 3 (Red/Orange on Santa Fe, Blue wire on Sonata). Open throttle slowly from idle position to wide-open throttle position. Resistance should change smoothly in proportion to the throttle valve opening. If resistance changes smoothly, go to next step. If resistance does not change smoothly, replace TP sensor. 3. Reconnect TP sensor connector. Using a voltmeter, backprobe sensor connector terminals No. 1 (Yellow/Black wire on Santa Fe, Green/White wire on Sonata) and No. 3 (Red/Orange on Santa Fe, Blue wire on Sonata). Turn ignition on, and measure TP sensor voltage. Voltage should be 250-800 millivolts. If voltage is not as specified, replace TP sensor.

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DESCRIPTION The Throttle Position (TP) sensor is a potentiometer. The TP sensor is connected to the throttle shaft on the throttle body. By monitoring the voltage on the signal line, the VCM calculates throttle position. As the throttle valve angle is changed (accelerator pedal moved), the TP sensor signal also changes. At a closed throttle position, the output of the TP sensor is low. As the throttle valve opens, the output increases so that at Wide Open Throttle (WOT,) the output voltage should be above 4.0 volts. PURPOSE The VCM calculates fuel delivery based on throttle valve angle (driver demand). A broken or loose TP sensor may cause intermittent bursts of fuel from an injector. This may cause an unstable idle because the VCM detects the throttle is moving.