Top 10 2003 Ford F150 Regular Cab Questions & Answers

The temperature blend door actuator is located on the right side of the transmission hump under the evap. case. The floor ducts cover it.

here are all poss causes of check engine light.
Generic Trouble Codes

P0001-P0099 – Fuel and Air Metering and Auxiliary Emission Controls
Code Description
P0001 Fuel Volume Regulator Control Circuit/Open
P0002 Fuel Volume Regulator Control Circuit Range/Performance
P0003 Fuel Volume Regulator Control Circuit Low
P0004 Fuel Volume Regulator Control Circuit High
P0005 Fuel Shutoff Valve Control Circuit/Open
P0006 Fuel Shutoff Valve Control Circuit Low
P0007 Fuel Shutoff Valve Control Circuit High
P0008 Engine Position System Performance (Bank 1)
P0009 Engine Position System Performance (Bank 2)
P0010 A Camshaft Position Actuator Circuit (Bank 1)
P0011 A Camshaft Position - Timing Over - Advanced or System Performance (Bank 1)
P0012 A Camshaft Position - Timing Over - Retarded (Bank 1)
P0013 B Camshaft Position - Actuator Circuit (Bank 1)
P0014 B Camshaft Position - Timing Over - Advanced or System Performance (Bank 1)
P0015 B Camshaft Position - Timing Over - Retarded (Bank 1)
P0016 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor A)
P0017 Crankshaft Position - Camshaft Position Correlation (Bank 1 Sensor B)
P0018 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor A)
P0019 Crankshaft Position - Camshaft Position Correlation (Bank 2 Sensor B)
P0020 A Camshaft Position Actuator Circuit (Bank 2)
P0021 A Camshaft Position - Timing Over - Advanced or System Performance (Bank 2)
P0022 A Camshaft Position - Timing Over-Retarded (Bank 2)
P0023 B Camshaft Position - Actuator Circuit (Bank 2)
P0024 B Camshaft Position - Timing Over - Advanced or System Performance (Bank 2)
P0025 B Camshaft Position - Timing Over - Retarded (Bank 2)
P0026 Intake Valve Control Solenoid Circuit Range/Performance (Bank 1)
P0027 Exhaust Valve Control Solenoid Circuit Range/Performance (Bank 1)
P0028 Intake Valve Control Solenoid Circuit Range/Performance (Bank 2)
P0029 Exhaust Valve Control Solenoid Circuit Range/Performance (Bank 2)
P0030 HO2S Heater Control Circuit (Bank 1 Sensor 1)
P0031 HO2S Heater Control Circuit Low (Bank 1 Sensor 1)
P0032 HO2S Heater Control Circuit High (Bank 1 Sensor 1)
P0033 Turbo Charger Bypass Valve Control Circuit
P0034 Turbo Charger Bypass Valve Control Circuit Low
P0035 Turbo Charger Bypass Valve Control Circuit High
P0036 HO2S Heater Control Circuit (Bank 1 Sensor 2)
P0037 HO2S Heater Control Circuit Low (Bank 1 Sensor 2)
P0038 HO2S Heater Control Circuit High (Bank 1 Sensor 2)
P0039 Turbo/Super Charger Bypass Valve Control Circuit Range/Performance
P0040 O2 Sensor Signals Swapped Bank 1 Sensor 1/ Bank 2 Sensor 1
P0041 O2 Sensor Signals Swapped Bank 1 Sensor 2/ Bank 2 Sensor 2
P0042 HO2S Heater Control Circuit (Bank 1 Sensor 3)
P0043 HO2S Heater Control Circuit Low (Bank 1 Sensor 3)
P0044 HO2S Heater Control Circuit High (Bank 1 Sensor 3)
P0045 Turbo/Super Charger Boost Control Solenoid Circuit/Open
P0046 Turbo/Super Charger Boost Control Solenoid Circuit Range/Performance
P0047 Turbo/Super Charger Boost Control Solenoid Circuit Low
P0048 Turbo/Super Charger Boost Control Solenoid Circuit High
P0049 Turbo/Super Charger Turbine Overspeed
P0050 HO2S Heater Control Circuit (Bank 2 Sensor 1)
P0051 HO2S Heater Control Circuit Low (Bank 2 Sensor 1)
P0052 HO2S Heater Control Circuit High (Bank 2 Sensor 1)
P0053 HO2S Heater Resistance (Bank 1 Sensor 1)
P0054 HO2S Heater Resistance (Bank 1 Sensor 2)
P0055 HO2S Heater Resistance (Bank 1 Sensor 3)
P0056 HO2S Heater Control Circuit (Bank 2 Sensor 2)
P0057 HO2S Heater Control Circuit Low (Bank 2 Sensor 2)
P0058 HO2S Heater Control Circuit High (Bank 2 Sensor 2)
P0059 HO2S Heater Resistance (Bank 2 Sensor 1)
P0060 HO2S Heater Resistance (Bank 2 Sensor 2)
P0061 HO2S Heater Resistance (Bank 2 Sensor 3)
P0062 HO2S Heater Control Circuit (Bank 2 Sensor 3)
P0063 HO2S Heater Control Circuit Low (Bank 2 Sensor 3)
P0064 HO2S Heater Control Circuit High (Bank 2 Sensor 3)
P0065 Air Assisted Injector Control Range/Performance
P0066 Air Assisted Injector Control Circuit or Circuit Low
P0067 Air Assisted Injector Control Circuit High
P0068 MAP/MAF - Throttle Position Correlation
P0069 Manifold Absolute Pressure - Barometric Pressure Correlation
P0070 Ambient Air Temperature Sensor Circuit
P0071 Ambient Air Temperature Sensor Range/Performance
P0072 Ambient Air Temperature Sensor Circuit Low
P0073 Ambient Air Temperature Sensor Circuit High
P0074 Ambient Air Temperature Sensor Circuit Intermittent
P0075 Intake Valve Control Solenoid Circuit (Bank 1)
P0076 Intake Valve Control Solenoid Circuit Low (Bank 1)
P0077 Intake Valve Control Solenoid Circuit High (Bank 1)
P0078 Exhaust Valve Control Solenoid Circuit (Bank 1)
P0079 Exhaust Valve Control Solenoid Circuit Low (Bank 1)
P0080 Exhaust Valve Control Solenoid Circuit High (Bank 1)
P0081 Intake Valve Control Solenoid Circuit (Bank 2)
P0082 Intake Valve Control Solenoid Circuit Low (Bank 2)
P0083 Intake Valve Control Solenoid Circuit High (Bank 2)
P0084 Exhaust Valve Control Solenoid Circuit (Bank 2)
P0085 Exhaust Valve Control Solenoid Circuit Low (Bank 2)
P0086 Exhaust Valve Control Solenoid Circuit High (Bank 2)
P0087 Fuel Rail/System Pressure - Too Low
P0088 Fuel Rail/System Pressure - Too High
P0089 Fuel Pressure Regulator 1 Performance
P0090 Fuel Pressure Regulator 1 Control Circuit
P0091 Fuel Pressure Regulator 1 Control Circuit Low
P0092 Fuel Pressure Regulator 1 Control Circuit High
P0093 Fuel System Leak Detected - Large Leak
P0094 Fuel System Leak Detected - Small Leak
P0095 Intake Air Temperature Sensor 2 Circuit
P0096 Intake Air Temperature Sensor 2 Circuit Range/Performance
P0097 Intake Air Temperature Sensor 2 Circuit Low
P0098 Intake Air Temperature Sensor 2 Circuit High
P0099 Intake Air Temperature Sensor 2 Circuit Intermittent/Erratic

