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#1 greyhound

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Posted 31 March 2010 - 05:33 PM

I have a 1990 Ford F-150,with 5.8 and e40d tranny with dual gas tanks.Over the weekend the truck stopped while driving down the road.We had spark and no fuel pressure.We put a new fuel pump in and the truck runs great for about 5 min.Then it runs rough and dies.No fuel pump pressure again and the rear tank was empty.Next day we put 8 gallons in the tank again and drove 2 miles and it stopped again with no pressure and the tank was empty again.Today we checked the filter and it was ok.Cranked over the motor and nothing came out of the line from the rear tank.WE ONLY USE THE REAR TANK.The rear tank was empty again.Then the mid tank had Fuel running out of it.It was full.The mid tank has never worked because the pump was not working.I put gas in it one time and the next day after driving it was empty.So how does the fuel go from rear tank to mid tank?How can I fix this?Can I get rid of the mid tank?And use only the rear tank ans get rid of this pain in the rear.I missed 2 days of work and dont know what to do.Thanks Guys,Rick

#2 miesk5

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Posted 01 April 2010 - 01:04 PM

yo Rick;
Was this recall ever done (call your dealer or check on line @ Ford @ http://www.flmowner....age/RecallsPage
Have the VIN ready

ATTACHMENT I: Owner Letter
-----------------------------------------------------------------------------------
At Ford Motor Company, we are constantly working to improve our products. The reason for this letter is to tell you about a no charge coverage program (Extended Coverage Program 01M05).

What is the no charge coverage program? Your vehicle may experience a fuel cross-flow condition if the check valve in the fuel pump/sender assembly becomes damaged. If this check valve becomes damaged, fuel may be supplied from one tank and some or all of the unused fuel may be returned to the other tank. Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap.Note: Your vehicle was covered under Safety Recall 93S68 which was initiated in late 1993 to address fuel cross-flow. If Safety Recall 93S68 has never been performed on your vehicle, we encourage you to have it performed. If Safety Recall 93S68 was performed and you are still experiencing fuel cross-flow, then the cost to repair the cross-flow condition will be covered under this extended coverage program, number 01M05.

Note: Your vehicle was covered under Safety Recall 93S68 which was initiated in late 1993 to address fuel cross-flow. If Safety Recall 93S68 has never been performed on your vehicle, we encourage you to have it performed. If Safety Recall 93S68 was performed and you are still experiencing fuel cross-flow, then the cost to repair the cross-flow condition will be covered under this extended coverage program, number 01M05.

What does Extended Coverage Program 01M05 cover?... This program extends the coverage for the cross-flow condition to 12 years or 150,000 miles from your vehicle's warranty start date, whichever occurs first. This coverage will automatically transfer to subsequent owners. If the vehicle already has more than 150,000 miles, this coverage will last until December 31, 2001.

If your vehicle should experience a fuel cross-flow condition, your dealership will repair the condition free of charge (parts and labor).

Refunds ... If your vehicle had a fuel cross-flow condition which was the cause of a repair which occurred before the date of this letter, Ford is offering a full refund. For the refund, please give your paid original receipt to your Ford or Lincoln Mercury dealer. To avoid delays, do not send receipts to Ford Motor Company.

If you've changed address or sold the vehicle... Please fill out the enclosed prepaid postcard and mail it to us if you have changed address or sold the vehicle.

Quality Care is the commitment of Ford Motor Company and its dealerships to provide you with a superior service and ownership experience. We stand committed with our dealers to assist you with all of your automotive service needs. With our nationwide dealer network, we're here to ensure you receive Quality Care service so that your vehicle maintains peak performance throughout your ownership experience.

We hope this no charge coverage confirms our commitment to your satisfaction. We pride ourselves on becoming the world's leading consumer company for automotive products and services.
------------------------------------------------------------------------------
Safety Recall 93S68 - All 1990, 1991, 1992 and certain 1993 Model Year F-Series Vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter Engines and Dual Fuel Tanks

Affected Vehicles
All 1990, 1991, 1992 and certain 1993 model F-Series vehicles equipped with 4.9, 5.0, 5.8 or 7.5 Liter engines and dual fuel tanks.

Reasons For Recall
Some of the affected vehicles may experience a cross tank fuel flow condition due to the damaged check valve in the fuel pump/sender assembly. Fuel may be supplied from one tank and some or all of the unused fuel may be returned to the other tank. Should this occur, the capacity of the receiving tank may be exceeded and fuel may overflow from the filler cap. Fuel spillage in the presence of an ignition source could potentially result in a fire.

