Technical Service Bulletins
|Publication Date: October 1, 2010|
|2008-2010 F-250, F-350, F-450, F-550|
New Service Level for Short Block: An enhanced remanufactured short block engine is now available. The new short block is built to a higher level than the prior version and includes the majority of the fasteners and gaskets required to properly complete the repair. The remanufactured enhanced short block includes, but is not limited to the following incremental content:
- Complete oil sump (Upper and Lower Oil Pans).
- Engine Rear Cover with Crankshaft Rear Seal.
- Engine Front Cover with oil pump and Crankshaft Front Seal.
- Oil Cooler and Oil Filter assemblies.
- Oil Temperature and Pressure sensors.
- Engine Coolant Temperature sensor.
- Crankshaft and Camshaft Position sensors.
- Thermostat housing with both thermostats.
- Complete fuel filter kit.
Follow the Service Procedure steps to correct the condition.
Carefully follow the enhanced short block build-up and repair robustness procedures contained in the Workshop Manual to ensure the conditions listed are properly addressed.
|NOTE:||A COMPREHENSIVE (ALL INCLUSIVE) LABOR OPERATION HAS BEEN ESTABLISHED IN SERVICE LABOR TIME STANDARDS (SLTS) WHICH COVERS THE REMOVAL AND INSTALLATION OF THE ENGINE ASSEMBLY, DISASSEMBLY AND THE BUILD-UP OF THE ENHANCED SHORT BLOCK, AS WELL AS THE TIME REQUIRED TO PERFORM THE REPAIR ROBUSTNESS ACTIONS.|
|NOTE:||IN THE EVENT THAT A COOLING SYSTEM VENTURI TEE IS NOT PRESENT, IT SHOULD BE INSTALLED. A SERVICE LABOR TIME IS NOW AVAILABLE.|
Repair Robustness Actions:
Warranty analysis indicates a high incidence of repeat repairs on vehicles that have previously had the engine short block replaced. Analysis of the repeat failures indicates that performing the following mandatory repair robustness actions will significantly reduce the potential for repeat engine failures:
- Clean residual oil accumulation from the Charge Air Cooler (CAC) system.
Oil accumulation in the CAC system primarily results from oil level growth in the crankcase, which typically results from leaking high pressure pump seals, leaking injectors, and/or frequent Diesel Particulate Filter (DPF) regeneration events. The oil is then ingested from the CAC system into the intake system during heavy acceleration, causing over-fueling and heat damage to cylinders (primarily, but not limited to, cylinders #2 and #8). If the oil is not properly cleaned from the CAC system, the failure can reoccur very quickly.
- Flush radiator and backflush heater core.
These cooling system heat exchangers can become restricted with rust and corrosion debris that accumulate in, and are circulated through, the cooling system. Restricted heat exchangers elevate operating temperatures and can result in de-rated engine performance and/or engine damage.
- Replace engine coolant using only Motorcraft® Premium Gold Engine Coolant (VC-7-B). This is the only approved coolant for the 6.4L engine.
The specified coolant contains silicates which protect aluminum system components from pitting and corrosion, and nitrites to protect against cylinder cavitation. The use of incorrect engine coolant can result in the build-up of corrosion in the cooling system, which collects in the heat exchangers and contributes to component failure.
- Ensure proper coolant-to-water concentration.
Insufficient coolant concentration lowers coolant boiling point and contributes to system corrosion. Excessive coolant concentration elevates system temperatures and cause overheating.
- Replace the degas bottle cap.
A leaking degas bottle cap can cause coolant leaks and lower system pressure, which lowers the coolant boiling point and creates water pump/front cover cavitation. Low coolant level also results in localized boiling of coolant which damages the radiator and other cooling system components.
- Verify proper installation of the Cooling System Venturi Tee.
The Venturi Tee, introduced under Customer Satisfaction program 08B06 (expired), must be installed with the correct orientation to prevent excessive temperature cycling and cracking of the of the upper radiator tubes.
- Verify condition of EGR Coolers prior to re-installation.
Leaking EGR Coolers allow coolant into the air intake system, which can result in cylinder hydro-lock and piston and connecting rod damage. Coolant can also ignite in the combustion chambers causing cylinder damage. In addition, coolant in the exhaust system damages the Diesel Oxidation Catalyst (DOC) and Diesel Particulate Filter (DPF).
- Reprogram the Powertrain Control Module (PCM) to latest service level. Refer to the TSB list below by build date for PCM programming.
NOTE: THE 2010 MODEL YEAR DOES NOT REQUIRE A PCM UPDATE.
- TSB 09-16-09 vehicles built on or before 8/2/2007.
- TSB 09-19-10 vehicles built 8/3/2007 to 1/2/2008.
- TSB 09-18-15 vehicles built 1/3/2008 to 9/15/2008.
- TSB 09-16-08 vehicles built 9/16/2008 to 9/26/2009.
NOTE: THE ABOVE TSB LABOR OPERATIONS WILL BE ALLOWED TO BE CLAIMED WITH THE ENHANCED SHORT BLOCK LABOR OPERATION 6007B3.
Calibration enhancements include cooling system over-temperature protection and reduced oil growth from DPF regeneration events.
Information Only – Not Warrantable
NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by “do-it-yourselfers”. Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.
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