Fulltext TSBs

Technical Service Bulletins

TSB
10-23-6
  • 6.4L ENGINE – LACKS POWER, MIL ON WITH DTCS P20E2, P20E3, P20E4, P2080, P2084, P242B, P0544, P2031, P242A, OR P200E
Publication Date: November 22, 2010

FORD:
2008-2010 F-250, F-350, F-450, F-550

ISSUE:

Some 2008-2010 F-Super Duty vehicles equipped with a 6.4L diesel engine may exhibit a lack of power, malfunction indicator lamp (MIL) on with diagnostic trouble codes (DTCs) P20E2, P20E3, P20E4, P2080, P2084, P242B, P0544, P02031, P242A, or P200E.

ACTION:

Follow the Service Procedure to correct the condition.

SERVICE PROCEDURE

If any exhaust gas temperature (EGT) sensor connector has been disconnected during testing, with the ignition on and the engine off:

  • Reconnect the EGT sensor.
  • Turn the ignition Off for 30 seconds before attempting to start the vehicle. Do not crank or start the engine until the ignition has been turned off for a minimum of 30 seconds.

Failure to follow this procedure may result in a 60 minute no crank, no start condition as a result of the failure mode effects management (FMEM) programmed into the powertrain control module (PCM).

  1. Turn key off.
    1. Access 34-pin connector, C110, located on the driver's side frame inside the engine compartment just below and to the left of the brake fluid reservoir. For identification purposes, C110 contains two (2) 10-gauge wires, one red and one brown/red.
    2. Disconnect connector C110, and inspect pins on both sides of the connector for debris.
    3. Using contact cleaner, CRC QD™Electronic Cleaner or Permatex® Electrical Contact Cleaner and a cleaning brush, clean pins on both sides of C110 connector.
    4. Apply a liberal amount of Motorcraft® Electrical Grease to the male pins of connector C110 and reconnect connector.
    5. Proceed to Step 2.
  2. Identify suspect EGT sensor based on DTC. Make sure the key is in the off position. Remove the EGT sensor connector from the frame rail, remove the mounting tab from the connector assembly. (Figures 1)


    Figure 1 – Article 10-23-6

  3. Disconnect the EGT sensor connector and inspect both component and harness side pins for debris.
  4. Use CRC QD™Electronic Cleaner or Permatex® Electrical Contact Cleaner and a cleaning brush to clean the EGT connector pins on both component and harness side. (Figure 2)


    Figure 2 – Article 10-23-6

  5. Apply a liberal amount of Motorcraft® Electrical Grease to the EGT component male connector pins. (Figure 2).
  6. Slide the shrink tubing over the EGT connector/harness. Reconnect the EGT. Center the shrink tubing on the EGT/harness connector assembly. Shrink the tubing using a heat gun. (Figure 3)


    Figure 3 – Article 10-23-6

  7. Using two (2) tie wraps, secure the EGT connector assembly to the main harness. (Figure 4)


    Figure 4 – Article 10-23-6


PART NUMBERPART NAME
XG-12Motorcraft® Electrical Grease
8C3Z-5J213-DSensor – Exhaust Gas
8C3Z-19H285-AShrink Tubing

WARRANTY STATUS:

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

OPERATIONDESCRIPTIONTIME
102306A2008-2010 F-Super Duty 6.4L: Clean And Reseal Electrical Connectors Following Service Procedure (Do Not Use With Any Other Labor Operations)1.0 Hr.

DEALER CODING

BASIC PART NO.CONDITION CODE
5J21342

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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