To correct this condition, the fuel pressure regulator will be replaced and a check valve will be installed between each fuel supply line and fuel tank.

Free Fuel Line Removal Tool
Standard fuel line removal tools can be used to disconnect fuel lines. However, because of the number of vehicles to be serviced, two free tools (#T93T-9550-AH) will be provided to each Ford dealer. These tools will be in your next Dealer Mail System (DMS) shipment (DMS packing slip #930902).

Parts Kit Codes
The required parts kit code for each vehicle will be shown on the attached VIN listing and will be printed at the top of each Owner Letter. Ask owners for the kit code shown on their letter when the owner calls for a service appointment.

Affected Vehicles: 1990 - 1992 and certain 1993 Model Year F-Series vehicles with 4.9, 5.0, 5.8 or 7.5 Liter Engines and Dual Fuel Tanks

WARNING: DO NOT SMOKE, CARRY LIGHTED TOBACCO OR ANY OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL-RELATED COMPONENT. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.

WARNING: FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVE BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN.

CAUTION: Each kit and instruction sheet is unique. Be sure to use the kit and instruction sheet that matches the vehicle to be serviced. Detailed instructions are not reproduced here but are included in each kit.


Follow all instructions in each kit carefully. In particular, note the following items:
* Be sure to leak test each truck before returning it to the customer.
* Be careful not to kink fuel lines when reinstalling fuel tanks.
* Do not mix parts. Some parts look similar. For example, some kits contain short check valve connectors (orange tag with part number imprinted); other kits contain long check valve connectors (white tag with part number imprinted).
(See detailed instructions included in each kit)

Kit AA:
(I.S. 8115) 1990/91 F-Series with Dual Fuel Tanks and 4.9L Engine (except 137" and 161" WB).

Kit BB:
(I.S. 8116) 1990/91 F-Series with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine (except 137" and 161" WB).

Kit CC:
(I.S. 8117) 1992/93 F-Series with Dual Fuel Tanks and 4.9L Engine (except 137" and 161" WB).

Kit DD:
(I.S. 8118 ) 1992/93 F-Series with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine (except 137" and 161" WB).

Kit EE: (Chassis Cab)
(I.S. 8122) 1990/91 F-Series Chassis Cab 137" WB with Dual Fuel Tanks and 4.9L Engine.

Kit FF: (Chassis Cab)
(I.S. 8123) 1990/91 F-Series Chassis Cab 137" WB with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine.

Kit GG: (Chassis Cab)
(I.S. 8124) 1990/91 F-Series Chassis Cab 161" WB with Dual Fuel Tanks and 4.9L Engine.

Kit HH: (Chassis Cab)
(I.S. 8125) 1990/91 F-Series Chassis Cab 161" WB with Dual Fuel Tanks and 5.0L/5.8L/7.5L Engine.

Labor Allowances
Install new fuel pressure regulator and check valves (or new fuel lines with built-in check valves):

APPLICATION PARTS KIT TIME LABOR CODE
1990/91 4.9L Engine AA 1.6 Hrs. Insert in Box "B" on Form 1864
1990/91 5.0L/5.8L/7.5L Engine BB 1.5 hrs. Insert in Box "B" on Form 1864
1992/93 4.9L Engine CC 1.9 hrs. Insert in Box "B" on Form 1864
1992/93 5.0L/5.8L/7.5L Engine DD 1.8 Hrs. Insert in Box "C" on Form 1864
1990/91 Chassis Cab 4.9L Engine EE, GG 2.5 Hrs. Insert in Box "C" on Form 1864
1990/91 Chassis Cab 5.0L/5.8L/7.5L FF, HH 2.4 Hrs. Insert in Box "C" on Form 1864


NOTE:
Add 0.1 hour Administrative Allowance to the total repair time.

Add additional 0.3 hour if truck is equipped with fuel tank skid plates.

Add additional 0.1 hour if truck is over 8,500 lbs. and equipped with a 5.8L engine.

Parts Requirements

Parts will not be direct shipped for this recall.

For Kits AA, BB, CC, and DD, order your parts requirements through normal order processing channels.

For Kits EE, FF, GG, and HH, order your parts by calling Renkim Corporation at 1-800-325-5621. When calling, be prepared to announce Recall 93S68, give your name, dealer name, P & A code, the VIN number of the vehicle to be serviced, and the kit part number required (do not order Kits AA, BB, CC or DD by calling this number.).

