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2004 XLT 4.0 SOHC, 185K. A/C works fine, all settings, but lately cuts out when more power is demanded, like climbing a highway incline. When this occurs, blower motor is heard to continue running, but little or no air is discharged from dash vents. Upon backing off throttle demand, normal A/C...

It has always been emphasized by Dana Spicer Engineering that they like to see about 2 degrees of misalignment between connections to a Cardan (Universal Joint): This allows for equalization of wear in the parts, promoting long life. This angle varies in vehicles continuously with suspensions...

Anyone willing to take a crack at this? I've been trying to imagine why, in this age of OHC engines, anyone would offer an interference engine? Obviously, both types exist. I picture the valves, 2 of them by example, "using" up a certain amount of combustion chamber volume, into which no piston...

2004 Ex, 4.0L SOHC. Hassling with CEL over a year. P0054 O2 Heater Resistance Bank 1 Pos 2; P0060 O2 Heater Resistance Bank 2 Pos 2. Naively, my first work involved checking the heater resistance in 1, 2 since the other code had not yet appeared. It was well within range. I went the whole 9...

Compression Ratio is defined as the ratio of combustion chamber volume to the SUM of C.C. volume + the swept cylinder volume. Here's my problem: Guy has a 4.6, stock bore and stroke, 43cc combustion chamber volume. 4.6 is 4600cc, take 1 cylinder, 4600/8 = 575cc swept volume. C.R. works out to...

Does anyone know the typical after-use thickness of a crush sleeve? Maybe have one laying around, throw a mic or calipers on it? This information would help us a lot. Thanks! imp

I always figured when an automatic did some real unusual things, it was either low on fluid, or something had failed, never to work properly again until repaired. 1990 F-150, 351W, E4OD trans. Shows 62K, Contractor's truck, bought from him, original owner, likely 162K, can't tell. Last week...

Here per @gmanpaint . I probably have learned more about Ford's 9-inch axle than anything else they built. Everyone seems to like them, myself included. Might say I "cut my teeth" learning by doing on cars, about when Ford introduced it's now-famous 9-inch, with 9" ring gear, though they built...

Would it be allowable or advisable (maybe needed by some) to start a thread in which I explain the Ford 9-inch axle? I'd bet somebody uses it in a racing Ex. Where would I post it? imp

2004 Explorer, 4.0 SOHC 4X4, lately a "one-key" wonder. Been studying the Ford Wiring Diagrams diligently for a few days now, trying to see deeper into their scheme of disabling the vehicle. Much of this has been hashed & rehashed nearly to death. But I think I spotted something significant. Ya...

Do not think this has been discussed. If it has, point me there! Otherwise: Somewhere in my recent past work, I encountered information stating that beginning in 2009 all new vehicles sold must have the provision of storing certain codes which cannot be erased by usual means. Those "permanent"...

Around 1990, earlier maybe, Ford went to new style starter with planetary gearing, smaller diameter, and I believe the motor or output shaft was offset from center. Does anyone know if the old style, bigger OD starter will work in place of the newer design? Thanks! imp

Symptoms: Not an Explorer, yes. .94 Mustang GT 5.0 HO. Lately, sluggish acceleration at mid-range ~ 2000 rpm, 2nd, 3rd gears, with half-throttle, given more, sudden surge of power. Idles fine. Starts fine. So far: Replaced fuel filter first, after checking fuel pressure, which was OK at idle...

What if a guy wanted to be rid of all the excessive controlling factors 3rd. gens introduce, like ABS able to disable, PCM, too, why could he not institute an early 1st. gen. operating system? Biggest problem I see is the microprocessor dash: could an early Ex gauge panel be cobbled to mount in...

55 mph, in 5th. gear, TCC engaged, tach rock-steady. At cruise, feels like driving on a road having light rills, like a washboard. Very light added throttle worsens feeling. First thought, slipping TCC; tach would show that. Depress O/D OFF, goes down into 4th. gear smoothly, everything...

OK, I admit it. Replaced water pump after now and then puddle of coolant under engine. Only occasionally, added water once in a month's time, down ~ a quart. Could not detect any wetness above pump, looking at possibility of cracked thermostat housing (plastic, I've heard they crack). Pump...

Even though I had already done very extensive automotive work by then in Chicago, I started hearing some things different from what I had experienced before, after I took over Dealership of an ARCO station in Las Vegas. One thing I noticed was that cooling systems seemed to react a bit...

'94 5.0L HO engine, occasionally suddenly fails to return to idle, plenty of power, hunts up and down, 1200 down to 500, several times, then dies. Throttle raises speed instantly, off throttle problem returns. Have a brand new 5.0 in a corner of my shop, put it's Throttle Body complete, TPS and...

The engine below is a Caterpillar Diesel, Double-Overhead Camshaft experimental engine (back then, about 1967), which we had lent to us at Victor Manufacturing & Gasket Co., set up on one of our dynamometers. Cat was developing the engine as a possible entry into the long-haul trucking scene...

Yeah, not an Explorer, but also drive one, so why not ask for help? '94 Mustang GT I bought recently has window tint all scruffed from rubbing the inside rubber gasket. Just got back from O'Reilly Auto Parts, where a bewildering number of tints was available. Store Mgr. little help, said they...

