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Page 206 APPENDIX

ELECTRICAL WIRING POWERTRAIN CONTROL SYSTEM APPLICATION

NOTE: The powertrain control module requires battery power to be supplied at all times to maintain the keep-alive memory. Keep this in mind when installing load disconnect switches or solenoids. TP Throttle Position Sensor: Supplies a throttle position signal to the PCM processor. Do not tap into or splice any wire to the TP Sensor. For 6.0L diesel engines use the TPO wire, circuit 1857 (YE/WH). VSS Vehicle Speed Sensor: The source varies by model. Sources include the Anti-Lock Brake System (ABS) module, a transmission speed sensor or the Transfer Case Speed Sensor (TCSS) for 4x4 model equipped with a manual transfer case. The vehicle speed signal is either a speed variable frequency AC signal, or a SCP Data message depending on the source. The vehicle speed signal must be operational for key sub-systems and the vehicle diagnostics to operate properly. Do not tap into or splice any VSS signal wire, sensors or engine and transmission damage may occur. For 6.0L diesel engines use VSO wire, circuit 239 (WH/OG) for the vehicle speed signal. For all other engines, installation of an additional sensor will be required. SPEEDOMETER CALIBRATION The vehicle speedometer receives the calibrated speed signal (sine wave) from the ABS Module or the Rear only ABS (ZWAL) Module through Circuit 679 (GY-BK) [except Mexico where the signal is received from the Central Timing (CTM) Module]. The input to the ABS, ZWAL, or CTM Module is provided by the DSS (Differential Speed Sensor) in the rear axle through Circuits 523 (R-PK) and 519 (LG-BK). If a tire change is performed, it is necessary to configure the ABS, ZWAL, or CTM Module so that the correct vehicle speed is indicated on the speedometer. The square tooth tone wheel in the rear axle is attached to the ring gear. A variable reluctance sensor is mounted to the front section of the rear axle housing with a precise air gap with respect to the tone wheel. These two components make up the DSS (Differential Speed Sensor). The rear axle case has a fixed mounting boss for the variable reluctance sensor and therefore the air gap is non-adjustable. All factory wheels have 120 teeth for every rear axle ratio offered. If the rear axle is change, provisions for a tone wheel and the variable reluctance sensor have to be made. Calculations involving the circumference and output frequency would have to be made and are beyond the scope of this manual. It is necessary to configure the ABS, ZWAL, or CTM Module so that the correct number of tone wheel teeth are recorded in the module. The following table gives tire sizes and revolutions per mile values. If the tire make and size is not found in the table, the tire revolutions per mile must be calculated as outline below. The tire manufacturer may be able to provide the revolutions per mile value. Once the tire revolutions per mile value is known, proceed to the Module Configuration section. TIRE SIZE AND REVOLUTIONS PER MILE

MAKE/ APPLICATION FIRESTONE/ ALL SEASON GOODYEAR/ ALL SEASON GENERAL/ ALL SEASON GOODYEAR/ ALL TERRAIN GENERAL/ ALL TERRAIN FIRESTONE/ ALL SEASON FIRESTONE/ ALL TERRAIN GENERAL/ ALL SEASON GENERAL/ ALL TERRAIN FIRESTONE GOODYEAR REVOLUTIONS/ MILE 682 655 657 653 654 655 649 653 654 605 620

