1983-1987 Ford Bronco II Service & Repair Manual

Ford Pick-ups & Bronco Automotive Repair Manual by Mark Christman, John B Raffa and John H Haynes Member of the Guild of Motoring Writers Models covered: F-100, F-150, F-250, F-350 and Bronco with 300 cu in (4.9L) inline six-cylinder, 232 cu in V6, and 255, 302 (5.0L), 351 (5.8L), 400 and 460 cu in (7.5L) V8 engines. Manual and automatic transmissions. Two-wheel drive and four-wheel drive. 1980 thru 1995 Does not include diesel engine or Super Duty vehicles (4X1 - 880) AIICOE FGHU KlMNO P Haynes Publishing Group Sparkford Nr Yeovil Somerset BA22 7JJ England Haynes North America, Inc 861 Lawrence Drive Newbury Park California 91320 USA ... (

Acknowledgements We are grateful to the Champion Spark Plug Company, who supplied the illustrations of various spark plug conditions, and to the Ford Motor Company for their assistance with technical information and certain Illustrations. Wiring diagrams were pro- vided by Mitchell International. © Haynes North America, Inc. 1995 With pet1TIlssJon from J.H. Haynes & Co. ltd. A book in the Haynes Au1omotive Repair Manual Series Printed in the U.S.A. All rights reserved. No part of this book may be reproduced or transmitted in any form or by any means, electronic or mechanical. includ- ing photocopying. recording or by any information stotage or retrieval system. without permission in writing from the copyright holder. ISBN 1 56392 152 9 Ubrary of Congress Catalog Card Number 95-076872 While every attempt is made to ensure that the information in this manual IS correct. no liability can be accepted by the authors or publishers . for loss, damage or injury caused by any errors In. or omissions from. the information given. .. 94-416

Contents Introductory pages About this manual 0-5 Introduction to the Ford Pick-ups and Bronco 0-5 Vehicle Identification numbers 0-6 Buying parts O-S Maintenance techniques, tools and working facilities o-s Jacking and towing 0-15 Booster battery Oump) starting 0-17 Automotive chemicals and lubricants 0-1S Safety firstl 0-19 Conversion factors 0-20 Troubleshooting 0-21 Chapter 1 Tune-up and rcutlne maintenance 1-1 Chapter 2 Part A Inllne six-cylinder engine 2A-1 Chapter 2 PartB 28 vs engines 28-1 Chapter 2 PartC V6 engine 2C-1 Chapter 2 PartD General engine overhaul procedures 20-1 Chapter 3 Cooling, heating and air conditioning systems 3-1 Chapter 4 Fuel and exhaust systems 4-1 Chapter 5 Engine electrical systems 5-1 Chapter 6 EmiSSions control systems 6-1 Chapter 7 Part A Manual transmission 7A-1 Chapter 7 Part B 78 Automatic transmission 78-1 Chapter 7 PartC 7C Transfer case 7C-1 Chapter 8 8 Clutch and driveline 8-1 Chapter 9 9 Brakes 9-1 Chapter 10 10 Suspension and steering systems 10-1 Chapter 11 11 Body 11-1 Chapter 12 12 Chassis electrical system 12-1 Wiring diagrams 12-22 Index IND-1 IND