My recently bought '94 vehicle (5.0L HO) has had it's smog pump bypassed using a shorter drive belt. The air diverter valve has been removed, but both check valves are still present. My question is, aside from emissions violation (no test or inspection in my location), how would operation...

My '94 EEC-IV car has two cables operating the Throttle Plate. One is obviously the Speed Control. I got to thinking, how is the Speed Control used in conjunction with "Drive By Wire"? A signal must be generated and it takes over control of the Throttle Body Drive Motor. Anyone "into" this at...

What year did the chip key enter service? I owned a '96 Ex, and do not think it had that feature yet. My '99 later, I can't be sure at all. My understanding is that, several different "disable" schemes were used, such as "crank engine, but disable injectors". Several of those were patently...

How does one know the cats are causing DTCs? At my wit's end, recurring code "HO2S Heater Resistance Bank 1 Position 2". Everything possible has been done to eliminate the O2 sensor as the cause, including completely re-wiring it after replacing all 4 sensors. Heater Resistance checks out just...

OK, not an Ex, but still, a 5.0L. Recently bought '94 Mustang GT w/5.0L, pulled out a plug today, condition OK, but was the cheapest bottom of the line Autolite, #25, Copper (supposedly, do not understand the relation to "copper". Researched RockAuto for plugs. They list a bunch, for EITHER VIN...

Unresolved P0054 "HO2S Heater Resistance Bank 1 Pos 2" has driven us to this, today...... Good old EEC-IV, simpler electronics, less finicky ABS, workhorse 5.0L HO with 5-speed, 161,000 miles, original paint, near immaculate appearance, acceptable gray leather, very little modified...

My '96 showed unusual signs coasting down a long grade on the way to town, a distance of 25 mi. Off gas pedal, RPMs dropped as expected, about 50-55 MPH, to around 1000, then bumped up a bit, then down again, this repeating several times before the creek crossing at the bottom. Then things got...

Building my '79 Ranchero, using ex-police car 5.0L HO and AOD, I swung the engine and transmission in and out while assembled together. Involved having front of vehicle quite high off ground, and lowering them in/out at a steep angle, ~ 45 degrees. Having to get appropriate mount brackets and...

PCM suspected, I ordered a new one, which came with 2 "pre-programmed" (PATS) keys. Had teeth cut by locksmith duplicating my oiriginal keys. Installed replacement PCM, inserted key, PATS indicator winked properly, started engine. Other key won't start engine. The explanation which came with the...

Not sure where to OP this. In 1996, having owned two 5.0 Mustangs, an '89 and '90, then putting a Whipplecharger on the '89, I was hooked! Always loved the old Bronco originals, picked up a '70 derelict, an ad from a Ford Parts guy who bought at auction through his dealership, '91 wrecked Police...

2004 4.0L 4X4. Bought with 92K, on general principles, replaced rear U-Joints, front "front" U-Joint, but left C-V at Transfer Case alone. The funky Torx bolts up front, crummy bolts at C-V, replaced with Allen bolts. The C-V worries me. What kind of life can be expected out of one of these...

Back when I learned about lead-acid batteries, talk was about a "sulphated" battery, highly discharged, and how to go about bringing it back. My old F-700, sitting for 4 years, last started up about a year ago, 1998 model, EFI, PCM drained battery to dead. Yanked it out today, wanna sell the...

Would anyone be good enough to "school" this old guy more on how to get & use Forscan to manipulate non-working keys? History: DTCs pointed to bad PCM, bought a rebuild, came with two keys. Installed PCM, started engine fine with one key, other did not work. Failed to follow written...

Has anyone converted a 4.0L OHC install in a Gen 3 using EEC-IV? I am seriously considering it. Lots of potential pitfalls to work around, though. Sick and tired of chasing nebulous CELs, originating from no findable cause. imp

2004 Explorer, using 2004 Ford Wiring diagrams, I'm finding incorrect color codes in places where no man other than the factory could have gone. I have the Battery Junction Box lifted out and turned sideways, cover removed, viewing fuse connections from under them. Problem is a nasty recurring...

What provision is in place, if any, to prevent the electronic clutch from engaging due to a faulty Wheel Speed Sensor? My '04 did this today twice, always shortly after starting up. First time, moving very slowly, the vehicle stopped abruptly as though a wheel ran into something, produced a...

Left front grumbled for ~ 6 mo., getting worse, so opened 'er up. Ordered hub & brng. assy. yesterday noon, paid 10 cents over "3 to 5" days for "1 to 3". Expected del'y. said Tuesday after the holiday. 10:30 this morning, it's here! O'reilly price on-line $217! RockAuto had a bunch, up to $166...

2004 Ex 4.0L, 154K miles. The heater is contained in the sensor, and is powered directly by 12 volts. That much I can see from the Ford wiring diagrams. The heater is turned on and off by the PCM, which closes and completes the ground circuit to the heater. Power to the heater is supplied by a...

Are they based on a Dana Spicer build, or are they actually Ford 8.8 modified for independent suspension and aluminum case? Just wonderin', as my Ford Shop Manual does not give a hint. imp

Can find no heater resistance issues in harness. All 4 HO2S replaced. Keep getting those two "Oxygen Sensor Heater Resistance" codes. One website stated those are generated if cat converter issues are detected. I drive 5 miles, CEL turns on, get those two, or just one. Getting both at once is...