MODEL YEAR

2003

ELECTRICAL: Guidelines for Powertrain Control System Application SYSTEM: All Powertrain Control Module wiring, in particular the 12A581 and 14401, must be a minimum of 2 inches from secondary ignition coil wires and at least 4 inches from the distributor, ignition coil tower, and starter motor (and its wiring) as well as 4 inches from the alternator output wiring. These clearances apply in particular to all PCM sensor and actuator pigtail wiring. PCM wires shall not be in the same bundle as other high-current non-PCM circuits (e.g., tachometer wire from coil to Thick Film Ignition Module (TFI), power seat/ door lock/window, horn, alternator reg.) for a distance of more than 20 inches. Please refer to Electrical on page 204. COMPONENTS: BPP Brake Pedal Position Switch: Supplies the processor a signal for converter clutch operation. A connection here may have an adverse effect on transmission operation. Refer to the ELECTRICAL WIRING SECTION "ADDING LIGHTS OR ELECTRICAL DEVICES" (page 207) for guidelines. CAUTION: Any connection to the PCM-V system (i.e., wiring, components) or alterations to the system may adversely affect vehicle operation (transmission and/or engine). BARO/ Barometer Pressure Sensor/Manifold Absolute MAP Pressure Sensor: Must be physically in a higher location than the intake manifold and angled with the vacuum nipple at least 4 degrees downwards. MAP vacuum line must have a downward slope to the manifold without any potential kinking or twisting. BARO has no vacuum line. DTR Digital Transmission Range Sensor: Located on the outside of the automatic transmission at the manual lever on all models except 6.0L diesel engines. The DTR sensor provides the position of the manual lever (P, R, N, D, 2, 1) to various vehicle circuits. Do not tap into or splice any wire attached to the DTR sensor or engine and transmission damage may occur. HO2 Heated Oxygen Sensor: Pigtail wire must be at least 4 inches from the exhaust pipe and exhaust manifold. If necessary, a clip should be used to secure its location. PCM Powertrain Control Module: Location must be completely shielded from weather and case grounded to sheet metal. It should be oriented such that no moisture can accumulate in the 104-way connector. The ambient temperature at the PCM module should not exceed 80° Centigrade (176° Fahrenheit). Exterior surface shall not exceed 140° F.

The Rotunda New Generation Star (NGS) Tester and the Ford Service Function (FSF) Program Card can be obtained from Hickok Electrical Instrument Company by contacting (216) 541-8060 extension 225. If your company has an account with Rotunda, contact Rotunda - OTC Division at 1-800-533-5338. MODULE CONFIGURATION Ensure that all harness connectors are connected to the module that requires configuration. Plug the NGS tester into the data link connector located below and to the right of the steering column. Actuate the ignition switch to the RUN position (engine off). Insert the Ford Service Function (FSF) Program Card into the Rotunda New Generation Star (NGS) Tester. Select SERVICE BAY FUNCTIONS using the trigger button. Scroll the highlight bar down to the module requiring configuration (see the Speedometer Calibration section). For the ZWAL Module, use the ABS option. Press the trigger button to select the module and select the TIRE SIZE/AXLE RATIO CONFIGURATION using the trigger button. The current configuration cannot be read on this vehicle line. Press the trigger button to continue. Select TIRE SIZE by pressing the trigger button. Use the dial to select the custom revolutions/mile entry and press the trigger button. Enter two zero's using the number buttons and enter the 3-digit revolutions/mile value for the desired tire using the number buttons. Using the dial, select TONE RING SIZE and press the trigger button. Use the dial to select the rear axle ring gear size (10.25 in, 10.5 in or 11.25 in) and press the trigger button. If the preceding options are not present, use the dial to select the custom number of teeth and press the trigger button. Enter two zero's using the number buttons and enter the 3-digit tone wheel teeth value using the number buttons. Unless the axle has been changed, enter 120 as the number of tone wheel teeth. Using the dial, select OPTION and press the trigger button. Use the dial to select N/A and press the trigger button. Using the dial, select VEHICLE and press the trigger button. Use the dial to select F250/350 and press the trigger button. Press done (numeric 8 button) and the module will be programmed with the above data entered. To reprogram, repeat the above procedure.

TIRE SIZE LT215/85R/16 LT235/85R16 LT235/85R16 LT235/85R16 LT235/85R16 LT265/75R16 LT265/75R16 225/70R19.5 225/70R19.5 7.50x17 7.50x17

CALCULATING TIRE REVOLUTIONS PER MILE Position the vehicle on level ground, load with the standard weight for the specific application, and inflate the tires to the recommended pressure (ensure that the tires are cold). Measure the tire height from the ground to the top of the tire in inches. Ensure an accurate reading to the nearest 1/8 inch. Divide 20,168 by the tire height in inches to get the tire revolutions per mile. Example: Measured tire height - 33 inches REVOLUTIONS/MILE = 20168/33 = 611 Revolutions/Mile REQUIRED TOOLS Rotunda New Generation Star (NGS) Tester. Ford Service Function (FSF) Program Card Version 1.1 or newer.

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