TSB's

6.4L Ford diesel down on power

Some 2008-2010 Ford F-Super Duty vehicles equipped with the 6.4L diesel may exhibit a lack of power, and may display DTCs P20E2, P20E3, P20E4, P2080, P2084, P242B, P0544, P02031, P242A or P200E.

If any EGT sensor connector has been disconnected during testing, turn the ignition on, with engine off. Reconnect the EGT sensor. Turn the ignition off for 30 seconds before attempting to start the engine. Do not crank or start the engine until the ignition has been turned on for a minimum of 30 seconds.

Failure to follow this procedure may result in a 60-minute no-crank, no-start condition as a result of the failure mode effects management (FMEM) programmed into the powertrain control module (PCM).

Turn the key off. Access the 34-pin connector C110, located on the driver’s side frame inside the engine compartment, just below and to the left of the brake fluid reservoir. For identification purposes, C110 contains two 10-gauge wires, one red and one brown/red.

Disconnect connector C110 and inspect the pins on both sides of the connector for debris.

Using contact cleaner (CRC QD Electronic Cleaner or Permatex Electrical Contact Cleaner and a cleaning brush, clean the pins on both sides of the C110 connector.

Apply a liberal amount of Motorcraft Electrical Grease to the male pins of connector C110 and reconnect the connector.

Identify the suspect EGT sensor based on the DTC. Make sure that the key is in the off position. Remove the EGT sensor connector from the frame rail, and remove the mounting tab from the connector assembly. 

Remove the EGT sensor connector from the frame rail and remove the mounting tab from the connector assembly.
<p>Remove the EGT sensor connector from the frame rail and remove the mounting tab from the connector assembly.</p>

Disconnect the EGT sensor connector and inspect both component and harness side pins for debris.

Use CRC or Permatex Electronic cleaner and a brush to clean the EGT connector pins on both the component and harness sides.

Apply a liberal amount of Motorcraft Electrical Grease to the EGT component male connector pins.

Slide shrink tubing over the EGT connector/harness. Reconnect the EGT. Center the shrink tubing on the EGT harness/connector and shrink using a heat gun.

Using two tie wraps, secure the EGT connector assembly to the main harness.

Apply electrical grease to the EGT male connector pins.
<p>Apply electrical grease to the EGT male connector pins.</p>

 

Install shrink tubing over the connector.
<p>Install shrink tubing over the connector.</p>

Secure the connector to the main harness with tie wraps.
<p>Secure the connector to the main harness with tie wraps.</p>

PART NUMBERS

Motorcraft Electrical Grease             XG-12

Exhaust gas temperature sensor      8C3Z-5J213-D

Shrink tubing                                     8C3Z-19H285-A

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