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TSB 93-23-14 Gasket Removal
Publication Date: NOVEMBER 10, 1993

FORD: 1988-93 CROWN VICTORIA, ESCORT, FESTIVA, MUSTANG, TAURUS, TEMPO, THUNDERBIRD
1989-93 PROBE
LINCOLN-MERCURY: 1988-89 TRACER
1988-92 MARK VIII
1988-93 COUGAR, GRAND MARQUIS, SABLE, TOPAZ, TOWN CAR
1991-93 CAPRI, TRACER
1993 MARK VIII
MERKUR: 1988-89 SCORPIO, XR4TI
LIGHT TRUCK: 1988-90 BRONCO II
1988-93 AEROSTAR, BRONCO, ECONOLINE, F SUPER DUTY, F-150-350 SERIES, RANGER
1991-93 EXPLORER
1993 VILLAGER

ISSUE: Some engine assemblies replaced under warranty have been found to be internally contaminated. This condition may be traceable to a previous repair involving removal of the valve cover(s), intake manifold and cylinder head(s). Scuffed pistons/bores, excessively worn crankshaft/camshaft bearings, low or no oil pressure, engine knocking and excessive oil consumption can result from improper engine gasket surface preparation.

ACTION: Refer to the following TSB article for gasket sealing surface preparation procedures recommended by Ford Motor Company.

SERVICE PROCEDURE
1. Identify the composition of the component part before proceeding with a cleaning operation. Determine whether the part is cast iron, steel, aluminum or plastic. This can usually be distinguished by the inherent hardness and/or weight of the part.
2. If the part is iron or steel, use a scraper with a high carbon blade, for best results. The key is to use a high carbon steel blade that is "razor-sharp." With a sharp blade, very little effort is required to peel off the old gasket.
a. Lay the blade flat on the surface and push slowly and evenly. Don't allow the blade corners to tip in and mar the surface.
b. Rounding off the blade corners with a small grinder will prevent scratching and gouging of the gasket surface.
WARNING: USE EXTREME CARE TO KEEP HANDS AND FINGERS CLEAR OF THE BLADE.
3. If the part is aluminum or plastic, a different scraper must be used. Carbon steel or any other steel edge will cut, mar, gouge or burr aluminum and plastic. A teflon or hard wooden scraper is recommended. First use a commercially-available spray solvent, allowing ample time for the solvent to act on the gasket. A suitable solvent should evaporate and leave no residue behind. Otherwise, the residue can cause a new leak to form.
NOTE: UNDER NO CIRCUMSTANCES ARE ANY GASKET SURFACES TO BE CLEANED AND PREPARED FOR SEALING BY USING A HAND GRINDER, ROTARY WIRE BRUSH, SANDING DISC OR PAD OR ANY OTHER POWER TOOL USING AN ABRASIVE SURFACE AS A CUTTING TOOL. THESE TOOLS HAVE BEEN FOUND TO PROMOTE ENTRY OF SANDING GRIT AND GASKET MATERIAL INTO ENGINE CAVITIES. THESE TOOLS CAN DAMAGE THE SURFACE FINISH AND POSSIBLY DISTORT THE ORIGINAL FLATNESS OF THE COMPONENT, LEADING TO FURTHER VACUUM, COMPRESSION AND/OR FLUID LEAKS.
4. To prevent gasket material or other foreign matter from entering internal engine compartments, place CLEAN shop towels over exposed cavities. Use extreme care when removing the towels; remove them SLOWLY. Cloth towels can drop as much foreign material into the engine as they originally collected during cleaning operations.
5. Another alternative is to use a portable shop vacuum. Moving a vacuum nozzle closely along with the scraper edge will help direct loosened gasket particles into the vacuum and away from the engine.
6. The same care used in preparing the gasket surface should be practiced when assembling component parts such as the intake manifold and cylinder heads. Both are critical leak areas requiring extra care during assembly. Some things to consider are:
a. Not all engines use the same sealants in the same places. Some parts use no sealant at all.
b. Consult the service manual first. Don't assume that a gasket needs sealant. Some gaskets are designed with a pre-cast bead. Adding sealant to this design type will create a leak by shimming the two mating surfaces.
c. Although some aftermarket gaskets look the same as the ones removed, use only Ford original equipment parts to ensure that the customer receives consistent quality and value.
d. Avoid gasket locating products such as "tack'ems". These chemicals may leave residues in the engine that are incompatible with the oil, and may even cause damage to the catalytic converter.
7. Practice CLEANLINESS when reinstalling components and gaskets.
a. A small leak path can become a larger one as fluid erodes a gasket.
b. Keep dirt, lint and unwanted chemicals off new gaskets.
c. DO NOT assume that once dirt enters the engine that the oil filter will cleanse the oil to its original state and protect the engine from harmful abrasives. Particles such as silica (sand) are small enough to pass through even the best oil filters. The grinding effect of sand and dirt in oil on internal bearing or wear surfaces is comparable to the effect of valve compound for lapping-in valves.
8. Torque sequence of components such as intake manifold and cylinder heads is extremely critical for proper sealing.
a. Not only does sequencing make a more effective seal, it also protects the part from warpage or distortions caused by improper tightening. b. Aluminum is particularly susceptible to warpage from uneven tightening of fasteners.
c. In some instances, fasteners used on aluminum components must be loosened in sequence. Consult the service Manual in EVERY instance for correct torque and/or de-torque values and sequences.
9. After a repair job, it is a good practice to use a black light leak test to confirm that the repair was successful. For example, it would be easy to assume that the rear main crankshaft seal was leaking when in fact the intake manifold gasket allowed oil to run down the back of the engine. Consider all the facts which allow fluid to travel outside the engine (fan air blast, road air blast, gravity, or escaping/pressurized fluid spray.