0-4 ... Haynes mechanic, author and photographer wHh Ford F250 pick-up

About this manual 0-5 Its purpose The purpose of this manual is to help you get the best value from your vehicle. It can do so in several ways. It can help you decide what work must be done, even if you choose to have it done by a dealer service department or a repair shop; It provides information and procedures for routine maintenance and servicing; and it offers diagnostic and repair procedures to follow when trouble occurs. We hope you use the manual to tackle the work yourself. For many simpler jobs, doing it yourself may be quicker than arranging an appointment to get the vehicle into a shop and making the trips to leave it and pick it up. More importantly, a lot of money can be saved by avoiding the expense the shop must pass on to you to cover its la- bor and overhead costs. An added benefit Is the sense of satisfaction and accomplishment that you feel after doing the job yourself. Using the manual The manual Is divided into Chapters. Each Chapter is divided Into numbered Sections, which are headed in bold type between horizontal lines. Each Section consists of consecutively numbered paragraphs. At the beginning of each numbered Section you will be referred to any illustrations which apply to the procedures in that Section. The reference numbers used In Illustration captions pInpoint the pertinent Section and the Step within that Section. That is, illustration 3.2 means the Illustration refers to Section 3 and Step (or paragraph) 2 within that Section. Procedures, once described in the text, are not normally re- peated. When it's necessary to refer to another Chapter, the reference will be given as Chapter and Section number. Cross references given without use of the word ·Chapter" apply to Sections and/or paragraphs in the same Chapter. For example, ·see Section a" means in the same Chapter. References to the left or right side of the vehicle assume you are Sitting in the driver's seat, facing forward. Even though we have prepared this manual with extreme care, neither the publisher nor the author can accept responsibility for any errors in, or omissions from, the information given. NOTE A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand. CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Cau- tion is found. Not heeding a Caution can result in damage to the assembly being worked on. WARNING A Warning provides a special procedure or special steps which must be taken while completing the procedure where the Wamlng is found. Not heeding a Warning can result in personal injury. Introduction to the Ford F-series and Bronco The F-series and Bronco models are conventional front-engine, rear-wheel drive vehicles. Over the years of production covered by this manual, engine op- tions include the 300 cu. in. (4.9L) inline six-cylinder engine, the 232 cu. In. V6 engine and the 255 cu. in., 302 cu. in. (5.0l), 351 cu. in. ts.eu 400 and 460 (7.SL)va engines. Power is transmitted through either manual or automatic transmission to a driveshaft and solid rear aXle on two-wheel drive (2WD) models. On four-wheel drive (4WD) models, a transfer case transfers power to the front axle by way of a driveshaft. Transmissions used include a four-speed manual, two different five-speed overdrive manuals, a three-speed automatic and two different four-speed overdrive automatics. Three different transfer cases are available - two manual shift and one electronic shift. All 2WD models use twin l-beam independent front suspension with coil springs and radius arms. 4WD models (except F3S0) use a similar independent front suspension with a two-piece front driveaxle assembly, coil springs and radius arms (except F250). F250 4WD models use leaf springs instead of coil springs on its independent front suspension. F350 4WD models use a solid front axle and leaf springs, All models use semi-elliptlcalleaf springs at the rear. All models are equipped with front disc and rear drum brakes. ---

0-6 J r Vehicle identification numbers The Vehicle Identification Number (VIN) is visible through the driver's side of the windshield Modifications are a continuing and unpubllclzed process in vehi- de manufacturing. Since spare parts lists and manuals are complied on a numerical basis, ihe Individual vehicle numbers are necessary to correctly identify the component required. Vehicle Identification Number (VIN) This very Important identification number is stamped on a plate attached to the dashboard Inside the windshield on the driver's side of , the vehicle (see illustrations). The VIN also appears on the Vehicle Certificate of Title and Registration. It contains Information such as where and when the vehicle was manufactured. the model year and the body style. Vehicle Certification Label The Vehicle Certlf1cation Label Is attached to the driver's side door pillar (see illustration), Information on this label includes the SAMPLE VIN NUMBER 1 FTC '--.,.,-' I 1 2 R10 A '-.,.-' I 3 4 1 Position 1, 2, and 3- Manufacturer, Make and Type (World Manufacturer Identifier) 2 Positlon.4- BrakeSystemtGVWR 3 Position 5, 6, and 7- Model or Line, Series, Chassis, Cab Type 4 Position 8 - engine Type 5 Position 9 - Check Digit 5 J U A 0 0 0 0 1 I I I 1-------- 5 6 7 8 9 6 Position 10 - Model Year 7 Position 11 - Assembly Plant 8 Position 12 - Constant "A" until sequence number of 99.999 is reached, then changes to Ii constant "S" and so on 9 Position 13 through 17 - Sequence number - begins al 00001 Vehicle Identification Number details

Vehicle identification numbers 0-7 >--... DAll:: 2Ja3 GVWIl: IlOO ...,.,. KG ,,-_~FRONT GAWR: 3320L8 REAR~A.'WR~:~4004~~L8~:::====~:j-~~ '508KG WITH 18161<G ..:. l--.LT 21MIeA ieo TIRES LT 216186R 180 ,--_~1e)( 8K RIMS 18)( 8K AT 51 PSI COLD AT 68 PSI COLD--------I~--('I THIS VEHICLE CONFORMS TO ALL APPLICABLE FEDERAL MOTOR VEHICLE SAFETY STANDARDS IN EFfECT ON THE DATE OF MANUFACTURE SHOWN ABOVE YIN: 1f"I'EJI2IHIPLA TYPE: TRUCK 7~~ w (t, (~ eJ) ~, lFl (GI (HI II111111111111 111I !---t-~ 050 ...,. BY FORD MOTOR CO. IN U.s.A. 7N 1M SPRING 2 D 2 8 WeB)eC)(D) The Certification label is located on the left front door post 1 Name and location of manufacture 2 Date of manufacture 3 Front Gross Axle Weight Rating in pounds (LB) and kilograms (KG) 4 Front tire size 5 Front rim size 6 Front tire cold psi 7 Gross Vehicle Weight Rating in pounds (LB) and kilograms (KG) 8 Rear Gross Axle WeIght Rating in pounds (LB) and kilograms (KG) 9 Rear tire siZe 10 Rear rim size 11 Rear tire cold psi 12 Vehicle Identification Number (VIN) A World manufacturer Identifier B Brake type and Gross Vehicle Weight Rating (GVWR) class C Model or line, series chassis cab or body type D Engine type E Check digit . F Modelyear G Assembly plant code H Sequential serial number 13 Type vehicle 14 Exterior paint codes (two sets of figures designates a two-tone) 15 Wheelbase in inches 16 Model code and GVW 17 Interior trim, seat and body/cab type 18 Transmission code 19 Rear axle code 20 Front axle code (If so equipped) 21 District/special order codes 22 External body type stripe code 23 Suspension identification codes A Auxiliary/option usage code (front) B Front spring code CA auxiliary/optIon usage code (rear) D Rear spring code 24 Front axle accessory reserve capacHy in pounds 25 Total accessory reserve capacHy in pounds Engine Identification label name ot the manufacturer, the month and year of production, the Gross Vehicle Weight Rating (GVWR), the Gross Axle Weight Rating (GAWR) and other vehicle specific Information. Some of the information Is in the form of codes, requiring a conversion chart to obtain the desired Information. Included are the conversions forthe rear axle ratio and transmission type codes (see Illustrations). Engine number The engine number is stamped onto a machined pad on the external surface of the engine block. There's also an identification label that's usuaJly on the valve cover (see illustration). The engine identification label can usually be found on the valve cover

