This is very common problem, ford has tsb for 10 years od build dates.
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TSB
00-24-3 ACCELERATOR PEDAL BRACKET - SHEET METAL CRACKS OR FATIGUES AT DASH PANEL AREA - ALL MODELS - VEHICLES BUILT 9/1/1990 THROUGH 7/1/1999
Publication Date: NOVEMBER 14, 2000
FORD: 1991-1999 EXPLORER
MERCURY: 1997-1999 MOUNTAINEER
ISSUE:
The accelerator pedal bracket may become loose or separated from the dash panel on some vehicles. This may be caused by repeated excessive force on the accelerator pedal, resulting in cracking of the dash panel sheet metal at the accelerator pedal bracket.
ACTION:
Repair loose or separated accelerator bracket and/or crack at dash panel. Refer to the following Service Procedure for details.
SERVICE PROCEDURE
Refer to Figure 1 illustration throughout Service Procedure.
Remove accelerator pedal pivot bolt and pedal from bracket.
With bracket placed in original position on dash panel, use the two (2) holes in base of bracket as pilots, and drill two (2) holes in dash panel using a 9mm (11/32") drill.
Examine dash panel on engine side for any cracks related to the attachment failure. If cracks are present, clean the surface with a suitable solvent and apply sealant to the cracks, such as RTV Sealant (F5TZ-19G204-AB).
Apply same sealant on the underside of the head flanges and all around the shanks of two (2) M8x16 hex flange Bolts (W500022-S309).
From inside the vehicle, with bracket held in original position, insert bolts through holes in bracket and dash panel.
On engine side of dash panel, assemble one (1) Flatwasher (391982-S191) (7/16" ID x 1.00" OD), and one (1) M8 prevailing torque hex flange Nut (W520112-S309) on each of the bolts. Tighten nuts to a torque of 27-33N-m (20-24 lb-ft).
Replace pedal and pivot bolt and tighten pivot bolt to a torque of 9-12 N-m (80-108 lb-in).
Check accelerator pedal for proper operation.
PART NUMBER PART NAME
F5TZ-19G204-AB RTV Sealant
W500022-S309 Bolt - Hex Flange (M8x16)
W520112-S309 Nut - Hex Flange (M8)
391982-S191 Flatwasher (7/16" ID x 1.00" OD)
OTHER APPLICABLE ARTICLES:
NONE
WARRANTY STATUS:
Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage
OPERATION DESCRIPTION TIME
002403A Repair Of Accelerator Pedal Bracket 0.6 Hr.
DEALER CODING
BASIC PART NO. CONDITION CODE
7801605 01
OASIS CODES:
111000, 404000, 614500
Figure 1 - Article 00-24-3
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Copyright © 2000 Ford Motor Company