Specific Technical Repair Code and Parts Ordering Instructions
SAFETY RECALL 88S99TECHNICAL INSTRUCTION - MUFFLERS
Exhaust System-Ford Components-Correct Routing and Retention
1983-1985 7.5L MODELS (MODELS WITH SINGLE AIR PUMP) 1985-1/2-1987 5.8L MODELS (OVER 8500 GVW WITH 4 BARREL CARBURETOR)
FIGURE 1:
The Ford exhaust system as shown in Figure 1, provides the correct routing and exhaust gas flow capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow, and therefore, reduce engine performance or cause overheatng.
FIGURE 3:
Inspect the exhaust system for leaks or ruptures. FOR 5.8L ONLY, it may be necessary to remove the heat shields as shown in Figure 3. Inspect the muffler outer wrapper lock seam for separation. If any such problems are found, notify the customer and request permission to repair the problem, at the customer's expense. Note any such problems and the customer's reaction to your repair request on your internal repair order form and retain in your records.
If a non-Ford exhaust system or exhaust components is noted on the unit, inform the customer of the potential for durability reduction, exhaust flow restriction, or overheating as indicated above. Note any such discrepancy and the customer's reaction on your internal repair order form and retain in your records.
FIGURE 1:
ALL 5.8L AND ONLY CALIFORNIA CALIBRATION 7.5L: If the unit is not equiped with the all-steel hangers shown in Figure 1, order and install the Ford Service Part as indicated in the attached chart.
SAFETY RECALL 88S99
TECHNICAL INSTRUCTION - MUFFLERS
FIGURE 5:
1985-1/2 - 1987 7.5L MODELS (MODELS WITH DUAL AIR PUMPS - SEE FIGURE 5)
FIGURE 2:
The Ford exhaust system as shown in Figure 2, provdes the correct routing and exhaust gas flow capacity for proper heat protection and engine performance. Non-Ford mufflers and exhaust pipes could be less durable than Ford components. Some mufflers may also restrict exhaust gas flow, and therefore, reduce engine performance or cause overheating.
FIGURE 3:
FIGURE 4:
Remove the heat shields covering the muffler by removing the retaining clamps securing the shields as shown in Figure 3. If the muffler is a non-Ford design or is a non-ribbed design (Figure 4), remove the Muffler and Outlet Pipe Assembly and replace with the heavy duty ribbed muffler assembly as indicated in the attached chart.
If the muffler is the heavy duty type (ribbed design - Figure 4), installed during the 1987 M53 recall, inspect the entire surface of the muffler for cracks or openings. If any such openings are found, replace the Muffler and Outet Pips Assembly with a new heavy duty ribbed muffler assembly. Advise the Ambulance Technical Hot Line 1-800-445-1571, if you find a ribbed muffler with cracks or openings.
FIGURE 2:
If the unit is not equipped with the all-steel hangers as shown in Figure 2, order and install the Ford Service Part as indicated in the attached chart.
ATTACHMENT III EXHIBIT 1 PAGE 3 OF 3
SPECIFIC TECHNICAL REPAIR CODE AND PARTS ORDERING INSTRUCTIONS
KIT NUMBER E3UZ-18472-C HEATER HOSE/BYPASS HOSE
1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR 5.8L 4V H.D. ENGINES
SPECIAL NOTE:
The following instructions describe the installation procedure for the heater hose/bypass hose improvement package. It is designed specially for Ford E-350 and E-250 (over 8500 pounds GVWR) based ambulances. The original Ford heater hose system has probably been modified by the ambulance body builder. It is not possible to identify all the designs and modifications used by these manufacturers. If you encounter difficulties not anticipated in these instructions, contact the Ford Ambulance Recall Hotline on 1-800-445-1571. PARTS LIST
Item Description Part Number Quantity
1 Silicons Hose - 5/8" I.D. *EST-M2D309-A 96"
2 Hose Clamp 388652-S2 20
3 "Y" Fitting D8UH-18663-AA 2
4 Tie Strap - 1/4" Wide 384213-S 10
5 Radiator Cap E5TH-8100-AA 1
*Engineering Specification Number
FIGURE 1:
HEATER HOSE REMOVAL
1. Close the shutoff valves that connect the rear heater unit to the Ford installed heater hoses (See Figure 1). Be sure to close both the supply and return hose valves. Failure to close these valves could cause coolant fill problems later.