0-8 Buying parts Replacement parts are available from many sources, which generally fall Into one of two categories - authorized dealer parts depart- ments and independent retail auto parts stores. Our advice conceming these parts is as follows: Retail auto parts stores: Good auto parts stores will stock fre- quently needed components which wear out relatively fast, such as clutch components, exhaust systems, brake parts, tune-up parts, etc. These stores often supply new or reconditioned parts on an exchange basis, which can save a considerable amount of money. Discount auto parts stores are often very good places to buy materials and parts needed for general vehicle maintenance such as oil, grease, filters, spark plugs, belts, touch-up paint, bulbs, etc. They also usually sell tools and general accessories, have convenient hours, charge lower prices and can often be found not far from home. Authorized dealer parts department: This is the best source for parts which are unique to the vehicle and not generally available elsewhere (such as major engine parts, transmission parts, trim pieces, etc.). Warranty intormstion: If the vehicle is still covered under warranty, be sure that any replacement parts purchased - regardless of the source - do not invalidate the warranty! To be sure of obtaining the correct parts, have engine and chassis numbers available and, if possible, take the old parts along for positive Identification. used once. If they are removed, they lose their locking ability and must be replaced with new ones. Rusted nuts and bolts should be treated with a penetrating fluid to ease removal and prevent breakage. Some mechanics use turpen- tine In a spout-type oil can, which works quite well. After applying the rust penetrant, let it work for a few minutes before trying to loosen the nut or bolt. Badly rusted fasteners may have to be chiseled or sawed off or removed with a special nut breaker, available at tool stores. If a bolt or stud breaks off in an assembly, it can be drilled and removed with a special tool commonly available for this purpose. Most automotive machine shops can perform this task, as well as other repair procedures, such as the repair of threaded holes that have been stripped out. Flat washers and lockwashers, when removed from an assembly, should always be replaced exactly as removed. Replace any damaged washers with new ones. Never use a lockwasher on any soft metal surface (such as aluminum), thin sheet metal or plastlc, Maintenance techniques, tools and working facilities Maintenance techniques There are a number of techniques Involved In maintenance and repair that wlll'be referred to throughout this manual. Application of these techniques will enable the home mechanic to be more efficient, better organized and capable of performing the various tasks properly, which will ensure that the repair job is thorough and complete. Fasteners Fasteners are nuts, bolts, studs and screws used to hold two or more parts together. There are a few things to keep in mind when working with fasteners. Almost all of them use a locking device of some type, either a lockwasher, locknut, locklng tab or thread adhe- sive. All threaded fasteners should be clean and straight, with undamaged threads and undamaged corners on the hex head where the wrench fits. Develop the habit of replacing all damaged nuts and bolts with new ones. Special locknuts with nylon or fiber Inserts can only be