PART NUMBER DESCRIPTION CLASS DEALER PRICE
F4PZ-9155-A Kit AA - 1990/91 4.9L (all wheel bases except 137" WB and 161" WB) AG $25.00
F4PZ-9155-B Kit BB - 1990/91 5.0L/5.8L/7.5L (all wheel bases except 137" WB and 161" WB) AG $25.00
F4PZ-9155-C Kit CC - 1992/93 4.9L Engines AG $25.00
F4PZ-9155-D Kit DD - 1992/93 4.9L Engines AG $25.00
F4PZ-9155-E * Kit EE - 1990/91 4.9L Chassis Cab 137" WB AG $50.00
F4PZ-9155-F 1 Kit FF - 1990/91 4.9L Chassis Cab 161" WB AG $50.00
F4PZ-9155-G 1 Kit GG - 1990/91 4.9L Chassis Cab 161" WB AG $50.00
F4PZ-9155-H 1 Kit HH - 1990/91 5.0L/5.8L/7.5L Chassis Cab 161" WB AG $50.00

* Must be ordered by calling 1-800-325-5621 - see instructions above..
-----------
FSA 01M05 Fuel Cross-Flow

ATTACHMENT III: Technical Information
--------------------------------------------------------------------------------
FUEL CROSS FLOW WARRANTY EXTENSION AFFECTED VEHICLES: ALL 1990, 1991, 1992 AND 1993 MODEL YEAR F-SERIES VEHICLES EQUIPPED WITH 4.9, 5.0, 5.8 OR 7.5 LITER ENGINES AND DUAL FUEL TANKS

NOTE: Check OASIS to see if either Safety Recall 00S57 or 93S68 is open. If either recall is open, do not continue with this procedure. Instead, perform the appropriate safety recall and return vehicle to the owner.

SERVICE PROCEDURE:
1. Attach an EFI/CFI fuel pressure gauge to the Schrader valve on the engine fuel rail.
WARNING: FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE, EVEN WHEN THE ENGINE IS NOT RUNNING. BEFORE SERVICING OR DISCONNECTING ANY OF THE FUEL LINES OR FUEL SYSTEM COMPONENTS, THE FUEL SYSTEM PRESSURE MUST BE RELIEVED TO PREVENT ACCIDENTAL SPRAYING OF FUEL, CAUSING PERSONAL INJURY OR A FIRE HAZARD.
2. Start the engine and record the fuel pressure reading. Turn the ignition key to the OFF position. Then relieve the fuel system pressure by slowly opening the manual valve on the fuel pressure gauge. Remove the gauge from the fuel rail.


ALL EXCEPT CHASSIS CAB

6-CYLINDER ENGINES
- If the fuel pressure is 55 PSI or less, perform all of the following:
* External Check Valve Installation And Return Line Inspection �%uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection �%uFFFD%uFFFD Front Tank.
- If the fuel pressure exceeds 55 PSI, perform all of the following:
* Fuel Pressure Regulator Replacement.
* External Check Valve Installation And Return Line Inspection �%uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection �%uFFFD%uFFFD Front Tank.

8-CYLINDER ENGINES
- If the fuel pressure is 39 PSI or less, perform all of the following:
* External Check Valve Installation And Return Line Inspection �%uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection �%uFFFD%uFFFD Front Tank.
- If the fuel pressure exceeds 39 PSI, perform all of the following:
* Fuel Pressure Regulator Replacement.
* External Check Valve Installation And Return Line Inspection �%uFFFD%uFFFD Rear Tank.
* External Check Valve Installation And Return Line Inspection �%uFFFD%uFFFD Front Tank.

FUEL PRESSURE REGULATOR REPLACEMENT
NOTE: Perform only if fuel pressure exceeds levels specified earlier in this procedure.

1. Install a memory saver, then disconnect the battery negative cable.
2. Disconnect the vacuum line from the fuel pressure regulator, which is located on the fuel rail.
3. Remove the retaining screws from the fuel pressure regulator.
4. Remove and discard the fuel pressure regulator, gasket and O-ring seal from the fuel rail manifold.
5. Lubricate the new fuel pressure regulator O-ring with light oil (10W30 oil WSE-M2C903-A2 or equivalent). Install the new O-ring and the new gasket on the new regulator.
6. Position the new fuel pressure regulator with O-ring and gasket onto the fuel rail and install the retaining screws. Tighten the screws to 4 Nm (35 lb-in).
7. Connect the vacuum line to the new fuel pressure regulator.

EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION �%uFFFD%uFFFD REAR TANK (NON-CHASSIS CAB VEHICLES)

1. Install a memory saver, then disconnect the battery negative cable.
2. Drain the rear fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent.
3. Raise the vehicle on a hoist.
4. Position the spare tire out of the way.
5. Loosen the hose clamp at the fuel filler hose connection to the rear fuel tank.
6. Position a safety stand under the rear fuel tank.
7. Remove the fuel tank support straps.
8. Access the fuel delivery module (FDM) at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank.
9. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return lines for kinking.
- If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step.
- If the nylon return line is kinked, repair the line as necessary using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool), before continuing this procedure.
10. NOTE: Remove and discard the black hairpin clip on 1990 and 1991 model year vehicles. A new clip will be used when reconnecting the fuel supply line. Disconnect the fuel supply line at the FDM.
11. If equipped, remove and discard the old external check valve.
12. Install the external check valve to the supply tube of the FDM. Install the fuel line clip onto the external check valve.
13. Connect the fuel supply line to the external check valve. Install a new black hairpin clip on 1990 and 1991 model year vehicles.
14. Raise the rear fuel tank back into position while guiding the fuel filler hose onto the fuel tank.
15. Install the fuel tank straps. Tighten bolts to 38 Nm (28 lb-ft).
16. Tighten the fuel filler hose clamp to 4 Nm (35 lb-in).
17. Remove the safety stand.
18. Reposition the spare tire.
19. Lower the vehicle.

EXTERNAL CHECK VALVE INSTALLATION AND RETURN LINE INSPECTION �%uFFFD%uFFFD FRONT TANK (ALL VEHICLES)

1. Drain the front fuel tank, using Rotunda Fuel Storage Tanker 034-00002, 034-00014 or equivalent.
2. Raise the vehicle on a hoist.
3. Remove the skid plate if equipped.
4. Loosen the hose clamp at the fuel filler hose connection to the front tank.
5. Position a safety stand under the fuel tank.
6. Remove the fuel tank support strap bolts.
7. Access the FDM at the top of the tank by lowering the tank while guiding the fuel filler hose from the tank.
8. NOTE: For vehicles equipped with stainless steel braided flex lines, proceed to the next step. Inspect the nylon fuel return line for kinking.
- If the nylon fuel return line is not kinked or the vehicle is equipped with stainless steel braided flex lines, proceed to the next step.
- If the nylon return line is kinked, repair the line as necessary using Rotunda Tool 134-000001 (Plastic Fuel Line Fitting Connector Tool), before continuing this procedure.
9. NOTE: Remove and discard the black hairpin clip on 1990 and 1991 model year vehicles. A new clip will be used when reconnecting the fuel supply line. Disconnect the fuel supply line at the fuel delivery module.
10. If equipped, remove and discard the old external check valve.
11. Install the external check valve to the supply tube of the fuel delivery module. Install the fuel line clip onto the external check valve.
12. Connect the fuel supply line to the external check valve. Install a new black hairpin clip on 1990 and 1991 model year vehicles.
13. Reinstall the skid plate if removed.
14. Lower the vehicle.
15. Fill the fuel tanks.
16. Connect the battery negative cable, then remove the memory saver.
17. Without starting the engine, turn the ignition key on and off several times to pressurize the fuel system and check for leaks.
Posted Image
-----
Entire Recall, etc by Ford via Steve83 @ http://www.supermoto...ry/media/738363

96 Bronco, E4OD, Man Xfer Case & Hubs
 

in my archived BRONCO, Trucks & Vans Web site; http://web.archive.o...s.com/index.php;
select a LINK, Right Click and and Hit Properties;

copy the the second HTTP address

paste in a new browser to see the current page

 Thanks to All Who Serve


#3 miesk5

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Posted 02 April 2010 - 09:27 AM

I can't see my reply to you in the forum via this message mode; so go to that Ford wedsite for Recall Info & punch in the VIN there to see if the recall was Ever done.
I also can't see the Recall notice and URL I posted... I do believe that the Recall is good for as long as the truck is on the road.