Which type is it, ESOF ( Electronic Shift on the Fly ) or MSOF ( Mechanical Shift on the Fly ) ?

Best to check by jacking the truck up ( taking safety precautions, parking brake, chock the wheels, jack stands, etc ), turn the key to the run position and place into 4WD.
If the front drive shaft turns, the problem is in the transfer case.
If the front drive shaft does not turn, the problem is in the front axle.

I would suspect the front shaft does not turn, and the most common cause of this is the vacuum motor on the front axle, the vacuum lines to it, or the vacuum solenoids.
The vacuum shift motor is what locks the front wheels in, and without this action, the PM does not get the confirm that the truck is good to go, and illuminate the cluster indicators ( 4x4, and if 4L the Low Range lamps ).
There are 2 vacuum solenoids, one is 4WD one is 2WD ( to move the motor one way or the other ).
Start with checking for vac on the vacuum motor ( actually it is a diaphragm ). The pink line should have vacuum when in 4WD, the blue line should have vacuum when in 2WD. If not, time to work back towards the solenoids. Use a short length of hose on the vacuum solenoids, and retest.
If still missing vacuum on the 4WD solenoid, I would suspect it is bad, but best to test on the other side of it, to make sure the vacuum reservoir ( mounted behind the battery box ) is supplying vacuum to the solenoids.

