Fulltext TSBs

Technical Service Bulletins

TSB
00-1-6
  • SUSPENSION – FRONT STABILITY BAR MAY BREAK OFF – VEHICLES BUILT FROM 1/1/1998
Publication Date: DECEMBER 22, 1999

FORD:
1999 SUPER DUTY F SERIES

ISSUE:

The front stability bracket on the front axle may break off due to impact with a solid object or from fatigue.

ACTION:

Install a revised bracket. On vehicles built before 3/21/1999, install a new stability bar bracket which will raise the bar approximately 25mm (1″). This will reduce the possibility of breakage. Refer to the following Service Procedure for details.

SERVICE PROCEDURE

All 4X4 Vehicles Built Prior to 3/21/1999

  1. Raise vehicle on hoist and support front axle.
  2. Remove stability bar, stability bar insulators, and stability bar retainer from axle and links.
  3. Remove U-bolts and front spring cap from LH side of vehicle.
  4. Grind off the protruding stability bar bracket weldment from the front axle.

    NOTE:DO NOT REMOVE ENTIRE WELDMENT, JUST ENOUGH TO ALLOW ATTACHMENT OF STABILITY BAR MOUNTING BRACKET. THE ISOLATOR MUST CONTACT WELDMENT BASE.

    CAUTION:DO NOT GOUGE INTO SPRING CAP OF AXLE.

  5. Drill two (2) 12mm holes in the axle spring cap weldment on the surface where the stability bar bracket weldment was removed, as follows (RH side/passenger side described):
    1. Position one (1) hole 40mm down from the cap’s top edge and 25mm over from cap’s outer surface on the outboard side of vehicle.
    2. Position second hole 20mm down from the cap’s top edge and 60mm over from cap’s outer surface on the outboard side of vehicle.
    3. Mounting holes should line up with stability bar mounting bracket so that the bracket opens toward the center of the vehicle and the retainer for the stability bar holes are oriented vertically with respect to each other.
  6. Bolt on the Stability Bar Mounting Bracket (F81Z-5486-DB) in orientation described in Step above with two (2) Bolts (N605921-S426) and two (2) Nuts (N620482-S427) torqued to 47 7 N-m (25 5 lb-ft) (verify bracket holes are in the vertical position).
  7. Install the Front Spring Cap (YC3Z-5A316-AA) using U-bolts (F81Z-5705-BA) and Nuts (N805480-S426) torqued to 133 22.5 N-m (98 16 lb-ft).
  8. Install Stability Bar (F81Z-5482-FA or -AA) using Stability Bar Retainer (F81Z-5486-AA) with Bolt (N605921-S426) and Nuts (N620482-S427) torqued to 47 7 N-m (35 5 lb-ft).
  9. Attach stability bar to stability bar links with torque of 80 12 N-m (59 9 lb-ft).

All 4X4 Vehicles Built After 3/21/1999

  1. Raise vehicle on hoist and support front axle.
  2. Remove stability bar, stability bar insulators, and stability bar retainer from the axle and links.
  3. Grind off protruding stability bar bracket weldment from the front axle.

    NOTE:DO NOT REMOVE ENTIRE WELDMENT, JUST ENOUGH TO ALLOW ATTACHMENT OF STABILITY BAR MOUNTING BRACKET. THE ISOLATOR MUST CONTACT WELDMENT BASE.

    CAUTION:DO NOT GOUGE INTO SPRING CAP OF AXLE.

  4. Drill two (2) 12mm holes in the axle spring cap weldment on the surface where the stability bar bracket weldment was removed, as follows (RH side/passenger side described):
    1. Position one (1) hole 40mm down from the cap’s top edge and 25mm over from cap’s outer surface on the outboard side of vehicle.
    2. Position second hole 20mm down from the cap’s top edge and 60mm over from cap’s outer surface on the outboard side of vehicle.
    3. Mounting holes should line up with stability bar mounting bracket so that the bracket opens toward the center of the vehicle and the stability bar retainer holes are oriented vertically with respect to each other.
  5. Bolt on the Stability Bar Mounting Bracket (F81Z-5486-DB) in orientation described in Step above with two (2) Bolts (N605921-S426) and two (2) Nuts (N620482-S427) torqued to 47 7 N-m (35 5 lb-ft) (verify bracket holes are in the vertical position).
  6. Install Stability Bar (F81Z-5482-FA or -AA) using Stability Bar Retainer (F81Z-5486-AA) with Bolt (N605921-S426) and Nuts (N620482-S427) torqued to 47 7 N-m (35 5 lb-ft).
  7. Attach stability bar to stability bar links with torque of 80 7 N-m (59 9 lb-ft).

F-450/F-550 4X2 Vehicles Built Prior to 3/21/1999

  1. Raise vehicle on hoist and support front axle.
  2. Remove stability bar, stability bar insulators, and stability bar retainer from axle and links.
  3. Grind off protruding stability bar bracket weldment from the front axle on both spring caps.

