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TSB 96-07-15 Lock Distinctions
03/25/96
IF THE IMAGE IS TOO SMALL, click it.

LIGHT TRUCK: 1996 ECONOLINE, EXPLORER, F SUPER DUTY, F-150-350 SERIES, RANGER
MEDIUM/HEAVY TRUCK: 1996 F & B SERIES

ISSUE: A new single key (customer want) lockset is being introduced progressively at certain vehicle plants. This was done as part of the production prove-out of the new single key hardware. Introduction of this feature and the new lockset will continue through the 1996 model year.

ACTION: Install the current service level lockset if any replacement is necessary on the subject vehicles. After the new locks are in full production, the new locksets can be used instead of retrofitting the current service locksets. Refer to the Involved Vehicles Chart and Service Procedure and specific model for details.

SERVICE PROCEDURE
Determine if the vehicle has the new design locks. Use the following Service Procedure only if the vehicle has the new design locks and the new design locks are not yet available as service parts. Refer to the New Design Lock Availability Chart for the approximate availability dates for the new design locks per vehicle line.

If lockset replacement is necessary, order the needed components by referring to the following Current Service Locksets Chart.
NOTE: ON ANTI-THEFT SYSTEMS, THE NEW STYLE DOOR LOCKS HAVE A THREE-WIRE ANTI-THEFT SWITCH, WHILE THE OLD STYLE DOOR LOCKS HAVE A TWO-WIRE ANTI-THEFT SWITCH. THE TWO-WIRE SWITCH WILL WORK AS ONLY TWO (2) OF THE WIRES ARE USED ON THE NEW STYLE SWITCH.

REMOVAL
1. Remove door lock cylinders by referring to the appropriate Service Manual, Sections 01-12 and 01-14A.
2. Remove the ignition lock cylinder using the following steps:
a. Turn ignition lock cylinder to Run.
b. Place a 3.17 mm (1/8" diameter wire pin or small drift punch in hole in lower steering column shroud under ignition switch. Press retaining pin while pulling out on ignition switch lock cylinder to remove it from steering column cylinder housing.

INSTALLATION
Explorer
Install new lockset, door lock/liftgate cylinder retainers, and liftgate latch-to-release rod. Refer to the 1996 Explorer Service Manual, Sections 01-12 and 01-14A.

F-Series, Ranger, and F & B-Series
1. Install spacers in doors.
2. Install door lock and glove compartment lock cylinders by referring to the 1996 appropriate model Service Manual, Section 01-14A.
3. Install ignition lock cylinder. Refer to the 1996 appropriate model Service Manual, Page 11-04A-17.

Econoline
1. Install spacer in rear cargo door license plate housing (Figure 3).
2. Install door lock and glove compartment lock cylinders by referring to the 1996 Econoline Service Manual, Section 01-14A.
3. Install ignition lock cylinder. Refer to the 1996 Econoline Service Manual, Page 11-04A-17.

OTHER APPLICABLE ARTICLES: 96-7-2
WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper Warranty Coverage

OPERATION DESCRIPTION TIME
960715A Install Lockset - F-Series/Bronco 0.8 Hr. XC2Z1521990AA (Standard DL140)
960715B Install Lockset - Explorer/Ranger 0.9 Hr.
960715C Install Lockset - Econoline 1.3 Hrs.
960715D Install Lockset - F & B Series 1.3 Hrs.
DEALER CODING
BASIC PART NO. 1522050
CONDITION CODE 79
OASIS CODES: 112000

For other TSBs, check here.

See also:
. . .
___________________________________________________
95-24-4 DOOR - REPLACEMENT DOOR HAS LOOSE FITTING DOOR LOCK CYLINDER - SERVICE TIP
12/04/95

LIGHT TRUCK: 1981-96 F-150-350 SERIES
1983-96 BRONCO, RANGER
1986-95 AEROSTAR
1988-96 F SUPER DUTY
1992-96 ECONOLINE
1995-96 WINDSTAR
MEDIUM/HEAVY TRUCK: 1990-96 F & B SERIES

ISSUE: New replacement doors for past model years have a larger lock cylinder hole diameter. A loose fit will occur when installing the door lock cylinder. The lock cylinder mounting hole diameter in new doors has been increased in preparation for a new style lock cylinder. New locks will be phased in for future production.

ACTION: Install a spacer for the larger diameter door lock cylinder mounting hole. Refer to the following Service Procedure for details.
NOTE: THE DOOR LOCK CYLINDER SPACER HAS BEEN ADDED TO CERTAIN 1996 MODEL YEAR VEHICLES TO ELIMINATE THE LOOSE FIT CONDITION FROM THE SMALLER DOOR LOCK CYLINDER. SOME VEHICLES MAY BE BUILT WITH SPACERS ON ONE SIDE ONLY. THIS IS DUE TO THE BALANCE OF SUPPLIES OF RIGHT AND LEFT DOORS AT THE ASSEMBLY PLANTS AT THE TIME OF MODEL YEAR CHANGEOVER.

SERVICE PROCEDURE
DOOR LOCK CYLINDER INSTALLATION/REMOVAL
1. Whenever the door lock cylinder is removed, check for presence of lock cylinder spacer in the door in the lock hole. If one is present, check for damage and replace if necessary.
2. If replacement is necessary, refer to the Lock Spacer Usage Chart for proper part number application.
3. Snap a new spacer into the hole from outside the door.

DOOR OR LIFTGATE INSTALLATION/REMOVAL
When replacing the door or liftgate assembly, the new door or liftgate may have the larger lock cylinder hole. Measure the hole diameter. If dimension "X" is more than 24 mm, then a spacer is required. If it is less than 24 mm, then a spacer cannot be used.
NOTE: EVEN IF THE ORIGINAL DOOR HAS A SPACER, ONE IS NOT NEEDED IF THE "X" DIMENSION IS LESS THAN 24 mm IN THE NEW DOOR.

GENERAL INFORMATION REGARDING SPACER USAGE
The purpose of the spacer is to allow the flexibility of phasing in future lock designs without having to coordinate doors and locks in production or having to maintain two unique service doors. In general, the spacers are to be used with new doors (large hole) and old locks. The new doors are being phased in ahead of the new locks.

PART NUMBER . . . . . . . PART NAME
F6TZ-1521890-AA Door Lock Cylinder Spacer (Bronco & F-series)
F6UZ-1521890-AA Door Lock Cylinder Spacer
F68Z-1621890-AA Door Lock Cylinder Spacer
OTHER APPLICABLE ARTICLES: NONE
WARRANTY STATUS: INFORMATION ONLY
OASIS CODES: 111000, 112000