Engine - Runs Rough/Miss/Stumble at 1500 - 4000 RPM
TSB 08-8-304/28/08
6.0L VEHICLES BUILT 11/1/2007 - 1/15/2008 - RUNS
ROUGH, MISS, STUMBLE/FLUTTER BETWEEN
1500-4000 RPM - BROKEN CRANKCASE-TO-HEAD
TUBES
FORD:
2008 E-350, E-450
ISSUE
Some 2008 E-Series 6.0L vehicles built from 11/1/2007 through 1/15/2008 may exhibit an engine condition of runs rough, miss, stumble or flutter between 1500 to 4000 RPM due to broken crankcase-to-head tubes.
ACTION
Follow the Service Procedure steps to correct the condition.
SERVICE PROCEDURE
Verify Condition
1. With the engine at normal operating temperature, idle engine for 5 minutes.
2. Increase RPM slowly until wide-open-throttle is reached, release throttle and let the engine return to idle.
3. Check for any engine miss, stumble or flutter while holding engine RPM between 1500 and 4000 RPM.
4. If any miss, stumble or flutter is verified using the above procedure, replace both crankcase-to-head (Stand Pipes) tubes using the procedure below.
Crankcase To Cylinder Head Tubes (Stand Pipes) Replacement
1. Remove right hand (RH) and left hand (LH) valve covers. Refer to Workshop Manual (WSM), Section 303-01C.
2. Loosen the RH crankcase-to-head tube. (Figure 1)
3. Position the crankcase-to-head tube, separate the tube and allow the lower section to go back down. (Figure 2)
NOTE
DO NOT REMOVE THE OIL RAIL END PLUGS OR ACOUSTIC WAVE ATTENUATOR PORT FITTING. SERVICE PARTS ARE NOT AVAILABLE TO SUPPORT THESE COMPONENTS.
4. Remove the bolts and the RH high-pressure oil rail. (Figure 3)
NOTE
USE A SHOP TOWEL AND METAL BRAKE PARTS CLEANER TO REMOVE THE OIL RESIDUE PRIOR TO REMOVING THE CRANKCASE-TO-HEAD TUBE USING THE SPECIAL TOOL 303-1164.
NOTE
IF THE STAND PIPE IS BROKEN THE SPECIAL TOOL WILL NOT WORK. THE LOWER SECTION OF THE STAND PIPE WILL HAVE TO BE REMOVED USING CHANNEL LOCKS OR EQUIVALENT.
5. Remove the lower crankcase to head tube.
NOTE
APPLY CLEAN ENGINE OIL TO THE CRANKCASE TO HEAD TUBE D-RING SEALS, PRIOR TO INSTALLING.
6. Separate the new crankcase to head tube and position the lower section of the crankcase to head tube in the engine
CAUTION
USING THE BOLTS TO PUSH THE HIGH PRESSURE OIL RAIL INTO THE FUEL INJECTORS CAN DAMAGE THE FUEL INJECTORS AND HIGH PRESSURE OIL RAIL(S).
7. Position the high-pressure oil rail(s) on the injectors.
a. Place the high-pressure oil rail(s) on top of the carrier so that the four (4) single ball tubes are engaging the fuel injector lead angle.
b. Insert three (3) guide bolts, two (2) on the ends of the straight side of the high-pressure oil rail and one (1) in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 turns.
c. Manually press the high-pressure oil rail into the fuel injectors.
d. Inspect that the high-pressure oil rail mounting feet are flat against the mounting sur[ace.
e. Loosely install the six (6) bolts. (Figure 3)
8. Remove the three (3) guide bolts, install the remaining bolts and tighten the nine (9) bolts in the sequence shown. Tighten to 10 lb-ft (13 N.m). (Figure 4)
9. Apply clean engine oil and reassemble the crankcase-to-head tube. Install the upper crankcase-to-head tube. Tighten to 60 lb-ft (82 N.m).
10. Repeat the crankcase to cylinder head tube procedure on the left bank of the engine.
11. Install RH and LH Valve Covers Refer to WSM, Section 303-01C.
Parts Block
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.
OPERATION DESCRIPTION TIME
080803A 2008 Econoline 350/450 6.9 Hrs.
6.0L Built From 11/1/2007
to 1/15/2008: Replace Both
Crankcase-To-Head Tubes
(Stand Pipes), Includes
Time To Perform
Diagnosis In This Article
(Do Not Use With 9332A,
6584A, 8616A, 8620F,
8005A)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9A332 01
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