This is just the most common cause, best to confirm with the 1st test above, to know if you should look to the trans case, or axle.

This is what the vacuum shift motor looks like on the front axle


These are the vacuum shift solenoids

TSB
05-22-6
ISSUE:
Some 2001-2003 F-150, 2004 F-150 Heritage and 2001-2003 E-150/250 vehicles equipped with a 4.2L engine may exhibit the malfunction indicator lamp (MIL) on with diagnostic trouble codes (DTCs) P1131 and/or P1151 (system too lean bank 1 or 2). This condition may be due to leaking isolator bolts/port gaskets in the upper-to-lower intake manifold mounting area. This condition is sometimes intermittent and may not be apparent on a warmed-up engine.


SERVICE PROCEDURE

Perform a self test. If DTC P1131 and/or P1151 are the only codes stored in the powertrain control module (PCM) proceed to Step 2. If any additional DTCs are present, follow normal diagnostic procedures found in the PC/ED Manual.

Remove the upper intake and replace only the port gaskets (9H486) and isolator bolt assemblies (9S479). The new isolator bolt assemblies use a rubber material that is green in color, do not install the old isolator bolt assemblies with the black rubber material. Do not replace any other intake parts or gaskets.
While the upper intake manifold is removed, check the exhaust gas recirculation (EGR) orifices that are pressed into each primary port of the lower intake manifold. If any of the orifices are plugged with soot, clean and unplug them with a pick and solvent.

PART NUMBER PART NAME
1L3Z-9H486-AA Port Gasket
3F2Z-9S479-AA Isolator Bolt

Could be the clock spring, the relay or the horns themselves.

Pull the horn relay, and jumper the normally open contacts. The horn relay is in the BJB ( aka Battery Junction Box / Engine compartment fuse panel ). It is BJB half size relay 205.

Pull the relay, and using the diagram below to jumper the normally open contacts.



If this works, next is to test the coil operation, which are pins #1 & #2. Pin #1 should be the power from BJB Fuse #7, pin #2 is ground from the horn switch via the clock spring on the steering wheel.
Use a meter to test from pin #1 to a known good ground ( i.e. neg side of the battery or a factory ground lug on the fender ).
If you have + DC on that pin, next is to test the ground pin in the relay socket. Using a meter with DC-V from pin #2 to the + side of the battery, have someone press the horn switch on the steering wheel. If this tests OK, could be a problem with the relay. You can swap the fog lamp relay ( 206 ) or the trailer tow backup lamp relay ( 203 ) into this position to test with.
You can also bench test the relay by applying power and ground to pins #1 & #2 and a meter set to resistance on pins #3 & #5. The resistance should be less than 100 ohms with power applied to pins #1 & #2.

The fuses for the speed control from the factory are :
Engine Compartment fuse panel #7,
Cab fuse panel Fuses #15, #13, #5

The fuse that goes to the recall part is Fuse #13, 20A

The recall is 05S28. Description: Speed Control Deactivation Switch.
The part number for the recall is : 1L1Z-9F924-AA
The part has a fuse inline that is marked as non serviceable, but 1 revision I saw, it was just an ATM fuse under tape. Not sure if this is the final revision that was used on your truck ( or should have been used ).


The self test for the Cruise Control ( for 00-03 MY, with the CC light on the cluster ) :

With the key off depress and hold the cruise control off button while turning the ignition to the run position,don't start the truck, the cruise light will flash once to let you know it is in self test.
Five additional flashes indicate a bad cruise control servo

Release the cruise off switch and within 5 seconds depress the other switches in sequence:
1. on
2. resume
3. coast
4. set/ accel
The speed control light will flash as each switch is depressed.

If the last one does not flash it may then flash a code

After this the cruise will move the throttle to test the actuator and the cable.
Make sure the throttle returns to idle and turn the key off.
----------------------

Self-Test Diagnostics

WARNING:
This test is a key on engine off (KOEO) test only that is conducted in park only with emergency brake fully engaged.