Maintenance techniques, tools and working facilities 0-9 Fastener sizes For a number of reasons, automobile manufacturers are making wider and wider use of metric fasteners. Therefore, it is important to be able to tell the difference between standard (sometimes called U.S. or SAE) and metric hardware, since they cannot be interchanged. All bolts, Whether standard or metric, are sized according to diameter, thread pitch and length. For example, a standard 1/2 - 13 x 1 bolt is 112 inch in diameter, has 13 threads per inch and is 1 Inch long. An M12 - 1.75 x 25 metric bolt Is 12 mm In diameter, has a thread pitch of 1.75 mm (the distance between threads) and is 25 mm long. The two bolts are nearly identical, and easily confused, but they are not Inter- changeable. In addition to the differences 1n diameter, thread pitch and length, metric and standard bolts can also be distinguished by examining the bolt heads. To begin with, the distance across the flats on a standard bolt head Is measured in Inches, while the same dimension on a' metric bolt Is sized in millimeters (the same is true for nuts). As a result, a standard wrench should not be used on a metric bolt and a metric wrench should not be used on a standard bolt. Also, most standard bolts have slashes radiating out from the center of the head to denote the grade or strength of the bolt, which is an indication of the amount of torque that can be applied to It. The greater the number of slashes, the greater the strength of the bolt. Grades 0 through 5 are commonly used on a'Utomobiles. Metric bolts have a property class (grade) number, rather than a slash, molded into their heads to indicate bolt strength. In this case, the higher the number, the stronger the bolt. Property class numbers 8.8, 9,8 and 10.9 are commonly used on auto- mobiles. Strength markings can also be used to distinguish standard hex nuts from metric hex nuts. Many standard nuts have dots stamped into one side, while metric nuts are marked with a number. The greater the number of dots, or the higher the number, the greater the strength of the nut. Metric studs are also marked on their ends according to property class (grade). Larger studs are numbered (the same as metric bolts), while smaller studs carry a geometriC code to denote grade. Grade 1 or 2 Grade 5 Grade 8 Bolt strength markings (top· standard/SAElUSS; bottom - metric) Grade Identification Class Identification \ @ Hex Nut @ -- -- Hex Nut Property Grade 5 Class 9 3 Dots Arabic 9 Hex Nut @ Hex Nut @ © c±) @ Property Grade 8 Class 10 • CLASS CLASS CLASS 6 Dots Arabic 10 10.9 9.B B.B . Standard hex nut strength markings Metric hex nut strength MetriG stud length markings markings

0-10 Maintenance techniques, tools and working facilities It should be noted that many fasteners, especially Grades 0 through 2, have no distinguishing marks on them. When such is the case, the only way to determine whether it Is standard or metric is to measure the thread pitch or compare it to a known fastener of the same size.1993 Standard fasteners are often referred to as SAE, as opposed to metric. However, it should be noted that SAE technically refers to a non-metric fine thread fastener only. Coarse thread non-metric fasteners are referred to as USS sizes. Since fasteners of the same size (both standard and metric) may have different strength ratings, be sure to reinstall any bolts, studs or nuts removed from your vehicle in their original locations. Also, when replacing a fastener with a new one, make sure that the new one has a strength rating equal to or greater than the original. Tightening sequences and procedures Most threaded fasteners should be tightened to a specific torque value (torque Is the twisting force applied to a threaded component such as a nut or bolt). Overtightening the fastener can weaken it and cause i1 to break, while undertightening can cause It to eventually come loose. Bolts, screws and studs, depending on the material they are made of and their thread diameters, have specific torque values, many of which are noted in the Specifications at the beginning of each Chapter. Be sure to follow the torque recommendations closely. For fasteners not assigned a specific torque, a general torque value chart is presented here as a guide. These torque values are for dry (unlubrl- cated) fasteners threaded into steel or cast iron (not aluminum). As was previously mentioned, the size and grade of a fastener determine the amount of torque that can safely be applied to it. The figures listed Metric thread sizes Ft-Ibs M-6 6109 M-8 141021 M-10 28 to 40 M-12 SOt071 M-14 80 to 140 Pipe thread sizes 1/8 5108 1/4 121018 3/8 22 to 33 1/2 25 to 35 U.S. thread sizes 1/4 - 20 6 to 9 5/16 -18 12 to 18 5116 - 24 14 to 20 3/8 - 16 221032 3/8 - 24............................................................... 27 to 38 7/16 -14 : 40 to 55 7/16 - 20 40 to 60 112 - 13 55 to 80 Nm 9 to 12 19 to 28 38 to 54 68 to 96 109 to 154 7to 10 17 to 24 30 to 44 34 to 47 9 to 12 17 10 24 19 to 27 301043 37 to 51 55 to 74 55 to 81 75 to 108 T G- ~I"" I I' }- il II 1\ 'L\ \\\ ~\I\ ~ t .\ It tl 1.1 ~ .. I L Standard (SAE and USS) bolt dimensions/grade marks G Grade marks (bolt length) L Length (in inches) T Thread pitch (number of threads per inch) o Nominal diameter (in inches) ~ ... T--II~ .... )- l\ .1 I I l\'\ l\ 1\ ~ ~ .1 1 til I\I~ '--''''I L~ p_. Metric bolt dimensions/grade marks P Property class (bolt strength) L Length (in millimeters) T Thread pitch (distance between threads in millimeters) o ~iameter

1983-1987 Ford Bronco II Service & Repair Manual

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