Fulltext TSBs

Technical Service Bulletins

TSB
03-21-39
  • ENGINE – 7.3L DIESEL – ENGINE KNOCK OR “CACKLE” – 1999-2000 SUPER DUTY F-SERIES AND 2000 EXCURSIONS WITH ENGINE SERIAL NUMBERS 661894 THROUGH 1311240 – ALL 1998-2000 E-SERIES WITH ENGINE SERIAL NUMBERS 661974 THROUGH 1311240
  • NOISE – “CACKLE” OR ENGINE KNOCK – 7.3L DIESEL – 1999-2000 SUPER DUTY F-SERIES AND 2000 EXCURSIONS WITH ENGINE SERIAL NUMBERS 661894 THROUGH 1311240 – ALL 1998-2000 E-SERIES WITH ENGINE SERIAL NUMBERS 661974 THROUGH 1311240
Publication Date: October 7, 2003

FORD:
1998-2000 E SERIES
1999-2000 SUPER DUTY F SERIES
2000 EXCURSION

This article is being published to combine TSB 00-22-1 and 01-14-6 as part of a consolidated 7.3L diagnostic aid booklet.

ISSUE:

Some vehicles equipped with a 7.3L Powerstroke diesel engine with engine serial number 661894 through 1311240, may exhibit a noise above the normal sound of the diesel combustion. This noise may sound like a rod knock, but it is intermittent and increases in intensity as the engine warms up to operating temperature. This “cackle” noise may by caused by pressure variation within the fuel rail and in virtually all instances is attributed to cylinder #8 (driver side rear). The “cackle” noise does not cause damage the engine, or impact the engine’s performance or economy.

Engines after serial number 1311240 were built with a long lead injector in cylinder #8 and correct calibration from the factory. It is possible for engines with the long lead injector, from the factory or installed in service, to exhibit a “lifter noise” (the long lead injector can be identified by the “LL” stamp on top of the solenoid.) This noise is typically most noticeable when the vehicle is parked next to a brick or concrete wall, such as at a fast food drive through. This noise is a normal characteristic of the long lead injector and is not a reason to replace the injector.

ACTION:

Refer to the following Service Procedure for diagnostics, injector replacement, and Powertrain Control Module (PCM) reprogramming procedure.

SERVICE PROCEDURE

The “cackle” noise will typically be found early in an engine’s life due to low fuel pressure and/or the relationship of injectors and engine firing order, or fuel pressure below specification. If a mature engine develops the “cackle” noise, low fuel pressure is the likely cause. Before making a repair attempt, the following tests should be performed:

  1. Verify that the noise occurs with a hot engine, not cold.
  2. Verify that the vehicle has been driven long enough to purge the air out of the high-pressure oil system and the fuel system since the last injector/high pressure oil system repair. Air trapped in the system could induce the “cackle” noise.
  3. If the fuel pressure is less than 379 kPa (55 psi) in either head, repair it first and re-evaluate the “cackle” concern.
  4. Repair any other engine driveability concerns prior to attempting a repair for “cackle”. Example: low fuel pressure concerns may be causing low power and “cackle”. Repairing the low fuel pressure may correct both concerns. Also, an engine miss may be an indicator of valve train concerns.
  5. Verify that there is no air entering the fuel system. Air entering the fuel system will affect injector timing, causing unusual noise/performance.
  6. The Injector Performance Analyzer can be used to determine if the “cackle” is coming from cylinder #8. Cancel that cylinder to determine whether the noise still exists. “Cackle” cannot be identified using the Cylinder Contribution Test.

    If the noise is only present when engine is hot, and:

    1. no performance concern exists
    2. fuel pressure is above the minimum specification of 379 kPa (55 psi)
    3. there is no air present in the fuel/oil system
    4. a long lead injector is currently not installed

      then the engine is a candidate for a special Injector, F81Z-9E527-EARM (engine s/n 661894 – 896811) or XC3Z-9E527-AARM (engine s/n 896812 – end of 7.3L production).

      NOTE:IF THE NUMBER EIGHT INJECTOR HAS BEEN REPLACED PREVIOUSLY FOR A CACKLE NOISE CONCERN WITH PART NUMBER NOTED ABOVE, DO NOT REPLACE IT AGAIN. THE LONG LEAD INJECTOR CAN EXHIBIT A TICKING “LIFTER” NOISE AT NORMAL OPERATING TEMPERATURES. THIS IS CONSIDERED A NORMAL CONDITION AND DOES NOT REQUIRE SERVICE.