To sum-up, a successful leak repair depends on:
* Accurate diagnosis of the leak using Ford-recommended test equipment and procedures.
* Surface preparation and gasket installation using the proper cleaning tools.
* Exercising care and cleanliness during assembly/disassembly of components.
* Use of genuine Ford OEM parts.

OTHER APPLICABLE ARTICLES: 92-25-02
WARRANTY STATUS: INFORMATION ONLY

For other TSBs, check here.
____________________________________________________
TSB 01-24-6 ENGINE - ENGINE OIL SYSTEM PRIMING PROCEDURES - SERVICE TIPS
12/10/01

FORD:1995-1997 PROBE, THUNDERBIRD
1995-2000 CONTOUR
1995-2002 CROWN VICTORIA, ESCORT, MUSTANG, TAURUS
2000-2002 FOCUS
2002 THUNDERBIRD
1995-1996 BRONCO
1995-1997 AEROSTAR, F-250, F-350
1995-2002 E SERIES, EXPLORER, F-150, RANGER, WINDSTAR
1997-2002 EXPEDITION
1999-2002 SUPER DUTY F SERIES
2000-2002 EXCURSION
2001-2002 ESCAPE, EXPLORER SPORT TRAC, EXPLORER SPORT
LINCOLN:1995-1998 MARK VIII
1995-2002 CONTINENTAL, TOWN CAR
2000-2002 LS
1998-2002 NAVIGATOR
2002 BLACKWOOD
MERCURY:1995-1997 COUGAR
1995-1999 TRACER
1995-2000 MYSTIQUE
1995-2002 GRAND MARQUIS, SABLE
1999-2002 COUGAR1995-2002 VILLAGER
1997-2002 MOUNTAINEER

ISSUE: Reports of premature engine failure suggest some overhauled, new and/or remanufactured engine oil Systems are not correctly primed prior to initial engine start-up, after being installed in the vehicle. This may cause oil starvation during initial engine start-up.ACTIONPrior to starting a new, overhauled or remanufactured engine, the oil pump and oil system should be primed to eliminate the possibility of oil starvation at start-up. Refer to the following Service Information for details.

SERVICE INFORMATION: Regardless of engine design, it is extremely important that the engine oil pump is correctly primed, prior to initial engine start-up.

Overhead Cam Engines (OHC): Overhead cam engines use a G-rotor pump design and is driven by the crankshaft. If the engine is overhauled, the oil pump (prior to assembly) should be fed oil through the oil pick-up passage, prior to installing the pick-up tube and screen assembly. This can usually be accomplished by rotating the oil pump while oil is being fed into the oil pump inlet. Once the oil pump is primed, the oil pump can then be installed onto the engine.Remanufactured engines are usually cold tested before leaving the plant. As a result, the oil pump should not have to be removed from the engine and primed. Overhead cam engines, whether overhauled or remanufactured, prior to starting the engine, ensure the engine crankcase is filled to specification with engine oil. Disable the fuel supply to the fuel injectors (disable inertia fuel shut-off switch) and crank the engine in fifteen (15) second increments, until the oil pump is primed. An oil pressure gauge can be used to assist in determining when oil pressure is obtained. NOTE: ENSURE THE INERTIA FUEL SHUT-OFF SWITCH IS RE-ENABLED PRIOR TO ATTEMPTING TO START ENGINE.

Overhead Valve Engines (OHV): Overhead valve engines (push-rod type) use an oil pump driven by the camshaft via an intermediate shaft connected to the distributor or camshaft synchronizer assembly.Whether the engine is overhauled or remanufactured, the oil pump should be primed prior to starting the engine. If the engine is overhauled, ensure the crankcase is filled to specification with engine oil and using an engine oil pump priming tool kit, (commercially available) rotate oil pump until it is primed. An oil pressure gauge can be used to assist in determining when oil pressure is obtained.If a remanufactured engine is being installed, after the installation has been completed, ensure the crankcase is filled to specification with engine oil. Disable the fuel supply to the fuel injectors (disable inertia fuel shut-off switch) and crank the engine in (15) second increments, until the oil pump is primed. An oil pressure gauge can be used to assist in determining when oil pressure is obtained. NOTE ENSURE THE INERTIA FUEL SHUT-OFF SWITCH IS RE-ENABLED PRIOR TO ATTEMPTING TO START ENGINE.

OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 401000, 497000, 499000

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