    NOTE:DO NOT REMOVE ENTIRE WELDMENT, JUST ENOUGH TO ALLOW ATTACHMENT OF STABILITY BAR MOUNTING BRACKET. THE ISOLATOR MUST CONTACT WELDMENT BASE.

    CAUTION:DO NOT GOUGE INTO SPRING CAP OF AXLE.

  4. Drill two (2) 12mm holes in the axle spring cap weldment on the surface where the stability bar bracket weldment was removed, as follows (RH side/passenger side described):
    1. Position one (1) hole 40mm down from the cap’s top edge and 25mm over from cap’s outer surface on the outboard side of vehicle.
    2. Position second hole 20mm down from the cap’s top edge and 60mm over from cap’s outer surface on the outboard side of vehicle.
    3. Mounting holes should line up with stability bar mounting bracket so that the bracket opens toward the center of the vehicle and the stability bar retainer holes are oriented vertically with respect to each other.
  5. Repeat Step 4 in mirror image for LH side/driver side bracket.
  6. Bolt on the Stability Bar Mounting Bracket (F81Z-5486-DB) in orientation described in Step above with two (2) Bolts (N605921-S426) and two (2) Nuts (N620482-S427) torqued to 47 7 N-m (35 5 lb-ft) (verify bracket holes are in the vertical position).
  7. Install Stability Bar (F81Z-5482-FA or -AA) using Stability Bar Retainer (F81Z-5486-AA) with Bolt (N605921-S426) and Nuts (N620482-S427) torqued to 47 7 N-m (35 5 lb-ft).
  8. Attach stability bar to stability bar links with torque of 80 12 N-m (59 9 lb-ft).

F-450/F-550 4X2 Vehicles Built After 3/21/1999

  1. Raise vehicle on hoist and support front axle.
  2. Remove stability bar, stability bar insulators, and stability bar retainer from axle and links.
  3. Grind off protruding stability bar bracket weldment from the front axle on both spring caps.

    NOTE:DO NOT REMOVE ENTIRE WELDMENT, JUST ENOUGH TO ALLOW ATTACHMENT OF STABILITY BAR MOUNTING BRACKET. THE ISOLATOR MUST CONTACT WELDMENT BASE.

    CAUTION:DO NOT GOUGE INTO SPRING CAP OF AXLE.

  4. Drill two (2) 12mm holes in the axle spring cap weldment on the surface where the stability bar bracket weldment was removed, as follows (RH side/passenger side described):
    1. Position one (1) hole 40mm down from the cap’s top edge and 25mm over from cap’s outer surface on the outboard side of vehicle.
    2. Position second hole 20mm down from the cap’s top edge and 60mm over from cap’s outer surface on the outboard side of vehicle.
    3. Mounting holes should line up with stability bar mounting bracket so that the bracket opens toward the center of the vehicle and the stability bar retainer holes are oriented vertically with respect to each other.
  5. Repeat Step 4 in mirror image for LH side/driver side bracket.
  6. Bolt on the Stability Bar Mounting Bracket (F81Z-5486-DB) in orientation described in Step above with two (2) Bolts (N605921-S426) and two (2) Nuts (N620482-S427) torqued to 47 7 N-m (35 5 lb-ft) (verify bracket holes are in the vertical position).
  7. Install Stability Bar (F81Z-5482-FA or -AA) using Stability Bar Retainer (F81Z-5486-AA) with Bolt (N605921-S426) and Nuts (N620482-S427) torqued to 47 7 N-m (35 5 lb-ft).
  8. Attach stability bar to stability bar links with a torque of 80 12 N-m (59 9 lb-ft).

PART NUMBERPART NAME
F81Z-5486-DBMounting Bracket
N605921-S426Bolt
N620482-S427Nut
YC3Z-5A316-AACap – Front Spring
F81Z-5486-AARetainer – Stability Bar
F81Z-5484-ECInsulator
F81Z-5484-JAInsulator
F81Z-5482-FAStability Bar
F81Z-5482-AAStability Bar
F81Z-5705-BAU-Bolt
N805480-S426Nut

OTHER APPLICABLE ARTICLES:

NONE

WARRANTY STATUS:

Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATIONDESCRIPTIONTIME
000106AInstall Revised Stability Bracket And Stability Bar (Super Duty F Series 4X4 Built Prior To 3/21/1999)1.1 Hr.
000106BInstall Revised Stability Bracket And Stability Bar (Super Duty F Series 4X4 Built On Or After 3/22/1999)1.0 Hr.
000106CInstall Revised Stability Bracket And Stability Bar (F-450/550 4X2)1.6 Hrs.

DEALER CODING

BASIC PART NO.CONDITION CODE
548601

OASIS CODES:

303000, 304000, 702100




Figure 1 – Article 00-1-6




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Figure 6 – Article 00-1-6


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