      NOTE:THE ENGINE SERIAL NUMBER CAN BE FOUND ON THE LOWER LEFT SIDE OF THE ENGINE BLOCK REARWARD OF THE OIL FILTER.

      NOTE:THE NEW LONG-LEAD INJECTOR FOR “CACKLE” NOISE IS USED ONLY IN CYLINDER #8. DO NOT USE IN ANY OTHER CYLINDER DUE TO FUTURE CYLINDER CONTRIBUTION TEST DIAGNOSTICS BEING AT RISK. THE INJECTOR IS RECOGNIZABLE BY AN “LL” STAMPED ON THE SOLENOID WHERE THE UVC (INJECTOR HARNESS) CONNECTS.

      Replace the #8 injector by referring to the replacement procedure in the appropriate vehicle Workshop Manual. In addition to replacing the injector, the PCM MUST be reprogrammed to prevent the #8 injector from flagging a false Cylinder Contribution Test code during future diagnostic tests. After the repair, realize that some small amount of “cackle” may remain.

      NOTE:VEHICLES BUILT WITH ENGINE AFTER S/N 1311240 HAVE CORRECT CALIBRATIONS FROM THE FACTORY.


      PCM CALIBRATION INFORMATION
      ApplicationOld Part Number (-12A650-)Old Tear TagNew Part Number (-12A650-)New Tear TagNGS/WDS Qualifier
      F-250/350 M/T Federal Service Fix 1999.5XU2F-UAQEK0XU2Z-UBQEK1WDS Release B26.4 or Later
      F-250/350, F-450/550 M/T Federal Service 1999.5XU2F-PAZHL0XU2Z-PBZHL1WDS Release B25.4 or Later
      F-450/550/560 M/T 50S Service Fix 1999.5XU2F-XAVRP0XU2Z-XBVRP1WDS Release B25.4 or Later
      F-450/550/560 M/T 50S Service Fix 1999.5XU2F-VABAW0XU2F-VBBAW1WDS Release B25.4 or Later
      F-250/350 M/T California Service Fix 1999.5XU2F-YAGLI0XU2Z-YBGLI1WDS Release B25.4 or Later
      F-250/350 M/T California Service Fix 1999.5XU2F-SASBJ0XU2Z-SBSBJ1WDS Release B25.4 or Later
      F-250/350 A/T Federal Service Fix 1999.5XU2F-ZAYEV0, YEV1, YEV2XU2Z-ZDYEV3WDS Release B25.4 or Later
      F-250/350, F-450/550 A/T Federal Service 1999.5XU2F-RAMRT0, MRT1, MRT2XU2Z-RDMRT3WDS Release B25.4 or Later
      F-450/550/560 A/T 50S Service Fix 1999.5XU2F-ABARXM0, RXM1, RXM2XU2Z-ABDRXM3WDS Release B25.4 or Later
      F-450/550/560 A/T 50S Service Fix 1999.5XU2F-AAALVS0, LVS1, LVS2XU2Z-AADLVS3WDS Release B25.4 or Later
      F-250/350 A/T California Service Fix 1999.5XU2F-ACAXWF0, XWF1, XWF2XU2Z-ACDXWF3WDS Release B25.4 or Later
      F-250/350 A/T California Service Fix 1999.5XU2F-TAHQN0, HQN1, HQN2XU2Z-TDHQN3WDS Release B25.4 or Later
      E-350/450 A/T Federal Service Fix 1999.5XU2F-ADAUYQ0XU2Z-ADBUYQ1WDS Release B25.4 or Later
      E-350/450 A/T California Service Fix 1999.5XU2F-AEAJUK0XU2Z-AEBJUK1WDS Release B25.4 or Later
      E-350/450 A/T California Service Fix 2000XC2F-ANDCHK3, CHK4XC2Z-ANFCHK5WDS Release B25.4 or Later
      E-350 A/T California Service Fix 2000XC2F-BBAMYA0XC2Z-BBBMYA1WDS Release B25.4 or Later
      F-250/350 M/T California Service Fix 2000XC3F-CFATA3XC3Z-CGATA4WDS Release B25.4 or Later
      F-250/350 M/T California Service Fix 2000XC3F-DFFHP3XU7Z-DAFHP4WDS Release B25.4 or Later
      Excursion A/T 50S Service Fix 2000YC3F-ARFZYS5YU7Z-BAZYS6WDS Release B25.4 or Later
      Excursion A/T 50S R/C 2000YC3F-AVAAXD0YU7Z-AAAXD1WDS Release B25.4 or Later
      F-250/350 M/T Federal R/C 2000XC3F-AFDAC3XC3Z-AGXPC4WDS Release B25.4 or Later
      F-450/550 M/T California R/C 2000XC3F-KFVXY3XC3Z-KGVXY4WDS Release B25.4 or Later



