Fulltext TSBs

Technical Service Bulletins

TSB
08-12-6
  • RUST STAINS ON THE EDGES OF THE FRONT BUMPER CENTER VENT AND FOG LAMP OPENINGS
Publication Date: June 3, 2008

FORD:
2004-2005 F-150
2005 Excursion
2005-2008 F-Super Duty

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.

NOTE:OWNERS ARE EXPECTED TO WASH AND WAX THEIR VEHICLES, INCLUDING CHROME PARTS, TO REMOVE HARMFUL DEPOSITS AND PROTECT THE CHROME SURFACE. CORROSION DUE TO LACK OF MAINTENANCE OR DUE TO PITTING FROM STONE IMPACTS IS NOT COVERED UNDER WARRANTY. THE BACK SIDE OF THE BUMPER IS NOT CHROME PLATED. IT HAS A PROTECTIVE COATING THAT REDUCES, BUT DOES NOT ELIMINATE EXPOSURE TO THE ENVIRONMENT.

F-SUPER DUTY AND EXCURSION SERVICE PROCEDURE

NOTE:USE PROTECTIVE GLOVES FOR APPLYING BOTH THE MOTORCRAFT® CUSTOM BRIGHT METAL CLEANER AND THE ANTI-CORROSION COATING.

  1. Hoist vehicle until bumper is at working level. Follow all safety precautions as outlined in the Workshop Manual (WSM), Section 501-19.
  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)


    Figure 1 – Article 08-12-6

  13. Using a foam brush, coat the edges of the three (3) openings with Motorcraft® Anti-Corrosion Coating.

    NOTE:PAINT THE EDGE OF THE OPENINGS AND AT LEAST 1″ (25 MM) AREA AROUND THE INSIDE OF THE BUMPER ON ALL THREE (3) CUTOUTS.

  14. Remove the tape from the three (3) openings.
  15. Install bumper components and assembly in reverse order, torque the bumper retaining bolts to 85 lb-ft (115 N-m).

F-150 SERVICE PROCEDURE

NOTE:USE PROTECTIVE GLOVES FOR APPLYING BOTH THE MOTORCRAFT® CUSTOM BRIGHT METAL CLEANER AND THE ANTI-CORROSION COATING.

  1. Hoist vehicle until bumper is at working level. Follow all safety precautions as outlined in the WSM, Section 501-19.
  2. Remove front bumper per WSM, Section 501-19.
  3. Remove the fog lamp and bracket assembly retaining bolts, if equipped, to the bumper bar.
  4. Remove the nine (9) push pins from the air opening grille and remove the grille. Take care not to damage the fins on the push pins when removing the pins.

    NOTE:IT IS NOT NECESSARY FOR THIS PROCEDURE TO REMOVE THE TWO (2) SNAP-IN GRILLES AT THE LEFT AND RIGHT ENDS OF THE AIR OPENING GRILLE ASSEMBLY.

  5. Clean excessive dirt from an area of 2″ (50 mm) around the openings on the inside of the bumper bar.
  6. Clean the red rust stains from inside the chrome surface of the bumper with Motorcraft® Custom Bright Metal Cleaner.
  7. Install masking tape (typical) in center air opening and, if equipped, the two (2) round fog lamp openings. (Figure 1)
  8. Using a foam brush, coat the edges of the openings with Motorcraft® Anti-Corrosion Coating.

    NOTE:PAINT THE EDGE OF THE OPENING(S) AND AT LEAST 1″ (25 MM) AREA SURROUNDING THE INSIDE OF THE BUMPER AT THE OPENING(S).

  9. Remove the tape at the opening(s).
  10. Install the center opening grille assembly with the nine (9) push pin retainers. Replace any push pin retainers that may have been damaged during the removal procedure.
  11. Install the fog lamp and bracket assemblies, if equipped, and tighten the retaining bolts to 48 lb-in (5.4 N-m).
  12. Install bumper assembly as per WSM, Section 501-19.

    NOTE:DO NOT REUSE THE THREE (3) FASCIA ASSEMBLY-TO-FRONT BUMPER BOLTS (ITEM #3 IN WORKSHOP MANUAL). REPLACE THE BOLTS AND TIGHTEN TO 28 LB-IN (3.2 N-m).


PART NUMBERPART NAME
N811847-S301F-150 Facia Assembly-to-Front Bumper Bolt (3 per repair)
PM-13-AMotorcraft® Anti-Corrosion Coating
ZC-15Motorcraft® Custom Bright Metal Cleaner
N807389-SPush Pins – (F-150)

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

OPERATIONDESCRIPTIONTIME
081206A2004-2005 F-150, 2005-2008 F-Super Duty, 2005 Excursion Follow Service Procedure To Clean And Install Rust Preventative On Front Bumper, Includes Time To Remove And Install Bumper (Do Not Use With 17757A)1.5 Hrs.

DEALER CODING

BASIC PART NO.CONDITION CODE
17750P1