This article supersedes TSB 10-5-4 to update the Part List, Service Procedure and Service Labor Time Standards.

ISSUE:

Some 2010 Explorer, Mountaineer Explorer Sport Trac vehicles equipped with 4.0L engine and 2010 Mustang vehicles equipped with a 4.0L engine and manual transmission only may exhibit some or all of the following symptoms: Engine rattle noise, malfunction indicator lamp (MIL) on with diagnostic trouble code P0340, misfire codes, lacks power, runs rough or no start condition. This affects vehicles with engine build dates from 5/28/2009 to 6/30/2009.

ACTION:

Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE

1. Check the engine build date. Refer to Workshop Manual (WSM), Section 303-01A, for how to read engine build date. Date is in DD/MM/YY format.
   1. If the engine is not within the build date range for this procedure, do not continue with this procedure. Follow normal WSM diagnostics.
   2. If the engine build date is within the date range 5/28/2009-6/30/2009, proceed to one of the following procedures based on symptoms:

Symptom A

Vehicle exhibits engine rattle, worse in drive, between idle and 1100 RPM. No DTCs stored in powertrain control module (PCM).

Symptom B

Vehicle has DTC P0340 stored in the PCM with any of the following symptoms: misfire codes stored in the PCM, lacks power, and/or runs rough.

Symptom C

Engine cranks but does not start, DTC P0340 stored in PCM.

Symptom A:

1. Using a stethoscope, check for rattle-type noise near the front of the engine block cradle. (Figure 1)
   
   
   Figure 1 - Article 10-18-11
   
   
   1. If rattle-type noise is not present in this area, do not continue with this procedure. Follow normal WSM diagnostics for noise.
   2. If rattle-type noise is present near the front of the engine block cradle, proceed to Step 2.
2. Remove cylinder block cradle. Refer to WSM, Section 303-01A.
3. Replace the balance shaft sprocket. Use Kit A - Timing Gear Set Balance Shaft. While servicing the balance shaft sprocket, determine if the balance shaft assembly spins freely.
   1. No - Balance shaft assembly does not spin freely, proceed to balance shaft replacement procedure.
   2. Yes - Balance shaft assembly spins freely, proceed to Step 4.
4. Clean and reinstall cylinder block cradle, Refer to WSM, Section 303-01A.
5. Replace engine oil and oil filter.

Symptom B:

1. Remove all camshaft roller followers. Refer to WSM, Section 303-01A.
2. Remove all spark plugs.
3. Perform a cylinder leakage test on all cylinders. Refer to WSM, Section 303-00.
   1. If leakage exceeds 20% on any cylinder, replace the engine assembly. Refer to WSM, Section 303-01A.
   2. If leakage is 20% or less on all cylinders, proceed to Step 4.
4. Remove cylinder block cradle. Refer to WSM, Section 303-01A.
5. Replace balance shaft sprocket and balance shaft drive chain.
   1. While servicing the balance shaft sprocket, determine if the balance shaft assembly spins freely.
      1. No - Balance shaft assembly does not spin freely, proceed to balance shaft replacement procedure.
      2. Yes - Balance shaft assembly spins freely, proceed to Step 6.
6. Inspect front timing components (chains, sprockets, guides, tensioners) for damage.
   1. If damage is found, remove front engine cover and replace any damaged components. Replace front jackshaft bolt. Refer to WSM, Section 303-01A.
   2. If no damage is found, proceed to Step 7.
7. Clean and reinstall cylinder block cradle. Refer to WSM, Section 303-01A.
8. Reinstall spark plugs.
9. Reinstall camshaft roller followers. Refer to WSM, Section 303-01A.
10. Replace engine oil and oil filter.

Symptom C

1. Using a scan tool, monitor RPM signal during engine crank.
   1. If RPM signal is present and code P0340 is stored in the PCM, proceed to Step 2.
   2. If RPM signal is not present, do not continue with this procedure. Follow normal WSM diagnostics.
2. Using IDS, follow the prompts in the scan tool and perform a relative compression test.
   1. If relative compression test fails, replace long block assembly.
   2. If relative compression test passes, do not continue with this article. Follow normal WSM diagnostics.

Balance Shaft Replacement

1. Remove the two (2) balance shaft tensioner bolts and the tensioner.

   NOTE:

   DO NOT REMOVE THE BALANCE SHAFT SPROCKET BOLT.

2. Remove the two (2) balance shaft bolts and remove the balance shaft assembly.
3. Rotate the crankshaft until the number one (1) piston is at top dead center.
4. Install the new balance shaft assembly.
   1. The replacement balance shaft will have an alignment locking device installed and will already be aligned for installation. If the alignment locking devise is not present refer to WSM, Section 303-01 for alignment instructions.
5. Install the two (2) balance shaft assembly bolts. Tighten to 21 lb-ft (29 N-m).
6. Install the balance shaft drive chain.
7. Install the balance shaft tensioner and chain guide. Install the two (2) bolts and tighten to 21 lb-ft (29 N-m).

WARRANTY STATUS:

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage And Emissions Warranty Coverage
IMPORTANT: Warranty coverage limits/policies are not altered by a TSB. Warranty coverage limits are determined by the identified causal part.

DEALER CODING

NOTE: The information in Technical Service Bulletins is intended for use by trained, professional technicians with the knowledge, tools, and equipment to do the job properly and safely. It informs these technicians of conditions that may occur on some vehicles, or provides information that could assist in proper vehicle service. The procedures should not be performed by "do-it-yourselfers". Do not assume that a condition described affects your car or truck. Contact a Ford, Lincoln, or Mercury dealership to determine whether the Bulletin applies to your vehicle. Warranty Policy and Extended Service Plan documentation determine Warranty and/or Extended Service Plan coverage unless stated otherwise in the TSB article. The information in this Technical Service Bulletin (TSB) was current at the time of printing. Ford Motor Company reserves the right to supercede this information with updates. The most recent information is available through Ford Motor Company's on-line technical resources.

Copyright © 2010 Ford Motor Company