1. Enter self-test diagnostics by depressing the speed control OFF switch while turning the ignition key ON, making sure the engine does not start and is not running. The speed control indicator on the instrument panel will flash once to indicate that speed control module entered the diagnostic mode. Five additional flashes at this point indicate a defective speed control servo. Release the OFF switch.

2. Press the remaining switches in this sequence: ON, RESUME, COAST and SET/ACCEL.

If the ON switch is not depressed within five seconds after entering the diagnostics mode, the module times out and the procedure must be started over.

The speed control indicator lamp will flash as each switch is depressed. Press each switch in the sequence immediately after the indicator light goes out for the previous switch.

Note:
There will be a slight delay when the last button is pressed and the lamp flashes.

3. A lamp flash with the last button (SET/ACCEL) indicates that the static test passed. If the lamp does not flash with the last button and there are no additional flashes of the lamp, the switch is defective.

If the lamp does not flash with the last button, and additional flashes occur, follow the chart below for trouble codes:

- 2 flashes - BPP defective, circuit is defective, brake applied, CPP switch or jumper (if equipped).

- 3 flashes - deactivator switch is open or circuit defective.

- 4 flashes - vehicle speed signal is out of range or circuit is defective

4. Immediately (.25 second delay) after the static test, the speed control servo does a dynamic test by automatically actuating the throttle lever from 8 mm (0.315 in) to 12 mm (0.472 in) of travel from the idle position. During the dynamic throttle pull, observe throttle movement to witness any binding or sticking of the speed control cable and correct connection of speed control cable to throttle lever. Make sure the throttle returns to the idle position.

5. Return the ignition switch to the OFF position and proceed to the Symptom Chart.

Operationally vacuum shifts the front axle between 2WD and 4WD mode. The GEM ( Generic Electronics Module ) applies ground to the solenoid needed for the mode selected on the switch ( for ESOF ) or when the transfer case shift lever is moved ( MSOF ).The contact plates in the transfer case signal the GEM that the transfer case is engaged, and the Vacuum solenoids need to be activated ( either 2WD to 4WD or 4WD to 2WD ).

Lift and support the front of the truck so the front wheels are off the ground ( take safety precautions, chock wheels, jack stands, etc )
Key on, engage 4x4 and try to turn the front drive shaft.
- If it turns it is a problem with the transfer case.
- If it doesn't it is a front axle engagement problem ( this is what you seem to have, the transfer case is engaged and will drive the front shaft mine was a key on engine off test ).

- If the front drive shaft does not turn :
•With the truck running ( with front wheel back on the ground ), switch from 2WD to 4WD and back again, the vacuum shift motor should move the lever on the front axle.

-- If the vacuum shift motor does not move:
1.Check for vacuum on the lines while shifting between modes. Pink vacuum line is 2WD mode, Light Blue vacuum line is 4WD.
2.Check the fuses for the 4WD system and the solenoids.
3.Check the vacuum lines from the vacuum shift motor to the solenoids on the firewall.

4.Check the vacuum lines from the solenoids to the vacuum reservoir box behind the battery.
5.Check the vacuum reservoir box for cracks.
6.Typical solution is the vacuum lines ( to the solenoids or to the vacuum shift motor ) are cracked or the vacuum shift motor has a cracked diaphragm and has water in it.
7.Could be the shift plate contacts in the transfer case are corroded / not making good contact, and not activating the solenoids.


Usually the case is cracked vacuum lines from the solenoids, the next common is a cracked vacuum reservoir box, and 1 time I have seen the mount for the vacuum disconnect motor broken ( motor floating free so it could not push against the axle )

Click over image for zoom...

Fig. Powertrain Control Module - F-150 and Mark LT

Fig. Powertrain Control Module-5.4L and 6.8L Engines

Hope this helps (remember to rating this free answer).

There are four terminals on the relay. One is power, one is the pump circuit, the other two are for the magnet that closes the contacts.
You jumper a wire between the power and pump terminals in the box.
The relay is marked with a diagram and the pins on the relay are numbered.

you have to remove the entire radio out of the dash. theres 4 pin holes on the face of the radio. what I found worked best was a old metal coat hanger, cut 2- 8 inch lengths,fold them in a (U) shape & insert them in the holes to release the support bracket. O)nce u get it out there is a manual eject lever that will work for you.