Fuel System - Accelerator Pedal Vibrates
TSB 04-26-1512/31/04
ACCELERATOR PEDAL VIBRATION - 3.0L 2V
FORD:
2004-2005 Taurus
MERCURY:
2004-2005 Sable
This article supersedes TSB 04-22-4 to remove the 3.0L 4-valve engine as an application.
ISSUE
Some 2004-2005 Taurus/Sable vehicles equipped with a 3.0L 2-valve engine may exhibit a vibration felt in the accelerator pedal at 40-42 MPH (64-68 Km/h). This condition may be due to intake manifold resonance.
ACTION
Reroute the accelerator cable and install an updated cable support bracket kit. Refer to the following Service Procedure.
SERVICE PROCEDURE
Accelerator Cable Rerouting
1. Disconnect air cleaner tube at the air box.
2. Reroute the accelerator cable over the top of the brake fluid reservoir and on top of the air cleaner tube (Figure 1).
3. Use a cable tie to secure accelerator cable to the vacuum hose within 5/8" (16 mm) of the black plastic vacuum reservoir, directly above the brake fluid reservoir (Figure 1).
4. Reattach the air cleaner tube to the air box.
Bracket Installation
1. Disconnect the existing "christmas tree" retainer from the "pencil" brace (Figure 2).
2. Remove the existing pencil brace bolt from the cylinder head and the nut from the intake. Retain the nut for reuse and discard the pencil brace (Figure 2).
3. Slide the IAC wiring harness holder off the lower right throttle body bolt (Figure 2).
4. Remove the lower left throttle body bolt and discard (Figure 3).
5. Install the new throttle body stud in the lower left corner of the throttle body and torque to 40-60 lb-in (4.5-7 N.m) (Figure 3).
6. Install the new "chnstmas tree" retainer on the wiring harness, 3/4" (20 mm) towards the front of the vehicle and 180 degrees opposite the existing retainer. Use black electrical tape or equivalent to install, by applying to each side of connector (3 complete wraps around the harness) (Figure 4).
7. Install the new support bracket on both lower throffle body studs and fasten with bolt in cylinder head. Harness must be on the inboard side of bracket (Figure 3).
8. Install nuts on the throttle body studs and torque to 40-60 lb-in (4.5-7 N.m). (REUSE THE NUT THAT WAS RETAINING THE UPPER END OF THE OLD PENCIL BRACE TO INTAKE.)
9. Reinstall bolt into the cylinder head and torque to 30-40 lb-ft (41-54 N.m).
10. Insert the christmas tree retainer into the hole in the new bracket (Figure 3).
11. Reinstall the IAC wire harness holder on the lower right stud (Figure 2).
Parts Block
WARRANTY STATUS: Eligible Under Provisions Of New Vehicle Limited Warranty Coverage
OPERATION DESCRIPTION TIME
042615A 2004-2005 Taurus/Sable 0.8 Hr.
3.0L 2V: Reroute
Accelerator Cable
(Includes Time To install
New Bracket)
DEALER CODING
CONDITION
BASIC PART NO. CODE
9J444 43
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