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT.
2. Drain the coolant from the radiator by removing the radiator cap and carefully opening the drain cock at the bottom of the radiator. After the coolant has drained from the radiator, close the drain cock and discard the radiator cap.
3. Disconnect and remove any objects, such as thermactor pump filter/silencer or coolant overflow bottle, obstructing access to the heater hoses.
4. Inspect the hoses for chaffing or cuts (See Figure 1). Note the position of any straps or clamps for securing the new hoses at time of installation.
5. Disconnect the vacuum line from the water supply valve.
6. Disconnect the inlet and outlet hoses from the heater core, engine block, and rear heater shutoff valves (See Figure 1). Loosen each clamp and cut the hose first to prevent core damage. DO NOT twist hoses in the removal process. Disconnect the hoses from any locating clips. Discard all hose clamps.
NOTE: DO NOT disconnect the hoses routed from the shutoff valves to the rear heater unit.
FIGURE 1:
FIGURE 2:
HEATER HOSE INSTALLATION
1. Using hoses (Item 1), hose clamps (Item 2) and "Y" fittings (Item 3), assemble duplicate hose layouts of the removed hose assemblies (Figure 1).
NOTE: The hoses leading from the "Y" fittings may have to be slightly longer than the original hoses to avoid any kinks or bends. This is due to the replacement fittings having a different angle in the "Y" than the original "Y" or "T" fittings. Silicone hoses require the special clamps Included in the kit to prevent cutting the hose. DO NOT use any other type of clamp.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 1 OF 5
on 1-800-445-1571 if you have any questions.
HEATER HOSE/BYPASS HOSE
1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR 5.8L 4V H.D. ENGINES
2. Remove the vacuum operated water supply valve from the old hose assembly and install it into the new hose assembly.
NOTE: Make sure that the flow arrow stamped on the valve is pointing toward the heater core.
3. Torque the clamps (Item 2) to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper torque. Retorquing the clamps may cut the silicone hoses.
4. Connect the hose assemblies with clamps (Item 2) to the engine block, heater core and rear shut off valves.
5. Torque the clamps to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
NOTE: DO NOT retorque the clamps if they appear to loosen after initial installation with proper torque. Retorquing the clamps may cut the silicone hoses.
6. Connect the vacuum line to the water supply valve.
7. Using tie straps (Item 4), secure the hoses to an adjacent engine component to prevent chaffing or cutting during engine operation. The hoses may be secured in a manner similar to the original method if the removed hoses were not damaged as noted earlier. If the original hoses were damaged, route the hoses and secure them in a manner to prevent hose damage during engine operation.
WATER BYPASS HOSE REMOVAL AND INSTALLATION FOR VEHICLES WITH 7.5L ENGINES
1. Remove the distributer vacuum hose to improve accessibility to the water bypass hose.
FIGURE 2:
2. Remove the water bypass hose and clamps (See Figure 2). Discard the clamps.
3. Carefully remove any hose material which may have adhered to the intake manifold or water pump connections. Clean the connections with emery cloth or a file so that no burrs or rough surfaces are evident.
CAUTION: DO NOT ALTER (CUT OFF) THE INTAKE MANIFOLD AND/OR THE WATER PUMP HOSE CONNECTIONS. ANY DAMAGE SUCH AS SHARP EDGES, TO THESE CONNECTIONS WILL RESULT IN DAMAGE TO THE NEW BYPASS HOSE DURING INSTALLATION.
4. Using the removed hose as a pattern, cut a piece of silicone hose (Item 1) to the proper length and position it on the intake manifold bypass connection.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 3 OF 5
on 1-800-445-1571 if you have any questions
FIGURE 3:
HEATER HOSE/BYPASS HOSE 1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR 5.8L 4V H.D ENGINES
5. Position two (2) new hose clamps (Item 2) on the new hose, installed in Step 4, toward the intake manifold. (See Figure 3.)