ok, if Ford won't replace the check valve for free, read this;
"had a problem of the same sort. It would transfer
completely to the rear tank, but would not transfer completly to the
front tank, it would still take some fuel from the rear tank. the fuel
transfer switch was faulty. The ford dealer wanted $170 for a new
transfer switch, told em to piss off. Picked a 6 port fuel transfer
valve from JC whiney for $52, American made, look just like the old
one, comes with a mounting bracket. wiring harness, etc. So after
drilling a few holes it workes, the only problem is that the new
transfer valve is not made for Ford's screwy fuel line connections, I
replace the lines with regular 5/16" hose for the fuel return and 3/8"
hose for fuel supply. Total cost was about $70."
by Alex

btw; 1990 f-150 just has one hi-pressure pump in each tank

I don't have a source for on-line diagrams for you; you could get some from local libray using the on-line Chilton/Hayes tech via Auto Repair Reference Center Repair Manual, Mostly Chilton; many local library's offer free online access for their members; just log-in w/your library Card # and password; incl. all Broncos, & many MAKES! 1951 to 2009; some years (85-96, I believe) include: FULL Technical Service Bulletins and Recalls, Labor Hours per repair (plug in appl info); Wiring Diagrams, Vacuum Diagrams (in DRIVEABILITY AND EMISSIONS CONTROLS Section), Specifications (torques, etc.) & Maintenance Intervals
Source: by arrc.epnet.com
-----
read this too http://www.mightyaut...icles/tt112.pdf
scroll down a bit
-------------
&
Dear Mr. Ciulla: I own a 1992 Ford F-150 4X4 with dual fuel tanks. For past several months, the truck is taking fuel only from the rear tank and not using any fuel from the front at all, even though the selector switch is switched to Front tank.

I took the truck to Ford. They are saying that the Front fuel pump's check valve is bad and are asking a hefty chunk of money to fix it. so I took it to another mechanic and after checking it thoroughly he claims that the pump is not bad because when he switches to front tank, the pump runs and fuel comes out, however, the front tank remains full and the fuel comes out of the back tank. The switch is OK, relay is OK, Nobody can figure out what is the problem. Please help.

Thanks,
MSK

A. I would have to look at the selector switch for the problem. This has been the most frequent cause of this problem in the F-150's I've seen.

The way it works is voltage is supplied to the Fuel Tank Selector Switch whenever the Fuel Pump relay is energized (contacts closed). When the Fuel Tank Selector Switch is placed in the FRONT position, power is supplied to the Front Tank Fuel Pump. Fuel is then pumped from the front tank. The signal from the Front Tank Fuel Gauge Sender is carried to the Fuel Tank Selector Switch, and then to the Fuel Gauge in the Instrument Cluster.

When the Fuel Tank Selector Switch is in the REAR position, power is supplied to the Rear Tank Fuel Pump from the Fuel Tank Selector Switch. The Rear Tank Fuel Gauge Sender signal is transmitted to the Switch, and then to the Instrument Cluster.

When you check the switch, you have to be sure it's sending power to one fuel pump or the other, not both at the same time.
http://autorepair.ab...a/1a/bl484a.htm
------------

96 Bronco, E4OD, Man Xfer Case & Hubs
 

in my archived BRONCO, Trucks & Vans Web site; http://web.archive.o...s.com/index.php;
select a LINK, Right Click and and Hit Properties;

copy the the second HTTP address

paste in a new browser to see the current page

 Thanks to All Who Serve


#4 greyhound

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Posted 05 April 2010 - 02:29 PM

Hello,
To MSK-5,thanks for your help.Ford could not or would not help me out.They wanted 230 bucks for the gas valve.I took down both tanks.I could not find the gas valve as told.Nothing with 4 lines in and 2 lines out.The center tank was full of holes like swiss cheese.And the gas looked like root beer.The fuel pump plug was burnt black.I got rid of the center pump and tank.Hooked up my gas line and now the gas gauge works good again.Wish they made these trucks like my 60 panel truck.Then I could work on them.One question for anyone who can help.My 1990 supercab has the two windows in the side of the truck.Did Ford ever make these where you could open them up like the 1978 model trucks where they pushed out alittle to get air.My one greyhound goes with us everywhere and loves to put his nose out the window.Or did some one make a kit so you could open the side windows?Or a retro fit from another year truck?Its alittle hard to get pass the headrest to the opened drivers door window for fresh air.Thanks Rick
junkyard10@verizon.net

#5 damcar

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Posted 09 August 2010 - 11:23 AM

I have a 92 F-150 5.8L 4 x 4 supercab short bed with dual tanks and have the same problem of the rear tank pumping into the (front) midtank. The dealer keeps telling me my truck is not included in the recall. How can this be when it is the correct year and has dual tanks? I do not have a selector valve on this truck so I'm not sure what else I could check.

Any help is greatly appreciated.
Thanks.



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