      PCM CALIBRATION INFORMATION
      ApplicationOld Part Number (-12A650-)Old Tear TagNew Part Number (-12A650-)New Tear TagNGS/WDS Qualifier
      F-250/350 A/T California R/C 2000XC3F-EBDNVK3, NVK4XU7Z-ABNVK5WDS Release B25.4 or Later
      F-250/350 A/T California R/C 2000XC3F-PFCNH4XU7Z-BACNH5WDS Release B25.4 or Later
      F-250/350 M/T California R/C 2000XC3F-DCAHMR0XC3Z-DCBHMR1WDS Release B25.4 or Later
      F-450/550 A/T CFFV R/C 2000YC3F-BCAYLE0YU7Z-CAYLE1WDS Release B25.4 or Later
      F-250/350 A/T California R/C 2000XC3F-DDAUKN0XU7F-CAUKN1WDS Release B25.4 or Later
      E-350/450 A/T Federal R/C 2000XC2F-APDSZT3, SZT4XC2Z-APFSZT5WDS Release B25.4 or Later
      E-350/450 A/T Federal R/C 2000XC2F-BAARCU0XC2Z-BABRCU1WDS Release B25.4 or Later
      E-350/450 A/T California R/C 2000XC2F-AZBFHM1XC2Z-AZCFHM2WDS Release B25.4 or Later
      E-350 A/T California R/C 2000YC2F-ATBSBR1YC2Z-ATCSBR2WDS Release B25.4 or Later
      F-250/350 M/T Federal Warm Weather 1999F81F-JEBDT4F81Z-JFBDT5WDS Release B27.8 or Later
      F-250/350 M/T Federal Cold Weather 1999F81F-AFAWA4F81Z-AGAWA5WDS Release B27.8 or Later
      F-450/550/560 M/T 50S Warm Weather 1999F81F-LEDYK4F81Z-LFDYK5WDS Release B27.8 or Later
      F-450/550/560 M/T 50S Cold Weather 1999F81F-KECLB4F81Z-KFCLB5WDS Release B27.8 or Later
      F-250/350 M/T California Warm Weath 1999F81F-MEETR4F81Z-MFETR5WDS Release B27.8 or Later
      F-250/350 M/T California Cold Weath 1999F81F-CFZDR4F81Z-CGZDR5WDS Release B27.8 or Later
      F-250/350 A/T Federal Warm Weather 1999F81F-NGFUT6, FUT7F81Z-NJFUT8WDS Release B27.8 or Later
      F-250/350 A/T Federal Cold Weather 1999F81F-BHXLE6, XLE7F81Z-BKXLE8WDS Release B27.8 or Later
      F-450/550/560 A/T 50S Warm Weather 1999F81F-RGHPA6, HPA7F81Z-RJHPA8WDS Release B27.8 or Later
      E350/E450 A/T Federal 1998-1999F8UF-AFGMLU6F8UZ-AFHMLU7WDS Release B27.8 or Later
      E350/E450 A/T California 1998-1999F8UF-AGGPTH6F8UZ-AGHPTH7WDS Release B27.8 or Later

      Obtain an Authorized Modifications Decal (FPS 8262 – obtainable through DOES II, 25/pkg) and list the date, dealer number, and summary of modifications performed. Select a prominent place adjacent to the Vehicle Emission Control Information Decal suitable for installing the Authorized Modifications Decal. Clean the area, install the decal, and cover it with a clear plastic decal shield.


      AUTHORIZED MODIFICATIONS

      THE FOLLOWING MODIFICATIONS HAVE BEEN MADE:
      Replaced or Reprogrammed Powertrain Control Module (PCM) per TSB 03-21-39.
      THESE MODIFICATIONS HAVE BEEN APPROVED, AS APPROPRIATE, BY EPA AND CARB.
      DEALER NUMBER:——————————————DATE:

      CHANGE AUTHORITY:

      FPS 8262 9/78 FORD MOTOR COMPANY PRINTED IN U.S.A.




PART NUMBERPART NAME
F81Z-9E527-EARM#8 injector (s/n 661894 – 896811)
XC3Z-9E527-AARM#8 Injector (s/n 896812 – end of 7.3L production)

OTHER APPLICABLE ARTICLES:

NONE

SUPERSEDES:

00-22-1, 01-14-6

WARRANTY STATUS:

Information Only


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.

Copyright 2003 Ford Motor Company