6. Bend (double over) the new bypass hose downward and slide the hose on to the water pump bypass hose connection. (See Figure 3.)
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water pump bypass hose connection.
7. Position the bypass hose clamps and torque to 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose.
FIGURE 4:
FOR VEHICLES WITH 5.8L ENGINES
1. Remove the distributor vacuum hose to improve accessibility to the water bypass hose.
2. Remove the water bypass hose and clamps (See Figure 4). Discard the clamps.
Don't forget... ATTACHMENT III
call the Special Econline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 4 OF 5
on 1-800-445-1571 if you have any questions!
HEATER HOSE/BYPASS HOSE
1983-1987 ECONOLINE BASED AMBULANCES WITH 7.5L OR 5.8L 4V H.D. ENGINES
3. Carefully remove any hose material which may have adhered to the intake manifold or water pump connections. Clean the connections with emery cloth or a file so that no burrs or rough surfaces are evident.
4. Position a new formed bypass hose (Part number E8UZ-8597-A) on the intake manifold bypass connection.
5. Position two (2) new hose clamps (Item 2) on the new hose toward the intake manifold.
6. Bend and slide the hose on to the water pump bypass hose connection.
NOTE: Avoid using any sharp edged tool/instrument to position the new bypass hose on the water pump bypass hose connection.
7. Position the bypass hose clamps and torque to:) 2.5 - 3.0 N-m (22 - 26 in.lbs.)
8. Reinstall the distributor vacuum hose, PRESSURE TEST COOLING SYSTEM
1. Reinstall all of the objects such as the thermactor pump filter/silencer or coolant overflow bottle, that obstructed access to the heater hoses.
2. Fill the cooling system with a coolant mixture of 50/50 Ford Long Life Coolant E2FZ-19549-AA (ESE-M97B44-A) or equivalent and water, to 38 mm (1.5 inches) below the cap seal.
3. Install radiator cap (Item 5)
WARNING: DO NOT STAND IN LINE WITH OR NEAR THE RADIATOR FAN WHEN THE ENGINE IS RUNNING.
4. Start the engine, let it warm until the upper radiator hose is hot, shut off the engine. Allow the engine to cool, remove the cap and check the coolant level. Fill as required.
WARNING: NEVER REMOVE THE RADIATOR CAP UNDER ANY CONDITIONS WHILE THE ENGINE IS OPERATING. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO THE COOLING SYSTEM OR ENGINE AND/OR PERSONAL INJURY. TO AVOID HAVING SCALDING HOT COOLANT OR STEAM BLOW OUT OF THE RADIATOR, USE EXTREME CARE WHEN REMOVING THE CAP FROM A HOT RADIATOR. WAIT UNTIL THE ENGINE HAS COOLED, THEN WRAP A THICK CLOTH AROUND THE RADIATOR CAP AND TURN IT SLOWLY TO THE FIRST STOP. STEP BACK WHILE THE PRESSURE IS RELEASED FROM THE COOLING SYSTEM. WHEN YOU ARE SURE ALL THE PRESSURE HAS BEEN RELEASED, PRESS DOWN ON THE CAP (STILL WITH A CLOTH), TURN AND REMOVE IT
5. Using the Rotunda Cooling System Pressurization Kit 021-00012, pressurize the cooling system to 20 psi and check for leaks. Be sure to follow the instructions in the kit on the recommmended method of connecting the tester to the radiator.
6. If any leaks are found, correct as needed.
7. Pressure test the cooling system until no leaks we found.
8. Rechock the coolant level in the radiator to make sure that it is 38 mm (1.5 inches ) below the cap seal. If it is not, fill as required.
9. Reinstall the radiator cap and add coolant to the overflow bottle as required.
Don't forget... ATTACHMENT III
call the Special Econoline/Ambulance M53/S38 EXHIBIT 2
Technical Hotline PAGE 5 OF 5
on 1-800-445-1571 if you have any questions!