Fulltext TSBs

Technical Service Bulletins

TSB
08-25-5
  • DRIVERS SIDE COWL PANEL POPPED-UP
Publication Date: December 5, 2008

FORD:
2004-2008 F-150
LINCOLN:
2006-2008 Mark LT

This article supersedes TSB 07-24-5 to update the Service Procedure.

ISSUE:

Some 2004-2008 F-150 and 2006-2008 Mark LT (Excluding Heritage) vehicles may encounter a concern of the windshield cowl panel not being fully seated, popped up or giving the appearance of being warped.

ACTION:

Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

NOTE:HEAVY-PRESSURE MAY RESULT IN BREAKING OF THE J-HOOK.

  1. Attempt to seat the cowl panel by gently applying pressure, first downward, then rearward to the inboard rear area of the cowl panel, forward of the windshield to determine if it will engage the sheet metal flange below. (Figure 1)


    Figure 1 – Article 08-25-5

  2. Pull test will confirm if the hooks are engaged and that the sheet metal flange has not been bent too far forward. From the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. (Figure 2)


    Figure 2 – Article 08-25-5

Cowl Panel Cannot Be Seated – Continued

  1. Remove the cowl panel(s). Refer to Workshop Manual (WSM), Section 501-02 for removal instructions.
  2. Confirm engagement and proper installation of cowl grill. The cowl design makes use of long J-hooks (Figure 2, view A) on the bottom side of the cowl panel to engage a sheet metal flange below the cowl panel surface area. On vehicles built prior to August 2006, you will need to visually confirm that the J-hooks on the right hand (RH) parts are engaged to the sheet metal flange. The left hand (LH) part will need to be removed to observe this. Vehicles built after August 2006 have a raised feature forward of the screw attachment support tower on the RH part (near the center line of the vehicle), which is to ensure that the cowl panel is not built forward and is in the correct position for the J-hooks to engage the sheet metal flange. Check if the LH cowl panel is installed correctly, you can either tug the part forward or outward (towards the fender). Each move should cause the rear of the part or the split joint between the RH and LH cowl grills to pop up if the J-hooks were not engaged. Relying on an audible confirmation of engagement could cause a false-positive assessment of the parts being installed and retaining correctly and should not be used as the final indicator of correct installation.
  3. If the RH part does not have the split joint hook engaged to the sheet metal flange it must be set properly before the LH part can be corrected. Remove LH cowl grill and set aside. Loosen screw on RH cowl grill. Push down and rearward over the hook to engage the sheet metal flange. While holding part rearward, re-tighten the screw.
  4. If it is found that the LH parts cannot be installed correctly (the rear edge or split joint pops up after panel is shifted), remove the LH cowl panel (driver side) and place it out of the way. The flange to which the J-hook engages needs to be adjusted slightly upward 3/32″ (2 mm) in two areas using a pair of wide bill pliers (Figure 1, view B). Then install the cowl panel and retest by trying to shift either forward or outward. An audible click confirmation of hook engagement could cause a false positive assessment of the parts being installed correctly and should not be used as the final indicator of correct installation. Using the pull test, from the driver's side of the vehicle, with your left hand place your thumb on the fender top, then place your fingers into the cowl's lower portion for the wiper arm and pull lateral on the cowl panel. Panel will pop up at center when pulled outboard if the hooks are not properly engaged to the flange. This will confirm the flange has not been bent too far forward. If the rear edge and split joint stays down and the margin on the inboard edge to the LH part is consistent, then complete installation of the LH cowl has been achieved. (Figure 3)


    Figure 3 – Article 08-25-5

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
082505A2004-2008 F-150, 2006-2008 Mark LT: Attempt To Seat Cowl Panel, Includes Time To Adjust Flange If Necessary (Do Not Use With 17508A, 17526A, 17528A)0.3 Hr.

DEALER CODING

BASIC PART NO.CONDITION CODE
700201007